Tek Bot Assembly

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Copyright 2005 Oregon State University School of Electrical Engineering & Computer Science
This document is the property of Oregon State University and the School of EECS. Limited use is allowed according to the following criteria: materials are free to use except for cost of reproduction but must bear this statement. Materials created using this information may not be labeled as TekBots materials without the prior written consent of Oregon State University and the School of EECS.
Preface
Table of Contents
TABLE OF CONTENTS ............................................................................................................................................................ II
HOW TO USE THIS MANUAL ......................................................................................................................................................................... IV IMPORTANT SYMBOLS ................................................................................................................................................................................. IV
SECTION 1.................................................................................................................................................................................... 1 THE MECHANICAL FRAME ................................................................................................................................................... 1

MOTOR ASSEMBLY AND MOUNTING ............................................................................................................................................................ 2 ATTACHING THE BATTERY HOLDERS ........................................................................................................................................................... 4 ATTACHING THE ROLLER BALL .................................................................................................................................................................... 6 ATTACHING THE WHEELS ............................................................................................................................................................................. 6
SECTION 2.................................................................................................................................................................................... 9 CHARGER BOARD ASSEMBLY CHRG.1........................................................................................................................... 9

OVERVIEW .................................................................................................................................................................................................. 10 ASSEMBLING THE BOARD ........................................................................................................................................................................... 10 MOUNTING THE BOARD ON YOUR ROBOT ................................................................................................................................................... 14
SECTION 3.................................................................................................................................................................................. 16 THE MOTOR CONTROLLER BOARD MTR_CTLR.1 ................................................................................................... 16

PURPOSE ..................................................................................................................................................................................................... 17 PROCEDURE .........................................................................................................................................ERROR! BOOKMARK NOT DEFINED. MOUNTING THE BOARD ON YOUR ROBOT ................................................................................................................................................... 17
SECTION 4.................................................................................................................................................................................. 18 SENSOR BOARD SENSE.1 ................................................................................................................................................... 18

PURPOSE ..................................................................................................................................................................................................... 19 ASSEMBLING THE BOARD ........................................................................................................................................................................... 19 MOUNTING THE BOARD ON YOUR TEKBOT ................................................................................................................................................ 20
SECTION 5.................................................................................................................................................................................. 21 THE ANALOG CONTROLLER BOARD ANLG_CTLR.1 ............................................................................................... 21

PURPOSE ..................................................................................................................................................................................................... 22 PROCEDURE ................................................................................................................................................................................................ 22
Page ii TekBot Assembly Guide 2006 Oregon State University
Preface
SECTION 6.................................................................................................................................................................................. 27 FINAL ASSEMBLY ................................................................................................................................................................... 27

FINAL ASSEMBLY ....................................................................................................................................................................................... 28 TUNING YOUR TEKBOT .............................................................................................................................................................................. 30
APPENDIX A .............................................................................................................................................................................. 32 GENERAL REFERENCE MATERIAL .................................................................................................................................. 32

SCHEMATIC SYMBOLS ................................................................................................................................................................................ 33 RESISTOR COLOR CODE CHART ................................................................................................................................................................. 34 CAPACITOR CODE CHART .......................................................................................................................................................................... 35
APPENDIX B .............................................................................................................................................................................. 36 PARTS LIST ............................................................................................................................................................................... 36

OVERVIEW .................................................................................................................................................................................................. 37 MECHANICAL BASE .................................................................................................................................................................................... 37 CHARGER BOARD ....................................................................................................................................................................................... 39 SENSOR BOARD .......................................................................................................................................................................................... 41 ANALOG CONTROLLER BOARD .................................................................................................................................................................. 42 MISCELLANEOUS ........................................................................................................................................................................................ 43
APPENDIX C .............................................................................................................................................................................. 45 SCHEMATICS............................................................................................................................................................................ 45

