Robot Assembly Guide

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Revision as of 14:47, 7 February 2017 by Falcon (talk | contribs) (Step 8: Build Foot (2x))

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This page is based on HR-OS5 Research Humanoid Assembly Guide from Trossen Robotics






HR-OS5 Research Humanoid Assembly Guide

front.jpg

Kit Parts List

b_400_400_16777215_00__images_assembly_jimmy_mx-106.jpg MX-106T Servo 6x b_400_400_16777215_00__images_assembly_jimmy_mx-64.jpg MX-64T Servo 2x b_400_400_16777215_00__images_assembly_jimmy_mx-28.jpg MX-28T Servo 18x b_400_400_16777215_00__images_assembly_jimmy_hn05-n102.jpg Servo Horn Set for MX-64/MX-106, HN05-N102 10x b_400_400_16777215_00__images_assembly_jimmy_hn05-i101.jpg Idler Bearing Set, HN05-I101 2x b_400_400_16777215_00__images_assembly_jimmy_hn07-n101.jpg Servo Horn Set for MX-28, HN07-N101 10x b_400_400_16777215_00__images_assembly_jimmy_100-mm-cable.jpg 3 Pin Cable, 100 mm Length 10x b_400_400_16777215_00__images_assembly_jimmy_150-mm-cable.jpg 3 Pin Cable, 150 mm Length 10x b_400_400_16777215_00__images_assembly_jimmy_250-mm-cable.jpg 3 Pin Cable, 250 mm Length 4x b_400_400_16777215_00__images_assembly_jimmy_fr08-x101k.jpg Cross Frame Set, FR08-X101K 4x b_400_400_16777215_00__images_assembly_jimmy_fr05-f101k.jpg Flange Bearing Frame Set, FR05-F101K 8x b_400_400_16777215_00__images_assembly_jimmy_fr05-s101k.jpg Side Frame Set, FR05-S101K 4x b_400_400_16777215_00__images_assembly_jimmy_hw-64106hxw.jpg Wide Bracket 2x b_400_400_16777215_00__images_assembly_jimmy_foot-bracket.jpg Foot Bracket 2x b_400_400_16777215_00__images_assembly_jimmy_foot-sole-plate.jpg Foot Sole Plate 2x b_400_400_16777215_00__images_assembly_jimmy_tibia-bracket.jpg Tibia Bracket 2x b_400_400_16777215_00__images_assembly_jimmy_hw-64106hxl.jpg Long Bracket 4x b_400_400_16777215_00__images_assembly_jimmy_hw-64106h45.jpg 45° Bracket 8x b_400_400_16777215_00__images_assembly_jimmy_plastic-spacer.jpg Plastic Spacer 1x b_400_400_16777215_00__images_assembly_jimmy_lower-torso-plate.jpg Lower Torso Plate 1x b_400_400_16777215_00__images_assembly_jimmy_upper-torso-plate.jpg Upper Torso Plate 1x b_400_400_16777215_00__images_assembly_jimmy_nuc-plate.jpg NUC Plate 1x b_400_400_16777215_00__images_assembly_jimmy_intel-nuc.jpg Intel NUC Computer 1x b_400_400_16777215_00__images_assembly_jimmy_4gb-ram.jpg 4GB DDR3 Ram 1x b_400_400_16777215_00__images_assembly_jimmy_wifi-card.jpg WiFi Card 1x b_400_400_16777215_00__images_assembly_jimmy_sms200s3-30g.jpg 30 GB Solid State Drive 1x b_400_400_16777215_00__images_assembly_jimmy_cm730-plate.jpg CM730 Plate 1x b_400_400_16777215_00__images_assembly_jimmy_cm730.jpg Robotics CM730 Controller 1x b_400_400_16777215_00__images_assembly_jimmy_lower-shoulder-plate.jpg Lower Shoulder Plate 1x b_400_400_16777215_00__images_assembly_jimmy_upper-shoulder-plate.jpg Upper Shoulder Plate 2x b_400_400_16777215_00__images_assembly_jimmy_venom-battery.jpg 4000 mAh 7.4V LiPo Battery 1x b_400_400_16777215_00__images_assembly_jimmy_dc-power-adapter.jpg 12V 10A DC Power Adapter

