OPERATING MANUAL Version 01/11 PRO-BOT 128 Item no. 19 19 19 (Kit) Item no.
Table of Contents Page 1. 2. 3. 4. 5. 6. Introduction .............................................................................................................................................................................................. 4 Intended use ............................................................................................................................................................................................. 5 Symbol explanation ........................................
Page 11. Assembly stage II: Sight inspection of the circuit board ................................................................................................................... 28 a) Assembly plan (drive unit) ................................................................................................................................................................... 28 b) Assembly plan (main unit) .....................................................................................................
1. Introduction Dear Customer, Thank you for purchasing the PRO-BOT 128. This mobile robot is equipped with a programmable microcomputer, which allows you to define the behaviour and the basic reactions of the robot to external stimulations. We developed the PRO-BOT128 with the aim to meet the high expectations of our customers regarding quality and function.
2. Intended use This mobile robot is equipped with a programmable microcomputer, which allows you to determine basic behaviour patterns and reactions of the robot to external influences yourself. The robot PRO-BOT128 was developed as an experimental platform for all electronic technicians interested in robotics. In practical tests, it visualises the influence and effects of software parameters as well as physical parameters via the corresponding sensor technology.
4. Safety instructions The guarantee/warranty will be void if damage is incurred resulting from non-compliance with the operating instructions. Liability for any and all consequential damage is excluded! We do not assume any liability for damage to property or personal injury caused by improper use or the failure to observe the safety instructions! In such cases the guarantee is voided. General information • Due to the open type of construction, the PRO-BOT128 has sharp edges and corners.
Each robot kit leaves our company in an impeccable and function-tested state! Conrad Electronic SE offers a warranty of 24 months for the PRO-BOT128. Within this time, we will remedy possible transport damage upon delivery, production defects or breakdowns of the device free of charge. If the performance features of the robot do not meet your individual requirements, please use our 14-day money-back guarantee.
6. System description a) Performance features The PRO-BOT128 is a programmable microcomputer equipped with numerous sensors and mounted on a chassis with differential drive. With proper programming, the PRO-BOT128 is a fully functional small robot able to recognize external influences and react to them. At the same time, the PRO-BOT128 offers an ideal basis for own expansions with respect to sensors and actors, e.g. for competitions.
d) Control computer C-Control PRO 128 (Conrad item no: 198219) The control computer of the PRO-BOT128 is a computer of the C-Control PRO series. This is a compact module for universal application in measuring, control and regulation tasks and also able to perform serial data transmission and data storage processes. The control computer contains an advanced microprocessor, which allows the programming of the module in the popular and easy to learn programming languages BASIC and C.
7. General information This chapter provides an overview of how to handle the robot and the corresponding components. The required detailed information e.g. about programming is contained in the following chapters of this manual or the descriptions contained in the example programs. a) Electrostatic discharges Especially in dry air, the human body and the robot itself may become electrostatically charged (depends on the consistency of the flooring).
90% of the kits returned to us contain such soldering errors, cold soldering spots, the wrong solder, etc. Many a returned "masterpiece" does not show professional soldering work. Therefore only use electronic solder with the label "SN 60 Pb" (60% tin and 40% lead). This solder has a resin core, which serves as fluxing agent to protect the soldering spot from oxidation during soldering.
e) Required tools To assemble the PRO-BOT128 correctly (kit version), you need the following tools and materials besides the components (not part of the delivery!): • • • • • Stanley knife or saw Fine pointed pliers Side nippers (electronic side nippers) Small vice or so-called "third hand" Soldering iron • • • • • • • Here you should use an electronic soldering iron (ca. 20W to 40W) or better a soldering station (at least 50W).
8. Preliminary mechanical work Prior to starting with the electronics, you have to perform a number of mechanical steps. a) Motor pinion To enable the motors to transmit their force to the transmission, the motor pinions (the small gearwheels with the 1.9mm boring and the 10 teeth) must be mounted on the motor axis. If these pinions are not installed on the supplied motors, you have to press them on.
c) Photo transistors & IR LEDs Prior to soldering in, the photo transistors T1 and T2 must be covered with a piece of shrinkdown plastic tubing (approx. 1 cm long). This prevents the influence of external light from the side. The shrinkdown plastic tube can be shrunken with a special hot air blower or a cigarette lighter. Photo transistors T1 and T2 For the IR LEDs D6, D7, D8, D9, D10 and D11, the same applies as for T1 and T2. These also have to be covered with a shrinkdown plastic tube (approx.
9. Soldering instructions a) General information If you are not that apt at soldering yet, please read these soldering instructions first before proceeding. Soldering is an art! Although the robot kit does not require any special skills, it should not be assembled by a beginner without the assistance of an experienced helper. We do not only want you to gain experience when assembling this kit, but also later on with the finished product, e.g. when programming it.
b) Producing a clean welding spot With the help of a suitable tool, you can bend the pins in such a way that they will fit exactly into the corresponding holes (use bending tools, for example). These twist the pins by approx. 40° so that the parts do not drop out when turning the circuit board over. Now place the tip of the soldering iron and the tip of the solder directly on the pin and the soldering pad on the circuit board.