CHARGER BOARD ....................................................................................................................................................................................... 46 SENSOR BOARD .......................................................................................................................................................................................... 46 MOTOR CONTROLLER BOARD .................................................................................................................................................................... 47 ANALOG CONTROLLER BOARD .................................................................................................................................................................. 48
APPENDIX D .............................................................................................................................................................................. 49 SUPPLIERS................................................................................................................................................................................. 49
2006 Oregon State University
TekBot Assembly Guide
Page iii
Preface
This manual is designed to guide a builder through the process of constructing a basic TekBots platform from beginning to end in a step-by-step fashion. Little to no experience is assumed on the part of the builder, except for the understanding of how to solder electrical circuits.
HOW TO USE THIS MANUAL IMPORTANT SYMBOLS
This symbol indicates an important note that should be remembered. Paying attention to notes like these will make tasks easier and more efficient.
This symbol designates information that must be followed. If caution is ignored the task may appear impossible. Ignored caution symbols can lead to damaged systems.
This symbol represents something that should not be forgotten. Reminder symbols are used to make sure an important step has been completed before continuing.
The innovation symbol indicates an opportunity to advance beyond what is required. These sections will give more insight into the what, why, and how of a certain topic. Use these to learn more or get ideas for nifty innovations.
Page iv
Section 1: The Mechanical Frame
Section 1
The Mechanical Frame and Motors
Page 1
MOTOR ASSEMBLY AND MOUNTING

To make connections to the motors, we will use single conductors stripped from ribbon cable. Connectors will eventually be attached to the ends of these wires, as they will be plugged and unplugged many times. The stranded conductors in the ribbon cable will provide a more durable connection than solid wire, which would break after being flexed a few times. To attach wires to the motors, begin by finding the 10 conductor ribbon cable in the kit. This is brightly colored and about 15 long.
1. 2. Split the 10 strand ribbon cable into 5 pairs of wires 2 2. Split one pair of wires 3 3. Strip 1/8 of insulation from the ends, figure 1c.
4. Tin (see the meaning below) the motor terminals by lightly coating the copper motor contacts with solder. Be careful not to fill the holes with solder, figure 1d.
5. Slide of heat shrink tubing over the ends of the wires, figure 1e.
6. Pass the wire through the motor terminal and bend it back over itself. Crimping the wire onto itself holds it in place while the soldering is done, figure 1f.
7. Pass the leads of one of the three 0.1 microfarad capacitors (Cap1) into the two motor terminals. One lead of each of the rest capacitors (Cap2 and Cap3) goes into each terminals of the motor, figure 1g.
8. Solder both the wire and capacitors leads to the terminal. For Cap2 and Cap3, solder their loose leg onto the motors metal case. Cut the excess lead of the capacitors off, figure 1h.
9. Slide the tubing over the solder joint and heat it to shrink it, figure 1i.
to tin: to cover with solder in order to avoid wearing of the metal. Repeat steps 6 through 9 for the other motor terminal. And repeat steps 2 through 9 for the other motor.
Page 2 TekBot Assembly Guide 2006 Oregon State University
How to use heat shrink tubing.
Heat shrink tubing is a common product in electronics used for insulating electrical connections and preventing short circuits. The tubing when heated will try to contract to about 50% of its original size. Commonly this heat is applied using a heat gun but in a pinch, a lighter or soldering iron can be used. When using a soldering iron, stroke the soldering iron along the heat shrink several time from all angles. Watch for the tubing to shrink.
At the other end of the motor wires, a male .1 header connector needs to be soldered on. This connector will allow for the motors to be inserted and removed many times into the TekBot motor controller without being damaged. This process can be a little hard the first few times because the male headers move as you are solder the cables. You should find a place where you could stab the male headers so they are still. The box of your TekBot kit should work.
1. Split the other end of the motor wires about to 1. 2. Using one of the strips of male header in the kit, tin two side-by-side male pins with solder. Slide a piece of heat shrink onto each wire. 3. Solder one wire to each male header pin.
4. Slide the heat shrink into place, and shrink it.
*Male connector stabbed into a piece of card board.
Page 3
To attach the motors to the TekBot use the #4 sheet metal screws included in the kit. Align the motor so that the shaft projects out of the frame and screw in the screws, fig 3.
TekBots frame v1.03
Figure 3: Motor mounted to TekBot frame.
Be cautious to not over tighten the sheet metal screws holding the motors to the frame. Too much torque can damage the motors enough they may need to be replaced.
ATTACHING THE BATTERY HOLDERS

3/8 4-40 Flat head metal bolt To attach the battery holders, place them inside of the TekBot frame with their leads away from the motors. Insert the 3/8 4-40 flat head metal bolts through the holes in the battery holders with the head of the bolt inside of the battery compartment. Attach the nuts and tighten till snug.
3xAA Battery Holder
4-40 Metal nut

