Contents

About the Author

Acknowledgments

Introduction

image Chapter 1: Welcome Robot Inventor!

Four Disciplines

Anatomy of a Homemade Robot

Brains

Electrical Power

Sensors

Action and Feedback

Miscellaneous Components

Body

Building Up

Taking Small Bites

Making Modules

Keeping It Fun and Keeping It Light

Finding Camaraderie and Support

Onward and Upward

image Chapter 2: Where to Obtain Tools and Parts

Ordering Free Information

Discovering Hidden Messages

Considering Columns

Counting Parts

Comparing Prices

Saving Money

image Chapter 3: Safety

Benefiting from Age and Experience

Following Instructions

Reading Chemical Labels

Donning Safety Glasses

Hanging Glasses and Placing Them Face Up

Wearing Other Safety Clothes

Insuring Adequate Ventilation

Storing Properly

Talking About Your Activities, Materials, and Tools

Washing Before Eating

Avoiding Nasty Elements

Lead

Mercury

Cadmium

Purchasing Safer Parts Labeled RoHS

Shocking

AC vs. DC

Using Rechargeable Batteries and Professional Transformers

Connecting Through Circuit Breakers and GFCI Outlets

Saving the Ground Prong

Disconnecting Power

Steering Clear of Dangerous Robots

Sizing Up Motors

Lighting Up

Staying Rested and Level-Headed

image Chapter 4: Digital Multimeter

Must-Have Features

Digital

Digits

DC Voltage

DC Current

Resistance

Probes or Leads

Overload/Fuse Protection

Nice-To-Have Features

Capacitance

Diode

Continuity

Frequency

Duty Cycle

Autoranging

Auto Power Off

Transistor

Dual Display

Maximum

Minimum

Stand

Optional Features

Inductance

Data Interface

Scope

Backlight

Stopwatch/Single Pulse Width

Temperature

Sound

Count

Bar Graph

Data Hold

Data Auto

High/Low/Logic

Memory

Relative

Offset

Limit Testing/Compare

Holster or Rubber Boot

AC Features

AC Voltage

True RMS

AC Current

Obtaining Hook Probe Adaptors

Comparing Actual Multimeters

Understanding the Features of a Low-End Multimeter

Understanding the Features of a Mid-Range Multimeter

Understanding the Features of a Higher-End Multimeter

Comparing Prices with Features

Examining Other Meters

Do Not Proceed Without a Meter

image Chapter 5: Numbers and Units

Choosing the Metric System

Reducing Powers of a Thousand

M & m

Alternative for Greek Micro

Abbreviating Units

Too Little

Guessing Missing Units

Expanding from Three Digits

Converting Colors to Numbers

Determining Component Values with a Multimeter

Base Subjects Covered

image Chapter 6: Robot Line-Following

Defining the Course Conditions

Surface Materials

Course Lighting

Defining the Line

Curving and Crossing Lines

Summarizing Course Conditions

Picking the Robot’s Size

Seeing Sandwich

Examining Sandwich

Sandwich Body

Obtaining a Kit

Building Up

image Chapter 7: Nine-Volt Batteries

Testing Battery Voltage

Setting Up a Multimeter for Voltage Testing

Interpreting Test Results

9 V Battery Characteristics

9 V Battery Recommendations

Recommended

Not Recommended

Battery Brand Names

Using 9 V Batteries in Robots

Mounting Batteries

Powering Forward

image Chapter 8: Clips and Test Leads

The Gators Are Hungry Tonight

Obtaining Hook Clips

Testing Jumpers

Setting Up a Multimeter for Continuity Testing

Testing an Open Connection

Testing a Shorted Connection

Testing an Alligator Connection (Shorted)

Discovering Unintended Connections

Plumbing with Jumpers

image Chapter 9: Resistors

Limiting Power with Resistors

Obtaining a Resistor Variety Pack

Understanding Size and Tolerance

Cut It Out

Obtaining a Wire Cutter Tool

Resistance and Ohms

Measuring Resistance

Interpreting the Resistance Displayed on the Meter

Experiencing Resistance Ranges

Looking Up Resistor Values Online

Labeling and Storing

Obtaining Storage Cases

Resisting the Temptation to Skip Ahead

image Chapter 10: LEDs

Learning About LED Attributes

LED Sizes

LED Shapes

LED Lens Clarities

LED Viewing Angles

LED Colors

LED Brightness

LED Efficiency

Extreme Close Up of an LED

Identifying Multicolor LEDs

Bicolor

Tricolor or Tri-state

Full Color

Testing an LED

Setting Up a Multimeter for Diode Testing

Interpreting LED Test Results

Variety Pack

Brightening Your Way

image Chapter 11: Power On!

Introducing the Parts List

Testing the Parts Before Assembly

Reading a Schematic

Building the Power Indicator Circuit

Do You See The Light?