Before you use or charge the included batteries read the battery guide and lithium battery safety instructions and warnings. Do not charge or use if the battery is punctured, damaged, bloated, expanded, swollen, or otherwise deformed. Only use 2 cell, 7.4 V batteries. Do not leave batteries unattended when charging. Monitor batteries during charging for popping, hissing, smoke, sparks or fire. Also monitor the battery for any swelling or other deformities. Disconnect the battery from your charger immediately and do not use if you notice any of these symptoms. Do not charge batteries near flammable material. Charge batteries in a fireproof container when possible. Do not charge batteries while they are installed in your robot.

Hardware

The following hardware is required to build the HR-OS5. Most of these pieces are found in the kits, although they may not be used with the particular piece they are packaged with.

  • 148x bolt-m2-short.jpg Socket Head Cap Screw M2.5 x 4
  • 156x bolt-m2-med.jpg Socket Head Cap Screw M2.5 x 6
  • 56x bolt-m2-long.jpg Socket Head Cap Screw M2.5 x 8
  • 8x bolt-m2-long.jpg Socket Head Cap Screw M2.5 x 10
  • 12x button-m3-med.jpg Button Head Cap Screw M2.5 x 10
  • 104x nut-m2.jpg Hex Nut M2.5
  • 18x bolt-m3-short.jpg Socket Head Cap Screw M3 x 6
  • 27x bolt-m3-med.jpg Socket Head Cap Screw M3 x 8
  • 9x button-m3-med.jpg Button Head Cap Screw M3 x 8
  • 16x button-m3-long.jpg Button Head Cap Screw M3 x 14
  • 4x nut-m3.jpg Hex Nut M3
  • 18x thrust-washer-steel.jpg Thrust Washer Steel
  • 4x washer-m3.jpg Round Standoff M3 x 1
  • 4x m3spacer.jpg Round Standoff M3 x 4
  • 4x m3spacer.jpg Round Standoff M3 x 5
  • 9x standoff-ff-short.jpg Hex Standoff M3 x 10
  • 8x standoff-ff-long.jpg Hex Standoff M3 x 25

Tools Needed

  • M1.5 hex key
  • M2.0 hex key
  • M2.5 hex key
  • M2.5 nut driver
  • Phillips #0 screwdriver
  • Turbo-Lock blue thread lock (10 mL bottle)
  • Turbo-Lock plastic safe thread lock (2 mL tube)

Build Steps

Pre Step: Turbo Fuse

Turbo Fuse is non-permanent and plastic safe. It is used to keep nuts and bolts in place on robots since they move and shake around a lot. To use your Turbo Lock, squirt a small amount into a plastic spoon. As you build, before screwing a bolt into your robot, dip the tip of each bolt into the Turbo Lock and brush the excess off onto the side of the spoon. See the video above for more details.

Step 1: Install the Servo Horns (18x)

Unpack the MX-106 and MX-64 servos and servo horns sets.
Collect and set aside the ten M2.5 x 4 screws from the one M3 x 8 screw in each horn set for later use.
Place the thrust washer onto the splined side of the servo horn.
Note the orientation notch on the servo and the notch on the splined side of the servo horn.
Also note that on the non-splined side of the horn there are three small dots; one of which is further away from the other two and directly behind the notch on the back side. This will be referred to as the orientation dot in later steps. If you find this confusing, you may want to mark the orientation dot now with a marker at this time.
Align the orientation notches and gently apply pressure to partially engage the splines.
Confirm the orientation is correct before fully engaging the splines. It is very difficult to remove the horn after installation, and your robot will not work correctly if misaligned.
The thrust washer tends to pop out of position when the horn is pressed on. Stop before fully seating the horn to realign the washer. A small piece of stiff paper, such as a business card can be helpful to seat the thrust washer.
Substantial force may be required to fully seat the horn. This can be done by placing the horn face down on a hard, flat and evenly applying pressure to the back of the servo.
Fasten the horn down with a M3 x 8 screw. The screw is sufficiently tight when the horn begins to turn. Do not hold the horn in place when tightening, which could lead to over torquing.
Use the screwdriver to rotate the servo the remainder of one complete clockwise revolution so that it is back to its original orientation.
Don't forget to use the blue thread lock on this and all other screws, except where noted.