Figure 4: Battery holders attached to the TekBots frame
Cut the black wire from one battery holder and the red from the other battery holder 2 long. Strip the ends and twist them together. Solder these two wires together, figure 5. Cut a piece of shrink tubing and slide it over the solder joint. Using a heat gun or a soldering iron apply heat to all sides of the shrink tubing. The tubing will shrink to fit prevent the connection from shorting to the aluminum base.
Figure 5: The steps to connect the battery holders together.
Page 5
ATTACHING THE ROLLER BALL

Place the roller ball on the bottom of the TekBot frame. Insert the round head 10-32 3/8 bolts through the holes in the TekBots frame so that the head of the bolt is inside of the frame. Attach the nuts and tighten.
Figure 7: Roller ball mounted to TekBots frame
TekBots frame v1.03
If the bolts are put in upside down, you will damage your charger board when you attach it to the frame.
ATTACHING THE WHEELS

To attach the wheels to the motors install the adapter disks, included in the kit, to your wheels. Orient the adapter disk on the wheel with the wider flange aginst the wheel using the #2 brass screws in your kits screw through one of the four holes in the adapter disk into the wheel 3/8 10-32 Round head metal bolt
Roller Ball
Figure 8: Aligned and un-aligned adapter disk
10-32 Metal nut

Once the screw is tight look at the adapter and wheel. Is the adpater in the center of the wheel? If not adjust till the adapter is even if you have to remove and reinsert the screw. After the wheel and adpter is alligned insert the other three screws.
Figure 9: Disk mounted to wheel
To attach to the motors simply press fit the adapters on the the motor shafts. This is a very tight fit and will requires quite a bit of force to mount the wheels.
#2 Brass Screw
Adapter Disk
Figure 10: Wheel mounted to motor.
3 Wheel
Congratulations, you have completed the basic assembly of your robotic base. Yours should look like figure 11.
Page 7
Figure 11: A completed TekBots base.
Page 8
Section 2: Charger Board Assembly
Section 2
Charger Board Assembly chrg.1
Page 9
OVERVIEW
The charger board is the heart of the power supply for the TekBots base. It provides both a way for charging the on-board batteries and delivering battery voltage to all of the different connected systems. Resistor Color Codes: 0 Black 1 Brown 2 Red 3 Orange 4 Yellow 5 Blue 6 Green 7 Purple 8 Gray 9 White The above picture is a 1K ohm resistor. 1(Brown) . 0(Black) * 102(Red) = 1K ohm
ASSEMBLING THE BOARD

The charger board will be used to recharge the batteries on the TekBot and to distribute power to all of the different boards on the TekBot. 1. Resistors: Begin by soldering all of the resistors into place. Resistors are not polarized so you can put them in either way.
Parts List:
R4 R3 R1 R7 R6 R2 R8 R5 10 12 180 3.3K 330K 1% 390 4.7K 820K 1%
Figure 12: Resistors soldered in place.
2. Diodes: Solder the diodes into place. Diodes are polarized so it is important which lead goes into which hole. Most diodes will have a white or black band on one end. On the silkscreen, where the diode will be placed there should be a white band as well. Be sure that the white band on the silkscreen and the white or black band on the diode are on the same side when you insert the diode.
Page 10 TekBot Assembly Guide
Parts List:
D5,D6,D7, D8 D2 D1 D4 1N4004 1N5819 1N5245B TL431CLP
Figure 13: Diodes soldered into place
Parts List:
U1 TS912IN
3. Integrated Circuits: Solder the single Integrated Circuit (IC) into place. Be careful, it is polarized and must be inserted in the correct direction. There will be either a small dot or halfmoon notch on one end of the chip. Align this with the half moon notch on the silk screen of the board for correct insertion.
Page 11
Parts List:
C1 C2 C3 Ceramic .1uF - 50V Ceramic 47pF - 50V Electrolytic 330uF 35V
Figure 14: IC soldered into place.
4. Capacitors: Solder in the capacitors now. Capacitors may or may not be polarized. To figure if a capacitor is polarized examine it and see if there is a black stripe or a little line near one of the leads. This commonly means that the capacitor is polarized. For C3 make sure the black line is towards the outside of the board.
Parts List:
JP1 J8 J1, J2, J3, J4, J5, J6 .100" Shunt 2x1 Male Header 4x1 Female Header 2x1 Female Header PJ-002A P
J7
Figure 15: Capacitors soldered in place.
Page 12
5. Connectors: There are multiple connectors and jumpers on the charger board. These connectors come in three types; the power jack, female header, and male header. The male and female headers are made by cutting sections from the larger 36 position strips that are included in the kits. A detailed example of making the female headers is presented below. Making female connectors / headers: In your kits you should have several strips of female header material. In order to make the smaller jumpers you will use on all of your boards, you need to clip sections off of these strips. To do this, simply count the number of pins you need and cut the next pin in half. Be careful to not cut too close to the piece you are keeping or it may break when you cut it off. A good tool for doing this is a pair of diagonal cutters. Figure 17 shows these steps.
Figure 16: Connectors soldered into place.
Figure 17: Making female connectors.
Page 13
6. Finishing Up: Solder the remaining parts into the board. D3 is the LED charge indicator. It is a polarized part. The longer lead should go into the board where the + sign is on the silk screen. Q1, and Q2 are transistors. Transistors are polarized also. Q1 should be inserted so that it lines up with the silk screen. Q2 should be inserted so that the metal tab on the top of Q2 lines up with the thick white line on the silk screen.
Parts List:
D3 F1 HLMP1700 LED MFRX110 Fuse EG1213 Miniature Slide Switch 2N4401 TIP29C
S1 Q1 Q2
Figure 18: The completed charger board.
MOUNTING THE BOARD ON YOUR ROBOT