Experimenting with the Power Indicator Circuit

Understanding the Roles of Each Component

Measuring the Power Indicator Circuit

Measuring In-Circuit Voltage

Measuring Current Flow

Calculating Battery Life

Don’t Measure Voltage with Probe in Current Terminal

Circuit Summary

image Chapter 12: Solderless Prototyping

Needing A Better Way

Solderless Breadboards

Connecting with Holes

Binding Posts

Hungry for Breadboards

Solderless Breadboard Wire

Choosing Jumper Wire

Making Your Own Jumper Wire

Stripping the Insulation Off of the End of the Wire

Cutting the Wire to Length

Bending the End of the Wire

Making The Connection

image Chapter 13: Solderless Breadboard Setup

Considering Power Sources

Obtaining 9 V Battery Snap Connectors

Connecting Power to Binding Posts

Choosing a Power Switch

Understanding SPDT

Adding a Power Switch to the Breadboard

Connecting Power Buses

Adapting Multimeter Probes Using Jumper Wire

Connecting the Lower Bus

Split Down the Middle

Installing a Power Indicator LED

Checking Voltages at Certain Points

Trimming Leads

Demystifying the Robot’s Power Switch

Ready for More

image Chapter 14: Variable Resistors

Potentiometers

Trimpot

Turning the Dial

Obtaining Assorted Trimpots

Testing Potentiometers

Variable Brightness LED Circuit

Building the Variable Brightness LED Circuit

Brightness Balancing Circuit

Building the Brightness Balanced LEDs Circuit

Cadmium-Sulfide Photoresistors

Obtaining Assorted Photoresistors

Experiencing the Variable Resistance of a Photoresistor

Light-Controlled Circuit

Balanced Brightness-Sensing Circuit

Part List for Balanced Brightness-Sensing Circuit

Brightness-Sensing Pairs

Matching Photoresistors

Resistance-Balancing Potentiometer

Current-Limiting Resistor

Test Points

Converting Resistance to Voltage with a Voltage Divider

Building the Balanced Brightness-Sensing Circuit

Inability to Balance the Brightness-Sensing Circuit

image Chapter 15: Comparators

Voltage Comparator

Examining the LM393

Obtaining Comparators

Brightness Comparator Circuit

Comparing a Schematic with a Wiring Diagram

Labeling Parts

Drawing Connected and Unconnected Wire

Understanding the Brightness Comparator Circuit

Parts List for the Brightness Comparator Circuit

Building the Brightness Comparator Circuit

Adding Headlights

Understanding the Headlight Circuit’s Two LEDs

Building the Headlight Circuit

Repeating the Multiple LED Trick

Appreciating a Simple Mind

image Chapter 16: Transistor Switches

Defining Negative Power

Focusing on the 2907A Transistor

Testing Bipolar Transistors with a Multimeter

Testing with a Multimeter that Has a Transistor Socket

Testing with a Multimeter that Has a Diode Test

Bipolar Transistor Test Circuits

Examining the Schematic for the PNP Transistor Test Circuit

Building the PNP Transistor Test Circuit

Examining the Schematic for the NPN Transistor Test Circuit

Building the NPN Transistor Test Circuit

Brightness Comparator Circuit with Transistors

Calculating Current-Limiting Transistors

Building the Brightness Comparator Circuit with Transistors

Summarizing PNP and NPN Transistors

image Chapter 17: DC Motors

How DC Motors Work

Looking Inside an Iron-Core Permanent-Magnet DC Brush Motor

Looking Inside an Iron-Core Permanent-Magnet DC Brushless Motor

Looking Inside a Coreless Permanent-Magnet DC Brush Motor

Simple DC Motor Circuit

Selecting a Motor for the Simple DC Motor Circuit

Selecting a Battery for the Simple DC Motor Circuit

Building the Simple DC Motor Circuit

Primary Characteristics of DC Motors

Rotational Speed Characteristic of DC Motors

Torque Characteristic of DC Motors

Voltage Characteristic of DC Motors

Current Characteristic of DC Motors

Efficiency Characteristic of DC Motors

Audible Noise Characteristic of DC Motors

Electrical Noise Characteristic of DC Motors

Mass Characteristic of DC Motors

Dimension Characteristic of DC Motors

Summarizing the Characteristics of DC Motors

DC Gearhead Motors

Looking Inside a Spur Gearhead Motor

Describing Gear Ratios

Imperfect Speed to Torque Conversion

Disadvantages of Gearheads

Comparing Planetary Versus Spur Gearhead Motors

Choosing a Gearhead Motor

Moving Forward

image Chapter 18: Adding Gearhead Motors

Selecting Gearhead Motors

Obtaining the Gearhead Motors

Inspecting the Gearhead Motor

Adding Motors to the Brightness Comparator Circuit

Introducing the Diode

Building the Motors onto the Brightness Comparator Circuit

Completing the Electronics

image Chapter 19: Wheels

Anatomy of a Wheel

Characteristics of Robot Wheels

Creamy Air Filling

Tire Shapes

Tire Width

Tread Designs

Tire Diameter

Selecting Robot Wheels

Wheel Choice for Sandwich