Step 2: Attach the Cross Frames to the MX-106 Servos (4x)

Unpack the four cross frame sets, FRO8-X101K. Set aside the four long M2.5 x 8 screws in each set for later.
Use the four M2.5 x 6 screws to fasten two cross frame pieces to the back side of four MX-106 servos.
The cross frame pieces should be directly behind the the servo horn and oriented to produce the largest possible gap between the cross frame pieces.

Step 3: Build the Ankles and Hips (4x)

Insert two M2.5 nuts into the hex shaped recesses on four MX-106 servos without cross frames. Two of the servos should have nuts on the left side, two on the right side. Each servo only needs two nuts. If you have trouble inserting the nut into the slot, use a small hex key or screwdriver to guide the nut into place and apply pressure.
Install one short 3 pin cable (100 mm length) into each of the four servos. There is only one orientation in which the cable can be inserted. The cable should be installed on the same side as the nuts. You should end up with four servos total, each with one cable installed and two nuts.
The free end of the cable must be routed out towards the bottom of the servo (the shorter distance).
Insert each of the servos prepared in this step into the servos with cross frames prepared in the previous step so that the cable is sandwiched between the servos and the nuts are aligned with the holes in the cross frames.
Insert the nut holder assembly tool into the gap between the servos to hold the nuts in place when tightening. Without it, nuts will tend to fall out when trying to thread the screw (which is technically a bolt in this usage).
Use four M3 x 8 screws on each pair of MX-106 servos. you should end up with four assemblies, two identical mirrored sets.

Step 4: Built and Attach Flange Bearing Frame (4x)

Unpack the four FR05-F101K flange bearing frame sets.
Attach the black disk to the silver plate using seven or eight M2.5 x 4 screws. The side of the black disk with the diameter should be seated into the hole of the same diameter in the plate.
Insert two M2.5 nuts into the spaces above the cross frame pieces.
Wedge the silver frame over the faces of the servo with the tabbed end of the frame piece aligned with the center hole of the servo frame. This may require a fair amount of force. It is somewhat easier to insert the frame at one end of the servo and wiggle it along the length until the frame and servo holes are aligned.
Because of large tolerances in the frame dimensions it may be necessary to remove the screw closest to the face with the nuts to successfully install the flange bearing frame.
Note that the 3 pin port on the servo should not be covered by the plate.
Insert the nut holder tool and use four M2.5 x 8 screws to fasten the frame to the servo.

Step 5: Install Ankle/Hip Idlers (4x)

Unpack eight idler bearing sets; two for each of the assemblies.
Press the bearing by hand into large silver ring until it snaps into place.
Snap the small silver cap into the bearing from the same side that the bearing was inserted.
Assemble eight idlers following the same procedure.
Place one idler over each of the eight available attachments points.
Fasten each idler in place using one M3 x 6 screw. Only use the 6 mm long screw included in the idler bearing package. Do not use longer screws and do not over tighten. Using a longer screw may damage the servo.

Step 6: Attach Tibia Plate (2x)

Select two mirrored servo assemblies from the previous steps. When building the legs, the silver idlers will always be on the outside or front of the legs.
If you didn't align the servo horns when you installed them, make sure they are correctly centered now. As shown in the photo, with the "MX-106" text right side up, the orientation dot on the horn should be pointed straight up. The easiest way to align the horn is to turn it clockwise using a hex key in the center screw.
Attach the tibia plate to the servo horn and idler using ten M2.5 x 4 screws.
The flat front of the tibia plate should be co-planar with the unused idler.
The orientation dot on the servo should be on the line between the screw at the center of the servo horn and the center hole in the tibia plate.
The cable should extend up behind the tibia plate.

