The Robot Builder's Guide

Foreword......Page 4 Preface......Page 6 Introduction to this Guide......Page 12 Contents......Page 14 List of Figures......Page 22 Electronic Assembly Technique......Page 26 Soldering Technique......Page 27 Component Types & Polarity......Page 29 Component Mounting......Page 34 Component Value Markings......Page 35 Parts List......Page 202 Microprocessor Board......Page 36 Assembly......Page 37 Testing......Page 45 Assembly......Page 47 Testing......Page 51 Battery System......Page 53 Battery Charger......Page 54 Battery Pack Construction......Page 56 IR Transmitter......Page 58 Motor Switch Board......Page 61 Cable & Connector Wiring......Page 63 Sensor Wiring......Page 64 Touch Sensors......Page 68 Photocell Light Sensor......Page 69 IR Reflectance Sensor......Page 70 Single Bend Sensor......Page 71 Dual Bend Sensor......Page 72 Potentiometer......Page 73 Slotted Optical Switch......Page 74 Hall Effect Sensor......Page 75 Polaroid Motor......Page 76 Servo Motor......Page 79 Computer Cable Wiring......Page 81 Ratings & Specifications......Page 84 Measuring Motor Torque......Page 86 Speed, Torque & Gear Reduction......Page 87 Pulse Width Modulation......Page 88 Control......Page 89 Application......Page 90 Capacity......Page 92 Internal Resistance......Page 93 Rechargeability......Page 94 Battery Packs......Page 95 6.270 Battery Charger......Page 96 Fundamental LEGO Lengths......Page 98 LEGO Gearing......Page 101 Gear Reduction......Page 103 Low-Force Geartrains......Page 104 Sample Gearbox Design......Page 105 Analog & Digital Sensors......Page 106 Digital Inputs......Page 107 Connector Plug Standard......Page 108 Voltage Divider Circuit......Page 109 Tactile Sensors......Page 110 Touch Switch......Page 111 Bend Sensor......Page 113 Light Sensors......Page 114 IR Reflectance Sensor......Page 116 Slotted Optical Switch......Page 118 Magnetism (Hall Effect) Sensor......Page 119 Motor Current Sensor......Page 120 Robot Control......Page 122 Feedback Control......Page 123 Open-Loop Control......Page 125 Feed-Forward Control......Page 126 Manual Calibration......Page 127 Dealing with Changing Environmental Conditions......Page 128 Robot Control......Page 129 Sensor Unreliability......Page 130 Task-Oriented Control......Page 131 Coordination of Tasks......Page 135 IC Manual......Page 140 Getting Started......Page 141 IC Commands......Page 142 Line Editing......Page 143 A Quick C Tutorial......Page 144 Data Types......Page 146 Local & Global Variables......Page 147 Constants......Page 148 Operators......Page 149 Assignment Operators & Expressions......Page 150 Precedence & Order of Evaluation......Page 151 While......Page 152 LCD Screen Printing......Page 153 Formatting Command Summary......Page 154 Declaring & Initializing Arrays......Page 155 Declaring Pointer Variables......Page 156 Passing Pointers as Arguments......Page 157 Output Control......Page 158 Sensor Input......Page 160 Time Commands......Page 165 Overview......Page 166 Creating New Processes......Page 167 Destroying Processes......Page 168 Floating Point Functions......Page 169 Memory Access Functions......Page 170 Run-Time Errors......Page 171 Binary Source File......Page 172 Interrupt-Driven Binary Programs......Page 175 Passing Array Pointers to a Binary Program......Page 179 List Files......Page 180 Configuring IC......Page 181 Introduction to 6.270......Page 182 Kit Fee & Toolkit Fee......Page 183 Team Organization......Page 184 Credit Guidelines......Page 185 Schedule......Page 187 Balls......Page 194 Period of Play......Page 197 IR Beacon......Page 198 Contest Playing Table......Page 199 Structure......Page 200 $10 Electronics Rule......Page 201 Microprocessor & Memory......Page 208 Multiplexing Address & Data......Page 209 Memory Mapping......Page 210 Block Diagram......Page 211 Memory-Mapping the RAM......Page 212 74HC138 Memory Map Chip......Page 213 Digital Outputs......Page 216 Motor Drivers......Page 218 H-Bridge with Enable Circuitry......Page 220 L293 Motor Driver Chip......Page 221 Power Considerations......Page 224 Analog Inputs......Page 226 Motor Current Monitoring Circuit......Page 227 Input Multiplexing on the Expansion Board......Page 228 Serial Output......Page 229 Serial Input......Page 231 Power-Off Interrupt......Page 232 Power-Up Delays......Page 233 IR Transmission Circuit......Page 234 IR Beacon......Page 236 LCD Display......Page 237 Low-Battery Indicator......Page 239 Printed Circuit Layouts......Page 240 Microprocessor Board......Page 241 Expansion Board......Page 242 Motor Switch Board......Page 243 IR Beacon Board......Page 244 Retail Suppliers......Page 246 Ordering Catalogs......Page 247 Surplus Companies......Page 248 Retail Companies......Page 253 Speaker Driver Hack......Page 256 Foreword 4 Preface 6 Introduction to this Guide 12 Contents 14 List of Figures 22 Assembly Manual 26 Electronic Assembly Technique 26 Soldering