1. Use 3 4-40 metal machine bolts, 3 4-40 round spacers, and 3 4-40 metal nuts to mount the charger board to your aluminum base. Align your charger board as shown below and attach it. DO NOT MOUNT THE BOARD DIRECTLY TO THE METAL BASE; USE THE 4-40 SPACERS. Figure 19 shows an attached charger board.
Page 14
Figure 19: Diagram of spacer usage and base with connected charger board.
2. Now you need to connect your batteries to the charger board. To do this you will need to solder a male header onto the battery leads so that they can be plugged into the charger board. This process is the same as putting the male headers on the ends of the motor wires. Refer to section 1 for assistance. 3. Plug the battery connection into your charger board as shown in figure 20. Notice that the red lead is closer to F1. If you reverse this plug you WILL destroy your board and you will need to purchase a new one.
Figure 20: Battery holders plugged into the charger board.
Page 15
Section 3: The Motor Controller Board
Section 3
The Motor Controller Board mtr_ctlr.1
Page 16
Section 3: The Motor Controller Board
PURPOSE
The mtr_ctlr.1 board that comes with the TekBots base is pre-assembled except for the addition of female connectors for interfacing to the motors and the other system boards. This two channel control slows for two motors to be controlled.
MOUNTING THE BOARD ON YOUR ROBOT

Using 4 4-40 metal machine bolts, 4 4-40 round spacers, and 4 4-40 metal nuts mount the motor controller board. You can put this board anywhere you want on the acrylic layer of the robot. Be sure to use the nylon spacers for mounting the board, figure 23.
Figure 23: Mounting diagram for motor controller board.
Page 17
Section 4: Sensor Board
Section 4
Sensor Board sense.1
Page 18
PURPOSE
The forward mounted sensor board has two tactile switches used to signal the TekBot when it impacts an object.
ASSEMBLING THE BOARD

The sensor board is used by the TekBot to detect when it hits an object. When either switch is depressed a signal will be sent to the analog controller indicating the switch is depressed. 1. Resistors: Begin by soldering all of the resistors into place. Resistors are not polarized so you can put them in either way.
Parts List:
R1, R2 100
Figure 24: Resistors soldered in place.
2. Connectors: There are multiple connectors on the motor board. Construct the female headers as you did when building the charger board above.
Parts List:
J1, J2 2x1 Female Header
Figure 25: Connectors soldered into place.
Page 19
3. Finishing Up: Solder the two switches onto the board...
Parts List:
S1, S2 EG1201 Switches
Figure 26: The completed sensor board.
MOUNTING THE BOARD ON YOUR TEKBOT