Step 7: Attach Knee Servo (2x)

Build and attach idlers to two unused MX-106 servos using one M3 x 6 screw on each.
Make sure the servo horns are correctly centered.
Attach each servo to a tibia plate using ten M2.5 x 4 screws. The servo should be upside down (the MX-106 sticker will be upside down) and the silver idler should be on the same side as (and coplanar with) the one on the ankle.
Align the servo horn to point straight down. It should not point at the center of the five tibia screw holes.

Step 8: Build Foot (2x)

Attach one wide bracket to each foot plate using six M2.5 x 6 screws and six M2.5 nuts. Assemble two mirrored copies. Push the bolt through first and fasten it with the nut driver. The bolts should come from the flat side of the foot plate. When all 6 bolts and nuts are in place, tighten the nut down. The side of the foot plate with the bracket is the inside of the foot. The uncovered half of the plate is the outside.
Peel two strips of double sided tape and place them across the bottom of the foot plates as shown.
Press the foot sole plate onto the bottom of the foot bracket.

Step 9: Attach Foot (2x)

20x bolt-m2-short.jpg Socket Head Cap Screw M2.5 x 4 09a.jpg 09b.jpg 09c.jpg Attach the foot assembly to the ankle assembly using ten M2.5 x 4 screws. If you intend to shell the robot, do not use thread lock. This joint will have to be disassembled when installing the shell. The outside (non-bracket side) of the foot should be underneath the idler side of each leg. The angle should be oriented so that the idler on the front of the ankle is set back from the edge of the foot. The orientation dot on the servo should point straight down through the wide bracket on the foot.

Step 10: Build and Attach Thigh (2x)

24x bolt-m2-med.jpg Socket Head Cap Screw M2.5 x 6 20x nut-m2.jpg Hex Nut M2.5 10a.jpg 10b.jpg Unpack a side frame set and attach it to the outside of a long bracket using eight M2.5 x 6 screws and eight M2.5 nuts. Orient the side frame tabs to extend past the edge of the long bracket. For ease of access later, insert the screws so that the socket heads are on the inside of the long bracket. Insert two M2.5 nuts into the slots on the knee servo. Use the face of the servo that only has two nut slots. Press the side frame piece over the knee servo with the frame tabs pointing to the back of the leg and the tab holes unused. Insert the nut holding tool and fasten the side frame to the servo using four M2.5 x 6 screws.

Step 11: Attach Hip (2x)

20x bolt-m2-short.jpg Socket Head Cap Screw M2.5 x 4 11a.jpg 11b.jpg 11c.jpg Select and orient an unused MX-106 hip assembly from step 3 as shown. Only one of the hip assemblies can be oriented correctly. Make sure you use the correct one. The silver idlers must be on the outside and front of the leg and the cable must hang down towards to foot. Before screwing the hip together, check the servo horn orientation. The servo attached to the thigh is right-side up with the orientation point directed straight upward. Fasten the hip servo horn and idler to the thigh using ten M2.5 x 4 screws (only three screws per side are shown in the photos for this step).