Determining Minimum and Maximum Diameter

Determining the Maximum Diameter Based on Speed

My Choice of Wheels for Sandwich

Alternative Choices of Wheels for Sandwich

Cleaning Tires

Rolling Along

image Chapter 20: Coupler

Alternatives

Making Couplers If You Have Metal-Working Equipment

Printing Couplers

Tubing

Choosing Between Brass and Aluminum Tubing

Specifying and Obtaining Tubing Sizes

Measuring and Cutting the Tubing

Determining and Marking Tube Lengths

Cutting Tubing

Finishing the Cut by Sanding

Testing the Cut Pieces

LEGO Cross Axles

Selecting a LEGO Cross Axle Length

Obtaining LEGO Cross Axles

Gluing the Coupler Together

Coming Unglued

Using Epoxy

Adding a Setscrew to the Coupler

Marking a Hole for the Setscrew

Drill Press

Drill-Press Vise

Drilling the Hole for the Setscrew

Tapping the Hole for the Setscrew

Inserting the Setscrew

Admiring the Coupler

image Chapter 21: Soldering Equipment

Solder Wire

Flux

Soldering Iron

Soldering Stand

Soldering Sponge

Helping-Hand Tool

Desoldering Vacuum Tools

Steps of a Typical Soldering Session

Get Ready to Solder

image Chapter 22: Soldering and Connecting

Putting Together the Motors and Switches

Putting Together the Motors

Putting Together the Line-Following Switch

Putting Together the Tube LED Circuit

Finishing Up

Soldering Experience

image Chapter 23: The Motherboard

The Line-Following Circuit

Tweaking For Better Performance

Point-to-Point Soldering Versus a Printed Circuit Board

Point-to-Point Soldering the Line-Following Circuit

Testing the Robot’s Electronics

The Dangers of a Low-Resistance Circuit

Checking for Unsoldered Leads

Checking All Leads that Connect Directly to Positive Voltage

Measuring the Resistance of the Entire Circuit

Measuring the Voltage Drop

Reheating Solder Joints

Holding Your Breath

image Chapter 24: Body Building

Approaching Robot Bodies

Ethereal Drafting—Thinking About the Robot

Vision Revision—Accepting Constraints Based on Available Parts

Designing Custom Bodies

Printing in 3D

Embracing Prefabricated Platforms

Transforming the Sandwich Container

Creating Motor Holes

Mounting the Motors

Creating the Motor Tube

Installing the Motors and Tube

Adding the Switches and Battery Holder

Adding the Circuit Board

Drilling Holes for the Trimpots

Carving Out a Window in the Container Lid

Finishing Touches

Ready to Roll

image Chapter 25: Launching the Line-Follower

Correcting and Tweaking

Preliminary Examination

Trial Run: Following a Straight Line

Correcting Common Problems

Does This Look Straight to You?

The Maiden Voyage

Solving Steering Problems

Potential Improvements Line-following robot:

Protecting Against a Reversed Battery

Eliminating Surges with Capacitors

Improving Line-Following

Final Bow

image Chapter 26: Smoother, Smaller, Cheaper

Playing with Sensor Circuitry

Lowering Light Sensor Resistance

Driving Straight

Revising or Leaping?

Reducing Cost and Improving Capabilities

Shrinking Packages

Increasing Functionality

Shrinking Costs

Ever Changing

image Chapter 27: Encore

Robot Components

Logic Chips

Microcontrollers

Voltage Regulators

Capacitors

Solar Power

Resistor Networks

Pushbuttons

DIP Switches

Jumpers and Shorting Blocks

Tilt Sensor

Temperature Sensors

Touch Sensors

Object Detection and Infrared Remote Control

Distance and Object Sensor

Oscillators and Crystals

Sound

Relays

Adding Gears

Servos

Encoders—Determining Wheel Speed

Displays

Wireless Data and Control

Everyday Challenges

Houseplant-Watering Robot

Compost Cart

Trash Emptier

Window Washer

Roof Rat

Micro Snowplow

Slug Squisher

Automatic Street mailbox

Contests

Worldwide Robot Sumo

Trinity College Fire-Fighting

Atlanta Robot Vacuuming

Seattle Robotics Society Robothon

Dallas Personal Robotics Group Roborama

Central Illinois Robotics Club

Chicago Area Robotics Group (Chibots)

The Great Wide Open

image Appendix A: Appendix A

Magical Ohm’s Law

Ohm’s Law is Helpful in Selecting a Current-Limiting Resistor

Help in Determining Current from a Voltage

The Key Point of Ohm’s Law

The Larger Implication of Ohm’s Law

Things I’ve Accidentally Destroyed While Writing This Book

Which Way Does a 9 V Battery Get Installed?

Melting Switches

Popping Multimeter Fuses

Fool Me, Twice

Voltage’s Real Name

Ground, Not Negative Voltage

V Double Letter

image Appendix B: Appendix B

Getting Into 3D Printing

Leaping Not Very Far

Rapidly Improving

Printing the Motor Coupler

Designing the Model

Preparing to Print

Printing in 3D

Finishing the Coupler

Printing a 3D Wheel

Treading Lightly

Compromising with a Hybrid Wheel

Designing a Robot Body

Cover

Trying It Yourself

Index

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