Using 2 4-40 metal machine bolts, 2 4-40 round spacers, and 2 4-40 metal nuts mount the sensor board. Align the sensor board as shown below and attach it to the acrylic layer of the robot. Be sure to use the nylon spacers for mounting the board.
Figure 27: Base with connected sense board.
Page 20
Section 5: The Analog Controller Board
Section 5
The Analog Controller Board anlg_ctlr.1
Page 21
PURPOSE
The TekBots analog controller allows for simple TekBot behavior using only analog components. The board is 'programmable' using voltage references that can be set using on board potentiometers. It can be used to create a simple 'bump-bot' functionality, or as an emergency backup of a digital system.
PROCEDURE
Figure 28 shows the PCB (printed circuit board) of the analog board you will be using. The white writing/pictures on the PCB, called silkscreen, can help you to identify locations, orientation, and polarities for the components.
Figure 28: Analog board PCB
Page 22
1. Potentiometers: Solder the potentiometers in place as shown in Figure 29. They are designated R1 R4. 2. Resistors: Solder resistors in place as shown in Figure 30. Note that there is no R7. Parts List:
R1 R2 R3 R4
Potentiometer 10K 409H Ceremet Potentiometer 10K 409H Ceremet Potentiometer 10K 409H Ceremet Potentiometer 10K 409H Ceremet
Parts List:
R5 R6 R8 R9 R10 R11 R12
220 Resistor 1M Resistor 10K Resistor 10K Resistor 1M Resistor 100 Resistor 100 Resistor
Figure XX: Analog Control Board with Potentiometers in place.
Figure XX: Analog Control Board with Resisitors in place.
Page 23
Parts List:
D1 D2
1N5232B 1N5819
3. Diodes: Before you solder the diodes onto the analog board, please check their orientations: make sure the line of the diodes match the line on the silkscreen (the white pictures/writing on the PCB); then double check to see if the diodes are placed correctly. You may then solder the diodes onto the analog board.
Figure 31: Analog board with step 3 finished
Figure 32: This is a close-up of the diodes. Pay close attention on the diodes orientation.
Page 24
Parts List:
C1 C2 C4
10 F Capacitor 10 F Capacitor 0.1 F Capacitor
4. Capacitors: Solder the capacitors in place. C1 and C2 are polarized so make sure the orientation of each diode is correct (longer lead is positive). C4 is not polarized. If youre having trouble deciding the capacitor values, please refer to Appendix B analog board. There is also a capacitor code chart in Appendix A. 5. Comparator chip: Before you solder the comparator chip onto the analog board, check the orientation of the chip: make sure the semi-circle of the chip matches the semicircle on the silkscreen; then double check to see if the chip is placed correctly. You may then solder the comparator chip onto the analog board.
Parts List:
U1
IC LM339 Quad Comparator
Figure XX: Analog Control Board with Capacitors in place. 2006 Oregon State University
Figure XX: Analog Control Board with IC in place. TekBot Assembly Guide Page 25
6. Female headers: Solder female headers in place. The female headers are created like in previous sections for the Parts List: charger and motor controller boards.
J1 J2 J3 J4 J5
4-pin female header 2-pin female header 4-pin female header 4-pin female header 2-pin female header r
Now you may place the analog controller board onto the TekBot.
Figure 35: Analog board fully assembled.
Page 26
Section 6: Final Assembly
Section 6
Final Assembly
Page 27
FINAL ASSEMBLY
1. Our last step after all of the boards are mounted is to connect them together. You can put any of the boards anywhere you would like to except that the sensor board needs to be on the front of the TekBot so that it can detect its environment. 2. You will be assembling a system like the one shown in figure 10. To connect power to the boards, and signals between the boards, you should use pieces of CAT-5 cable available in your kits. This cable is very inexpensive and plugs in nicely to the female header receptacles on your boards.
Figure 36: The complete system.
3. Figure 38 shows the wiring for the boards used in your system. Figure 37 shows an example of a completely assembled robot.
Figure 37 Page 28 TekBot Assembly Guide 2006 Oregon State University
Figure 38: TekBot Wiring Diagram
Page 29
TUNING YOUR TEKBOT