Step 12: Build Arm (2x)

64x bolt-m2-short.jpg Socket Head Cap Screw M2.5 x 6 20x nut-m2.jpg Hex Nut M2.5 4x bolt-m3-med.jpg Socket Head Cap Screw M3 x 6 12a.jpg 12b.jpg 12c.jpg 12d.jpg 12e.jpg 12f.jpg Unpack a side frame set and attach it to the outside of a 45° bracket using eight M2.5 x 6 screws and eight M2.5 nuts. Orient the side frame so that the frame legs are pointed away from the 45° bracket. Also, the tabs must be oriented parallel to the longer side of the bracket. Create a mirrored set of arm brackets, with the frame tabs pointing in opposite directions. Build and install an idler on four MX-64 servos; secure each with a M3 x 6 screw. Select two of the MX-64 servos and insert two M2.5 nuts into the bottom face of each. Use the nut holder tool and fasten the side frame to the nutted servo using four M2.5 x 6 screws. Peel the paper off of eight clear plastic spacers and place one each over the servo horn and idler of the four MX-64 servo. Note: do not use blue thread lock on this joint, it is not plastic safe. Instead use plastic safe thread lock which is clear and smells like a super glue. Using the blue thread lock could cause the clear plastic spacers to shatter. Attach an additional 45° bracket to each assembly using ten M2.5 x 6 screws. When viewed from the front (as in the photos) the longer side of the bracket should be on the opposite side of the arm as the side frame tabs. On the arms, the idlers are always oriented toward either the inside or rear of the robot. Place a servo with spacers between the armature of the 45° brackets used in the previous step. The orientation point on the servo horn should be pointed at the center hole of the five ringed holes on the bracket. Attach the servo to the 45° bracket using ten M2.5 x 6 screws. You should have two mirrored sets of arms at the end of this step.

Step 13: Build Lower Shoulder (1x)

16x nut-m2.jpg Hex Nut M2.5 8x bolt-m2-med.jpg Socket Head Cap Screw M2.5 x 6 16x bolt-m2-long.jpg Socket Head Cap Screw M2.5 x 8 4x standoff-ff-long.jpg Hex Standoff M3 x 25 4x bolt-m3-med.jpg Socket Head Cap Screw M3 x 8 13a.jpg 13b.jpg 13c.jpg 13d.jpg 13e.jpg Insert four M2.5 nuts into each of two MX-106 servos. Use the slots closest to the horn on both sides of the servo. Attach two side frames to the lower shoulder plate. Note that the plate is not symmetrical; the round hole pattern is not in the center of the part. Orient the side frame so that the side without tabs is the shorter distance from the edge. Use eight M2.5 x 6 screws in the tapped holes and eight M2.5 x 8 screws with eight M2.5 nuts in the untapped frame holes. Attach four M3 x 25 aluminum hex standoffs to the lower shoulder plate using four M3 x 8 screws. The standoffs should be on the side of the plate without side frames. Insert and attach the MX-106 servos to the side frames using the nut holder tool and eight M2.5 x 8 screws. The inner screws are most easily installed using the ball end hex key provided with your robot.

Step 14: Build and Attach Upper Shoulder (1x)

16x bolt-m2-med.jpg Socket Head Cap Screw M2.5 x 6 8x bolt-m2-long.jpg Socket Head Cap Screw M2.5 x 8 8x nut-m2.jpg Hex Nut M2.5 14a.jpg 14b.jpg 14c.jpg Attach two side frames to the upper shoulder plate. The frame tabs should extend over the long edge. Use eight M2.5 x 6 screws in the tapped holes and eight M2.5 x 8 screws with eight M2.5 nuts in the untapped frame holes. Attach the upper shoulder plate to the MX-106 servos using eight M2.5 x 8 screws. The tabs on the upper shoulder side frames should be directly above the tabs on the lower shoulder side frames.

Step 15: Mount CM730 Controller and Attach Below Shoulder (1x)

12x bolt-m3-long.jpg Socket Head Cap Screw M3 x 14 mm 4x m3spacer.jpg Round Standoff M3 x 5 4x m3spacer.jpg Round Standoff M3 x 4 4x nut-m3.jpg Hex Nut M3 4x standoff-ff-long.jpg Hex Standoff M3 x 25 15a.jpg 15b.jpg 15c.jpg Mount the CM730 controller to the CM730 plate using four M3 x 5 long spacers, four M3 x 14 screws, and four M3 hex nuts. Attach four M3 x 4 long spacers, four M3 x 14 screws, and four M3 x 25 hex standoffs to the four outermost homes in the CM730 plate. Mount the CM730 plate to the underside of the lower shoulder plate using four M3 x 14 screws. The three small buttons on the CM730 should be on the same side as the horns of the shoulder servos.