Technique 27 Desoldering Technique 29 Component Types & Polarity 29 Component Mounting 34 Component Value Markings 35 Parts List 202 Microprocessor Board 36 Assembly 37 Testing 45 Post Checkout 47 Expansion Board 47 Assembly 47 Testing 51 Post Checkout 53 LCD Display 53 Battery System 53 Battery Charger 54 Battery Pack Construction 56 IR Transmitter 58 Motor Switch Board 61 Cable & Connector Wiring 63 Sensor Wiring 64 Touch Sensors 68 Photocell Light Sensor 69 IR Reflectance Sensor 70 Single Bend Sensor 71 Dual Bend Sensor 72 Sharp IR Sensor 73 Potentiometer 73 Slotted Optical Switch 74 Hall Effect Sensor 75 Motor Wiring 76 Polaroid Motor 76 Servo Motor 79 Computer Cable Wiring 81 Motors 84 DC Motors 84 Ratings & Specifications 84 Measuring Motor Torque 86 Speed, Torque & Gear Reduction 87 Pulse Width Modulation 88 Stepper Motors 89 Servo Motors 89 Control 89 Application 90 Batteries 92 Cell Characteristics 92 Voltage 92 Capacity 92 Power Density 93 Discharge Curve 93 Internal Resistance 93 Rechargeability 94 Cost 95 Battery Packs 95 6.270 Battery Charger 96 LEGO Design 98 Fundamental LEGO Lengths 98 LEGO Gearing 101 Gear Reduction 103 Chain Drives 104 Testing a Geartrain 104 Low-Force Geartrains 104 Sample Gearbox Design 105 Sensor Design 106 Sensors as Transducers 106 Analog & Digital Sensors 106 Sensor Inputs on the 6.270 Board 107 Analog Inputs 107 Digital Inputs 107 Connector Plug Standard 108 Sensor Input Wiring 109 Voltage Divider Circuit 109 Tactile Sensors 110 Touch Switch 111 Bend Sensor 113 Potentiometer 114 Light Sensors 114 Photocell 116 IR Reflectance Sensor 116 Slotted Optical Switch 118 Sharp Modulated IR Detector 119 Other Sensors 119 Magnetism (Hall Effect) Sensor 119 Motor Current Sensor 120 Robot Control 122 Basic Control Methods 123 Feedback Control 123 Open-Loop Control 125 Feed-Forward Control 126 Summary 127 Sensor Calibration 127 Manual Calibration 127 Dealing with Changing Environmental Conditions 128 Using Persistent Global Variables 129 Robot Control 129 Sensor Unreliability 130 Task-Oriented Control 131 Coordination of Tasks 135 IC Manual 140 Getting Started 141 Using IC 142 IC Commands 142 Line Editing 143 The main() Function 144 A Quick C Tutorial 144 Data Types, Operators & Expressions 146 Variable Names 146 Data Types 146 Local & Global Variables 147 Constants 148 Operators 149 Assignment Operators & Expressions 150 Increment & Decrement Operators 151 Precedence & Order of Evaluation 151 Control Flow 152 Statements & Blocks 152 If-Else 152 While 152 For 153 Break 153 LCD Screen Printing 153 Printing Examples 154 Formatting Command Summary 154 Special Notes 155 Arrays & Pointers 155 Declaring & Initializing Arrays 155 Passing Arrays as Arguments 156 Declaring Pointer Variables 156 Passing Pointers as Arguments 157 The IC Library File 158 Output Control 158 Sensor Input 160 Time Commands 165 Tone Functions 166 Multi-Tasking 166 Overview 166 Creating New Processes 167 Destroying Processes 168 Process Management Commands 169 Process Management Library Functions 169 Floating Point Functions 169 Memory Access Functions 170 Error Handling 171 Compile-Time Errors 171 Run-Time Errors 171 Error Codes 172 Binary Programs 172 Binary Source File 172 Interrupt-Driven Binary Programs 175 Binary Object File 179 Loading an icb File 179 Passing Array Pointers to a Binary Program 179 IC File Formats & Management 180 C Programs 180 List Files 180 File & Function Management 181 Configuring IC 181 Introduction to 6.270 182 Registration Policy 183 Kit Fee & Toolkit Fee 183 Team Organization 184 6.270 Alumni 185 Credit Guidelines 185 Schedule 187 Robo-Cup Contest Rules 194 Object 194 Balls 194 The Goal 197 Period of Play 197 Control 198 IR Beacon 198 Contest Playing Table 199 Structure 200 $10 Electronics Rule 201 Scoring 202 Organizers 202 Parts List 202 6.270 Hardware 208 Microprocessor & Memory 208 Multiplexing Address & Data 209 Memory Mapping 210 Block Diagram 211 Memory-Mapping the RAM 212 74HC138 Memory Map Chip 213 System Memory Map 216 Digital Inputs 216 Digital Outputs 216 6811 & Memory Schematic 218 Motor Drivers 218 H-Bridge Circuit 220 H-Bridge with Enable Circuitry 220 L293 Motor Driver Chip 221 Power Considerations 224 Expansion Board Motor & LED Circuitry 226 Analog Inputs 226 Motor Current Monitoring Circuit 227 Input Multiplexing on the Expansion Board 228 Serial Line Circuit 229 Serial Output 229 Serial Input 231 Battery-Backing the Static Ram 232 Powering the Memory Chip 232 Power-Off Interrupt 232 Power-Up Delays 233 IR Transmission Circuit 234 IR Beacon 236 LCD Display 237 Low-Battery Indicator 239 Printed Circuit Layouts 240 Microprocessor Board 241 Expansion Board 242 Battery Charger Board 243 Motor Switch Board 243 IR Beacon Board 244 Electronic Suppliers 246 Introduction 246 Retail Suppliers 246 Surplus Suppliers 247 Ordering Catalogs 247 Surplus Companies 248 Retail Companies 253 Speaker Driver Hack 256