1. Now you need to tune your TekBot so that is operates intelligently. We do this by adjusting the variable resistors R1, R2, R3, and R4 on the analog brain board. You will notice that these resistors are labeled Left Rev. and Right Rev. The variable resistors on the left (R1 and R2) control the robots response when the left switch is triggered, and the ones on the right (R3 and R4) work when the right switch is triggered. This allows for different responses to each switch. Lets begin by tuning the response to the left switch.
Figure 39: Analog board.
2. When the left switch is hit we want the robot to back straight up, then turn to the right and continue. To do this, first both motors should reverse then the left motor should turn forward while the right motor continues in reverse. So the reverse time on the left motor should be shorter than the right motor. On our TekBots, turning the variable resistors clockwise makes a wheel turn backwards longer. So adjust R3 and R4 so that when the left switch is hit the left wheel backs up for less time than the right wheel. Figure 40 shows an example of how these might be set.
Page 30
Figure 40: Left switch response settings.
3. Now set the right whisker to respond in the opposite manner with the right motor reversing for less time than the left motor.
Page 31
Appendix A: General Reference Material
Appendix A
General Reference Material
Page 32
SCHEMATIC SYMBOLS
Figure 41: A table of schematic symbols
Page 33
RESISTOR COLOR CODE CHART
Figure 42: Resistor Color Code Chart
Page 34
CAPACITOR CODE CHART
Figure 43: Capacitor Code Chart
Page 35
Appendix B: Part List
Appendix B
Parts List
Page 36
Appendix B: Parts List
OVERVIEW
This section contains a list of all of the parts used in the construction of the TekBot kit. When available, supplier and manufacturer part numbers are also listed to ease replacement. Contact information for the various suppliers is provided in appendix D.
MECHANICAL BASE
Qty 8 Description Bolts Brass Flat Head 1/2 Wood Screw
Figure A
Supplier McMaster Carr
Supplier # 92114A081
Fig. A
Fig. B
Bolts Metal 10-24 Pan Head 3/8 Standard
McMaster Carr
90279A240 Fig. C Fig. D
Bolts Metal 4-40 Flat Head 1/2" Sheet
McMaster Carr
90048A110
Bolts Metal 4-40 Flat Head 5/8" Standard
McMaster Carr
90273A112 Fig. E Fig. F
Bolts Nylon 8-32 Pan Head 3/8 Standard
McMaster Carr
94609A192
Nuts Metal 10-24
McMaster Carr
90480A011 Fig. G Fig. H
Nuts Metal 4-40
McMaster Carr
90480A005
Nuts Nylon 8-32
McMaster Carr
94812A114 Fig. I Fig. J
Metal Base v1.03
TekBots
base.1
Plexiglass Level v1.03
TekBots
base.1
Page 37
Fig. K
2 GMW GM-* Wheel Adapters K TekBots GMW
Fig. L
GM-8 Motors
Solarbotics
GM-8
Wheels 3 Dave Brown LiteFlight
TekBots
3 Wheel
Fig. M
Fig. N
5/8 Roller Ball
TekBots
Roller Ball 92745A545
Spacers 1.5 8-32 Nylon, Male-Female Threaded
McMaster Carr
Fig. O
Page 38
CHARGER BOARD
Qty 4 Description Diode Rectifier 1N4004 D041 Referenc e D5, D6, D7, D8 D2 Fig. A Supplier Mouser Supplier # 583-1N4004 Fig. A: Fig. B:
Diode Schotkey 1N5819 -DO204AL
Mouser
625-1N5819 Fig. D:
Diode Zener 1N5245B D035 Diode Zener TL431CLP TO 266AA (TO92) LED Red HLMP1700
D1
Mouser
625-1N5245B
Fig. C:
D4
Mouser
512-TL431CLP Fig. E: Fig. F:
D3
Mouser
512-HLMP-1700
Transistor BJT 2N4401 NPN TO92
Q1
Mouser
625-2N4401 Fig. G: Fig. H:
Transistor BJT TIP29C TO220
Q2
Mouser McMaster Carr McMaster Carr DigiKey
512-TIP29CTSTU
Bolts 4-40 Pan Head 3/8" - Standard
90273A108 Fig. I: Fig. J:
Bolts 4-40 Pan Head 1/2" - Standard Power Connector PJ-002A Female Coaxial Connecter Header - .100 Shunt w/Handle IC Dual Op Amp TS912IN
91773A110 CP-002A-ND
J9
JP1
DigiKey
A26242-ND
U1
Mouser
511-TS912IN
Page 39
7 1 6 2 1 1
Nuts 4-40 AC Adaptor 12V/120mA Plug-In Batteries Rechargeable NiCad Battery Holders 3XAA 6 Leads Fuse MFRX110 1.1A Resetable Capacitor Ceramic Disk - .1uF Capacitor Ceramic Disk - 47 pF Capacitor Electrolytic 330uF 1.8 Watt, 10 Resistor 1.8 Watt, 12 Resistor 1.8 Watt, 180 Resistor 1.8 Watt, 3.3K Resistor 1.8 Watt, 330K Resistor 1% Tolerance 1.8 Watt, 390 Resistor 1.8 Watt, 4.7K Resistor 1.4 Watt, 820K Resistor 1% Tolerance Nylon Spacers Switch - EG1213 Miniature SPDT S1 F1 C1 C2 C3 R4 R3 R1 R7 R6 R2 R8 R5 M N O P P Q R R R R R R R R S T
McMaster Carr TekBots TekBots Mouser Mouser Mouser Mouser Mouser Mouser Mouser Mouser Mouser Mouser Mouser Mouser Mouser McMaster Carr Mouser
90480A005
Fig. M:
Fig. N:
Wall Wart NiCad Battery 12BH331 652-MFRX110 581-SR205E104M 140-50S2-470J 140-XRL35V330 299-10 299-12 299-180 299-3.3K P330KCACT-ND 299-390 299-4.7K P820KCACT-ND 94639A615 612-EG1213 Fig. S Fig. T Fig. Q Fig. R Fig. O Fig. P
1 1 1 1 1 1 1 1 1 1 3 1
Page 40
SENSOR BOARD
Qty 2 Description 1/8 Watt Resistor 100 Referenc e R1, R2 Fig. A Supplier Mouser McMaster Carr McMaster Carr McMaster Carr Supplier # 299-100 Fig. A Fig. B
Bolts 4-40 Pan Head 1/2" Standard
91773A110 Fig. C: 90480A005 Fig. D:
Nuts 4-40
Spacers 3/16 Nylon
94639A615 Fig. E:
Switches Tact Switch EG1025
S1, S2
Mouser
612-TL1100G
Fig. F:
Switches Switch Key Cap EG1076
Mouser
612-TAA-BK
Page 41
ANALOG CONTROLLER BOARD