Step 16: Prepare NUC Computer Hardware (1x)

16a.jpg 16b.jpg 16c.jpg 16d.jpg 16e.jpg 16f.jpg Install the ram into the lower memory slot. Insert it at an angle as shown and then push straight down to lock in place. Remove the two Phillips screws from the posts adjacent to the narrow slots. Install the WiFi card in the lower slot. Reinstall the Phillips screws to hold the WiFi card down. Add miniature antenna to the WiFi card (not shown). Install the solid state drive in the slot above the WiFi card. Reinstall the Phillips screw to secure the solid state drive. Additional steps are required to make the NUC computer ready to use, but for clarity are not covered in this assembly guide.

Step 17: Mount NUC Computer and Attach Below Controller (1x)

4x bolt-m3-short.jpg Socket Head Cap Screw M3 x 6 4x washer-m3.jpg Round Standoff M3 x 1 9x standoff-ff-short.jpg Hex Standoff M3 x 10 9x button-m3-short.jpg Button Head Cap Screw M3 x 8 4x button-m3-long.jpg Button Head Cap Screw M3 x 14 17a.jpg 17b.jpg 17c.jpg 17d.jpg 17e.jpg Attach four M3 x 10 hex standoffs and four M3 x 1 spacers to the NUC plate using four M3 x 6 screws. The standoffs and spacers should be on the same side as the installed chips. Attach five M3 x 10 hex standoffs to one side of the NUC plate using five M3 x 8 button head screws. Mount the NUC to the plate using four M3 x 8 button head screws. Mount the combined NUC assembly under the CM730 controller using four M3 x 14 button head screws. The NUC assembly should be oriented so that the USB ports (blue) on the NUC computer are on the same side as the three small white push buttons on the CM730 controller.

Step 18: Build Top of Hips and Below NUC Computer (1x)

24x nut-m2.jpg Hex Nut M2.5 8x bolt-m2-long.jpg Socket Head Cap Screw M2.5 x 10 5x bolt-m3-med.jpg Socket Head Cap Screw M23 x 8 18a.jpg 18b.jpg 18c.jpg 18d.jpg Insert twenty-four M2.5 nuts into the two remaining MX-64 servos. Use every slot except those on the long faces furthest from the servo horns. Mount the upper torso plate to the MX-64 servos as shown. Use eight M2.5 x 10 screws. The plate should be attached on the side without servo horns. Use five M3 x 8 socket head screws to attach the upper torso plate to the hex standoffs on the bottom of the NUC plate.

Step 19: Build Remainder of Torso (1x)

12x button-m3-med.jpg Button Head Cap Screw M2.5 x 10 16x bolt-m2-short.jpg Socket Head Cap Screw M2.5 x 4 19a.jpg 19b.jpg 19c.jpg Press the torso plate over the MX-64 servos. The rounded notch in the plate should be oriented to fit over the servo horns. Attach the lower torso plate with twelve M2.5 x 10 button head cap screws. Attach two wide brackets to the MX-64 servo horns using sixteen M2.5 x 4 screws.

Step 20: Attach Arms to Torso (1x)

16x bolt-m2-short.jpg Socket Head Cap Screw M2.5 x 4 20a.jpg 20b.jpg 20c.jpg 20d.jpg 20e.jpg Bend the 45° brackets at the top of the arms inward to access the bracket mounting holes. Use sixteen M2.5 x 4 screws to attach the arms to the torso. When looking at the assembled torso, the two blue USB ports are on the front side.

Step 21: Attach Legs to Torso (1x)

20x bolt-m2-short.jpg Socket Head Cap Screw M2.5 x 4

21a.jpg 21b.jpg Use twenty M2.5 x 4 screws to attach the legs to the torso.