10. Assembly stage I: Installing the assembly elements on the circuit board a) Soldering on the brass shafts Soldering on the brass shafts for the transmission and the wheel support should be your first soldering step. As this requires a lot more heat than for the rest of the electronics, it may happen that the circuit board gets very hot and other components may be damaged as a result when soldering them in later on.
b) Resistors First you bend the connection wires of the resistors according to the modular dimension and inserted in the provided borings (see equipment plan). To prevent the components from falling out when turning the circuit board, bend the connection wires of the resistors at a 40° angle and then solder these together carefully with the conductors on the back of the circuit board. Now cut off the excess wires.
c) Light-dependent resistors (LDR) Resistors that change their resistance value in dependence on the light strength are called LDR (Light Dependent Resistor). These LDRs are soldered in on the bottom of the main unit and the pins angled beforehand in such a way that the transparent surface points outwards. Now you solder in a 3-pole socket strip JP3 between the two LDRs to achieve a light shading between the two LDRs. This allows you to detect a light source much more effectively.
e) Diode Angle the pins of the silicon diode with a small set of flat pliers or another suitable tool. When soldering them in, observe the polarity of the diode. The white ring on the diode indicates the cathode (minus, "-"). D4 = 1N4001 f) LEDs and IR LEDs Make sure that the polarity is correct when installing the LEDs. You can identify the cathode of the LED/IR diodes by the slightly flattened side of the plastic housing.
The 6 IR-LEDs TSU520 (D6, D7, D8, D9, D10, D11) are covered with a piece of shrinkdown plastic tubing (approx. 1cm long, see chapter 8. c). When soldering in the IR-LEDs, observe the correct polarity. The pin of the anode ("+") is longer than that of the cathode ("-"). On the circuit board, the anode is marked with an "A" (insert the longer pin here) and the cathode with a "K". Afterwards, solder in the 6 IR LEDs TSU520 angled by 90° so that they point radially outwards (see image below).
i) Infrared receiver TSOP1736 j) IC mounts Insert the mounts for the integrated circuits (ICs) into the corresponding positions on the equipment side of the circuit board. Attention! Observe the notches or any other marking on the front side of the mount! This is the marking (connection 1) for the IC, which has to be inserted later on.
l) Sound converter To enable the PRO-BOT128 to attract attention, it was equipped with a sound converter. This component consists of a piezo element on the inside, which converts the electric voltage to sound. Observe the polarity indication on the sound converter (plus/+ and minus/-) and solder on the part in line with the equipment imprint on the circuit board. LS1 = sound converter (cylinder-shaped housing) m) Microphone capsule A capacitor microphone is required for sound detection.
p) Jumper JP1 JP2 Jumper for JP1 The jumper must be plugged onto JP1 if you use rechargeable batteries to operate the PRO-BOT 128. When using normal batteries, you have to remove the jumper from JP1! For this purpose, also see chapter 10. t. JP2 is a 2 x 2-pole pin strip which serves for later connection to the PC (via the USB-RS232 adapter). Two pins each are soldered on to the top and the bottom of the circuit board.
r) Ribbon cable, pin socket and pin header Now the 6-pole pin headers CON1, CON2, CON3, CON4, CON5 und CON6 are plugged into the respective positions and soldered tight. Here you have to make sure that the pin headers are not only inserted on the right side of the circuit board. It is of vital importance that you also observe the correct position. Each pin header has a small groove on the side. This must match the marking on the circuit board.
s) Assembly of the motors and the transmission Once the equipment of the PRO-BOT's circuit board is completed, you still have to attach the cables to the motor and fix them in place. To connect the motors, you need a black and a red cable with a length of approx. 70 mm with stripped and tin-coated ends. If the enclosed cables are not yet prepared properly, strip the ends and coat them by holding them to the tip of the soldering iron with a bit of solder.
t) Circuit board distancers, battery support, charge socket The kit contains 6 circuit board distancers, 3 nuts M3 and 3 screws M3x10 to screw together the circuit board levels (drive unit, main unit, breadboard). Prior to screwing the circuit boards together, you have to solder the battery support onto the main unit (black cable = "BAT-", red cable = "BAT+").
11. Assembly stage II: Sight inspection of the circuit board Prior to commissioning the circuit, check once again that all components are positioned correctly and have the right polarity. Check on the soldering side (strip conductor side) whether strip conductors were bridged by solder residues, as this may lead to short circuits and the destruction of components. You further have to check whether cut off wire ends are located on top or below the circuit board, as these may also lead to short circuits.
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b) Assembly plan (main unit) 1.
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c) Assembly plan (breadboard) 1.
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13. Software installation Please note that the directory names can differ with newer versions of the software. a) CD content • C-Control PRO IDE Programming interface for C-Control PRO For possible updates, refer to www.c-control.de • C-Control PRO manual Instructions for C-Control PRO • PRO-BOT128 circuit diagram Circuit diagrams for the PRO-BOT128 • PRO-BOT128 datasheets Datasheets of the applied components For more information, refer to www.conrad.
c) Programming cable (Voltcraft USB programmer) Insert the CD included in delivery into the appropriate drive of your computer and start the installation program. Do not connect the programmer to the USB port on your PC until the installation is completed. Once the driver installation was successful, you can locate the programmer as a virtual COM port in the device manager. Remember the COM-Port number (e.g. COM4).