Qty 1 Description Diode Schotkey 1N5819 -DO204AL Referenc e D2 D1 Fig. A Supplier Mouser Supplier # 625-1N5819 1N5232BMSC T-ND 91773A110 Fig. C: Fig. D: Fig. A: Fig. B:
Diode Zener 1N5232B D035
Digikey McMaster Carr
C U1
Digikey McMaster Carr McMaster Carr
LM339NNSND
Spacers 3/16 Nylon
94639A615
Fig. E:
Fig. F:
Nuts 4-40 Capacitor Ceramic Disk - .1 Spacing .1uF Capacitor Tantalum 10uF
F C4
90480A005 581SR205E104M P2026-ND 323-409H10K 299-10K Fig. G: Fig. H:
Mouser
C1, C2 R1, R2, R3, R4 R8, R9 R11, R12 R6, R10
Digikey
Potentiometer 10K 409H Ceremet
Mouser
Fig. I:
Fig. J:
10K Resistor
Mouser
100 Resistor
Mouser
299-100
1M Resistor
Mouser
299-1M
220 Resistor
R5
Mouser
299-220
Page 42
MISCELLANEOUS
Qty 3 Description 36 Female Header Figure A Supplier DigiKey Supplier # 929974-0136-ND A116B-4-ND Small Protoboard Fig. C 1 10 Conductor Ribbon Cable 15 inches Mouser 5173302/10FT mtr_ctlr.1 Fig. E Fig. F Fig. D Fig. A Fig. B
1/16 Heat Shrink 1 foot
DigiKey
Protoboard
TekBots
mtr_ctlr.1 Assembled Motor Controller Board
TekBots
CAT-5 Wire 1 foot
TekBots
CAT-5 94639A615
Nylon Spacers
McMaster Carr
Nuts Metal 4-40
McMaster Carr
90480A005
McMaster Carr
91773A110
Page 43
EXTRA PARTS LIST

