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BUILD A

REMOTE-

CONTROLLED

ROBOT

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BUILD A

REMOTE-

CONTROLLED

ROBOT

DAVID R. SHIRCLIFF

Copyright © 2002 by The McGraw-Hill Companies, Inc. All rights reserved. Manufactured in the United States of America. Except as permitted under the United States Copyright Act of 1976, no part of this publication may be reproduced or distributed in any form or by any means, or stored in a data- base or retrieval system, without the prior written permission of the publisher.

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ABOUT THE AUTHOR

David Shircliff is a teacher at Seneca Ridge Middle School in Loudon County, Virginia, where he teaches classes in technology education. A dedicated electronics enthusiast, Mr. Shircliff has been researching and building robots for over 20 years.

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vii

CONTENTS

Preface ix Introduction xi

CHAPTER ONE. THE MOTORIZED PLATFORM 1

Preparing Motorized Wheels 1 The Platform 4 Mounting Wheels 6 Third Castor Wheel 9 Finishing Touches 11

CHAPTER TWO. BODY FRAMEWORK 13

Cutting Aluminum 13 Drilling and Cutting the Sections 15 Assembling Framework 30 Mounting Framework on the Platform 34 Mounting the Vacuum Outlet 35

CHAPTER THREE. POWER SUPPLY AND TEMPORARY CONTROL BOX 39

Mounting Batteries and Barrier Strips 39 Wiring Platform 43 Temporary Control Box 45 Control Box Construction 48 Wiring the Temporary Control Box 48 Using the Control Box 51

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PREFACE

I

n recent years robots have captured the interest of more and more people. Thanks to movies and TV, the notion of the robot as a mechanical companion and servant has become a common concept. As interest in robots grew, a number of books showing how to build robots at home began to appear. These books, however, were very technical, showing how to build computer-controlled mobile platforms that are consid- ered by most to be true robots. My interest in robots leaned more toward the popular con- cept of robots as humanlike friends and servants. I did not have the technical skill or funds to build a computer-controlled robot, so I decided to develop a robot that would fit the popu- lar image of robots and not be too difficult to complete or expensive to build. The result was Questor. While working on Questor, I tried to develop a project that I, as a beginner, could complete with little technical skill, using tools I had in my workshop. Also, I wanted Questor to look and function like a robot butler, a form I felt best fit the friend/servant theme. For this reason I needed a people-sized robot that would have great presence. I concentrated more on form than sophistication to develop an impressive looking, but relatively simple-to-build, project—a beginner’s project. Later, when I decided to write a book about the project, I wanted to avoid weaknesses I found in other how-to robot books. This book is heavily illustrated, helping to take the guesswork out of Questor’s construction. Next, the book deals only with the construction of the robot, and not the theories on which it is based. This type of information is best derived from specialty electronics and robotics books. I have included

ix

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a list of books and magazines that supply information, as well as other possible sources for robot kits and parts. It is my hope that you will use this book not only to build your own version of Questor, but to guide you in creating your own unique robot. This way your robot will reflect your knowl- edge and skill as a builder. Also, I hope that your robot will be used as a test bed for other robotics projects. If you are like me, once you build your own robot, you’ll always be trying to improve it.

David R. Shircliff

x PREFACE

would like to have. It applies more specifically to those types of robots at work in factories all over the world, shown here in Figs. I-2 through I-4. These assembly line type robots can do everything from welding a car (then painting it) to assembling delicate electronics components, all automatically, 24 hours a day if needed, and without a break. They don’t get sick (although when they do break down, they can be easily repaired or even replaced), ask for pay raises, or any pay for that matter, and can be retrained to do another job in a matter of minutes by simply changing the job program in their control computers. If you look again at Figs. I-2 through I-4, you will see that while the device most certainly looks mechanical, it does not look like a human. Instead it takes the shape of the most useful part of the human anatomy, from a robot stand- point, the arm. Both these definitions seem to be correct in their specific case, but there is a middle family between the simple auto- mated device and the sophisticated computer-controlled

xii INTRODUCTION

FIGURE I-1. The robots of the play R.U.R. (Rossum’s Universal Robots) attack their human masters. (Courtesy of New York Public Library at Lincoln Center.)

manipulator. This middle family is that of the show robot or showbot. Questor, the robot outlined in this book, is a mem- ber of the showbot family. Figures I-5 through I-8 picture examples of commercial show robots. A showbot in most cases has no computer brain. Instead it is controlled via a remote control system operated by a person somewhere out of sight. You might have seen or heard of a

INTRODUCTION xiii

FIGURE I-2. An industrial robot. ( Courtesy of Cincinnati Milacron. )

showbot entertaining groups of fascinated people in shopping malls or on TV as characters in movies. I even read about a showbot delivering a speech at a college graduation. Showbots, however, can be adapted for use in the home. This book lays the groundwork to construct one such home showbot, Questor. (See Figs. I-9 and I-10.) Questor was designed to look like and function like a butler. There is a drink dispenser built into his arm and a vacuum port in his mobile platform. I felt these two functions are what most people expect a robot servant to do. The arms, which help promote Questor’s humanoid shape, are nonfunctional; they serve only to hold the serving tray. The hands are made of two auto drink holders. A button located on the wrist (the area above where the hands are bolted on) controls the drink dispenser. His head is a lamp, and there are two headlights on the front of the mobile platform. These lights not only help the operator guide the showbot at night, but they are very useful during power blackouts. There is also a 12-volt direct current (dc) ciga- rette lighter plug on the side of the base. This is used to run bat- tery-powered appliances such as portable radios or TVs off the robot’s batteries.

INTRODUCTION xv

FIGURE I-5. Showbots come in many shapes and sizes. ( Courtesy of Ken Zaken, Robots 4 Fun. )

A horn located on the lower part of the front body panel announces Questor’s presence. I plan to add a tape recorder for prerecorded messages. This is something you could consider designing into your showbot. Finally, his body panels and arms were painted to look as though Questor is wearing a tuxedo jacket, and a light-up bow tie completes the look. I also designed Questor so he could be built using tools found in a home workshop and parts available in local hard- ware and electronics stores. However, there are a few parts you will have to order. The following list of what I’ve deter- mined are “must buy parts” shows items you will need to pur- chase before starting construction. The address for a parts supplier, Herbach & Rademan Company, is listed in Sources in the back of the book.

xvi INTRODUCTION

FIGURE I-6. The Six-T showbot can blow up balloons! ( Courtesy of The Robot Factory. )

remote control system, as are the rest of the parts, is a standard off-the-shelf item. At this point, you should read through the book to famil- iarize yourself with the diagrams, photographs, parts lists, and overall format. Once you plan your showbot, you can order the “must buy” items. You are now ready to enter the fascinat- ing world of robotics.

ROBOT BASICS

But first, a review of the basics. The construction of a remote-controlled robot, while not easy, need not be difficult. My motto when designing and building Questor was “keep it simple, stupid” (KISS)! The

xviii INTRODUCTION

FIGURE I-8. Quadracon and friend Peeper. ( Courtesy of Pelican Beach LLC, successor to ShowAmerica Inc. )

INTRODUCTION xix

FIGURE I-9. Questor the robot servant (front view).

FIGURE I-10. Side view.