Press the boot button (SW2) on the PRO-BOT128 and turn the robot on while keeping this button depressed. Now the C-Control PRO should appear in the output window. Once this is the case, you can open a program. To do so, move the mouse to "File/Open". Select the created software path (e.g. PRO-BOT128) and open a program there at "System test", e.g. "Beep-Check", the file "Beep.cprj". The program code appears in the editor.
Line check: Checks the line sensor. The red LED blinks and then stays lit. The output window shows the measuring values of the photo transistors. These may deviate from each other depending on the light incidence. The parts tolerance also plays a role here. To do so, place the robot on a white sheet of paper onto which you have drawn a line beforehand (approx. 1 cm thick, use a black felt-tip pen, for example, alternatively create this via the PC and print it out).
FLR_ON() Switches the front right LED on. FLR_OFF() Switches the front right LED off. BLL_ON() Switches the back left LED on. BLL_OFF() Switches the back left LED off. BLR_ON() Switches the back right LED on. BLR_OFF() Switches the back right LED off. ENC_RIGHT() Interrupt routine for the right wheel encoder. The variable "ODO_RIGHT" is incremented by 1 each. ENC_LEFT() Interrupt routine for the left wheel encoder. The variable "ODO_LEFT" is incremented by 1 each. ODO_RESET() Resets the wheel encoder to 0.
READ_LINE_RIGHT() as word Returns the analog value of the right line sensor (0 to 1023). LINE_LED_ON() Turns the LED of the line sensor on. LINE_LED_OFF() Turns the LED of the line sensor off. AKKU_SPG() as single Returns the rechargeable or normal battery voltage. GET_ADC(channel as byte) as word Read out any ADC channel (channel 0 to 7). DRIVE_INIT() Initialises the drive. Prior to using the drive, you have to call up this routine. DRIVE_ON() Sets the enable input of the L293D to high.
ACS_INIT() Initialises the anti-collision system, must be called up before use. ACS_LEFT() as byte Returns the status of the obstacle detection (left sensor): 1 = no obstacle 0 = obstacle detected ACS_RIGHT() as byte Returns the status of the obstacle detection (right sensor): 1 = no obstacle 0 = obstacle detected DELAY_MS(time as integer) Alternative time loop to AbsDelay(). Difference: Interrupts are still queried, the interpreter is not completely stopped (1ms time slot).
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Motors are not turning or turning in the wrong direction: • IC L293 and IC CD4093 plugged in properly? • Motors with right polarity (red and black cable)? • Transmission or motors are running too tight • Connection cable installed correctly, plugs in the right orientation? • Right program in C-Control PRO? • Insufficient PWM set in the program code? • Batteries/rechargeable batteries too weak? • Soldering error? Odometer does not work.
15. Final adjustment work Grease the axles slightly and attach the gear wheel with the black and white pattern to the short axis. Attach the wheel to the gearwheel with the 50 and 12 teeth, then attach this assembly to the rear axis and fix it in place with a set collar so that it can still easily rotate. Shift the temporarily attached motor carefully until it is aligned, the motor pinion grips on the entire width of the first gearwheel, and the motor pinion and the gearwheel can be rotated easily.
16. Parts lists C1, C4, C10 = 100µF/16V ....................................................... Conrad item no.: 445579 C2 = 22µF/16V ........................................................................ Conrad item no.: 445555 C7, C9 = 10µF/16V .................................................................. Conrad item no.: 445591 C3, C6 = 100nF/50V ................................................................ Conrad item no.: 453099 C5 = 10nF/50V ..................................................
CONx = pin plug ....................................................................... Conrad item no.: 739235 Pin header ................................................................................ Conrad item no.: 701980 Ribbon cable ............................................................................ Conrad item no.: 601922 IC mount 8-pole ........................................................................ Conrad item no.: 189502 IC mount 14-pole ........................................
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18. Expansion ideas Now you can start with your own experiments! If everything functions and your PRO-BOT128 has successfully passed the individual test programs, you can start developing own programs and hardware extensions.
19. Cleaning When rolling on the floor, dust and dirt as well as hair may accumulate in the drive. This hampers the drive and may lead to function disruptions. Therefore you should check the drive carefully and remove any dirt. Dust on the light barriers and on the sensors also leads to malfunctions. Remove dust by means of a clean long-hair brush and a vacuum cleaner. 20. Disposal a) General information Electric and electronic devices must not be disposed of in the domestic waste.
http://www.conrad.com Legal Notice These operating instructions are a publication by Conrad Electronic SE, Klaus-Conrad-Str. 1, D-92240 Hirschau (www.conrad.com). All rights including translation reserved. Reproduction by any method, e.g. photocopy, microfilming, or the capture in electronic data processing systems require the prior written approval by the editor. Reprinting, also in part, is prohibited. These operating instructions represent the technical status at the time of printing.