Qty 6 Description Capacitor Ceramic Disk - .1uF 10K Resistor Figure A Supplier Mouser Supplier # 581SR205E104M 299-10K Fig. A Fig. B
Mouser
Switch 10K ohm Square Sealed Potentiometer Photocell Resistors
Digikey
SW400-ND 652-3386H1-103 202411

LM339NNSN D
Fig. C
Fig. D
Mouser
Fig. F Fig. E
Jameco
Digikey
Page 44
Appendix C: Schematics
Appendix C
Schematics
Page 45
CHARGER BOARD
Figure 44: Block diagram of the charger board
SENSOR BOARD
Figure 45: Schematic of the sensor board
Page 46
MOTOR CONTROLLER BOARD
Figure 46: Block diagram of the motor controller board 2006 Oregon State University TekBot Assembly Guide Page 47
ANALOG CONTROLLER BOARD
Figure 47: Block diagram of the analog board Page 48 TekBot Assembly Guide 2006 Oregon State University
Appendix D: Suppliers
Appendix D
Suppliers
Page 49
DigiKey
701 Brooks Ave. South Thief River Falls, MN 56701-0677 (800) 344-4539 http://www.digikey.com 1000 N. Main Street Mansfield, TX 76063 (800) 346-6873 http://www.mouser.com 6700 SW 105th St, Suite 106 Beaverton, OR 97008 (800) 433-5700 http://www.alliedelec.com 220 Owen Hall Oregon State University Corvallis, OR 97331 tekbots_support@eecs.oregonstate.edu http://eecs.oregonstate.edu/tekbots 179 Harvest Glen Way N.E. Calgary, Alberta, Canada T3K 4J4 (866) B-ROBOTS http://www.solarbotics.com P.O. Box 7690 Chicago, IL 60680-7684 (562) 692-5911 http://www.mcmaster.com 1355 Shoreway Rd Belmont, CA 94002 (800) 831-4242 http://www.jameco.com
Mouser Electronics
Allied Electronics
TekBots
Solarbotics
McMaster-Carr
Jameco Electronics
Page 50
Thank you for choosing Oregon State University Tekbots!
Page 51

Tek Bot Assembly

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2006 Oregon State University

TekBot Assembly Guide

HOW TO USE THIS MANUAL IMPORTANT SYMBOLS

TekBot Assembly Guide

2006 Oregon State University

Section 1: The Mechanical Frame

2006 Oregon State University

TekBot Assembly Guide

Section 1: The Mechanical Frame

MOTOR ASSEMBLY AND MOUNTING

Section 1: The Mechanical Frame

How to use heat shrink tubing.

4. Slide the heat shrink into place, and shrink it.

*Male connector stabbed into a piece of card board.

2006 Oregon State University

TekBot Assembly Guide

Section 1: The Mechanical Frame

TekBots frame v1.03

Figure 3: Motor mounted to TekBot frame.

ATTACHING THE BATTERY HOLDERS

3xAA Battery Holder

4-40 Metal nut

Section 1: The Mechanical Frame

Figure 4: Battery holders attached to the TekBots frame

Figure 5: The steps to connect the battery holders together.

2006 Oregon State University

TekBot Assembly Guide

Section 1: The Mechanical Frame

ATTACHING THE ROLLER BALL

Figure 7: Roller ball mounted to TekBots frame

TekBots frame v1.03

ATTACHING THE WHEELS

Figure 8: Aligned and un-aligned adapter disk

10-32 Metal nut

Section 1: The Mechanical Frame

Figure 9: Disk mounted to wheel

Figure 10: Wheel mounted to motor.

2006 Oregon State University

TekBot Assembly Guide

Section 1: The Mechanical Frame

Figure 11: A completed TekBots base.

TekBot Assembly Guide

2006 Oregon State University

Section 2: Charger Board Assembly

2006 Oregon State University

TekBot Assembly Guide

Section 2: Charger Board Assembly

ASSEMBLING THE BOARD

Figure 12: Resistors soldered in place.

2006 Oregon State University

Section 2: Charger Board Assembly

Figure 13: Diodes soldered into place

2006 Oregon State University

TekBot Assembly Guide

Section 2: Charger Board Assembly

Figure 14: IC soldered into place.

Figure 15: Capacitors soldered in place.

TekBot Assembly Guide

2006 Oregon State University

Section 2: Charger Board Assembly

Figure 16: Connectors soldered into place.

Figure 17: Making female connectors.