Arexx DLR ASURO Montage- und Bedienungsanleitung
ASURO - 1
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ASURO - 1
ASURO
ROBOT KIT
Licence by DLR
Manufacturer
AREXX, Zwolle - NETHERLANDS
JAMA, Taichung - TAIWAN
www.arexx.com
Assembly and Operation MANUAL
Model ARX-03
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©
DLR Germany and AREXX - The Netherlands
© DLR Germany and AREXX - The Netherlands
©
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WARNING
* When you open the parts the return right will be disposed
* Read before you start assembly the instruction manual
* Be careful with tools
* Keep this product out of reach of children and do not build this kit when children are in
the neighbourhood, the tools and parts are dangerous for children
* Check the polarity of the batteries
* Keep the batteries dry, when the ASURO gets wet remove the batteries and let the
ASURO dry for some time
* Remove the batteries when you are not using the ASURO for a longer period
Introduction
ASURO is a mobile mini-robot, completely programmable in C and especially developed for education
at the German Aerospace Centre DLR, department for Robotics and Mechatronics. Assembly is easy
for experienced electronic technicians and feasible for a novice. Except for the printed circuit boards
(PCB) only standard parts for assembly will be used.
For programming we use freeware only. Therefore ASURO is exceptionally suitable as an introduction
into processor-controlled hobby electronics, for projects in schools and universities, for studies and
adult education centres. Special tools, which are freeware for private users, have been used for all
electronic development phases and software design, proving how robots can be designed without
using expensive tools or machines.
ASURO is equipped with a RISC-processor and two independently controlled motors, an optical line-
tracer, six collision-detector switches, two odometer-sensors, three optical displays and an infrared-
communication set for programming and remote control by a PC (see g. 0.1).
The Caution-symbol signalizes paragraphs with warnings, to be studied intensively, to
prevent damage to components or personal health.
We must inform all users, ASURO is no toy and is not to be handed out to children under the age of
three years, as they may swallow the dozens of small components.
Please provide some batteries and start the assembly!
And yes: ASURO is another way of saying: “Another Small and Unique Robot from Oberpfaffenhofen!”
© DLR & AREXX
Oberpfaffenhoven 2004
Jan Grewe
Robin Gruber
WWW.DLR.DE
WW.AREXX.COM
Fig. 0.1 ASURO blockdiagram
Fig. 0.1 ASURO blockdiagram
(see also appendix E)
(see also appendix E)
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CONTENTS
I. Mechanics 6
1. Necessary tools 6
2. Mechanical preparations 7
2.1. Motorpinion 7
2.2. Table-tennis ball 7
2.3. Axles 8
2.4. Wheelsenors 8
II. Electronics 9
3. Soldering instructions 9
3.1. Tip, solder and temperature 9
3.2. Preparing parts 10
3.3. Soldering parts 11
3.4 De-soldering 12
4. Electronic assemly 13
4.1. Assembly RS232-Infrared-Transceiver 13
4.2. Optional USB-Infrared-Transceivers 15
4.3. Assembly ASURO-PCB 16
4.4. Attachment of the motors 20
4.5. Power supply 20
5. Preparation for operation 21
5.1. RS232-Infrared-Transceiver 21
5.2. USB-Infrared-Tranceiver 22
5.2.2. Linux 23
5.3. ASURO operation 24
5.3.1. Display-elements 25
5.3.2. Phototransistors (T9, T10) 25
5.3.3. Switches 26
5.3.4. Odometrie 26
5.3.5. The engine 26
5.3.6. IR interface 26
5.3.7. READY? 27
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6. Trouble shooting 28
6.1. Failure of RS232-IR-Transceiver ! 28
6.1.1. Activated key and displayed symbol do not match 28
6.1.2. The Terminal-Programm does not display any symbol 28
6.1.3. Still not working 28
6.2. USB-Infrared-Tranceiver does not work 28
6.3. Back-LEDs (D15,D16) glimmen nach dem Einschalten nicht! 28
6.3.1. Back-LEDs do not glow at start up 29
6.3.2. Only one of the back LEDs is glowing 29
6.3.3. Status-LED (D12) is not activated biocolored after start up 29
6.4. A display does not work 29
6.4.1. Status-LED D12 does not work 29
6.4.2. Front-LED D11 does not work 29
6.4.3. Left Back-LED D15 does not work 30
6.4.4. Rigth Back-LED D16 does not work 30
6.5. Linentracer (T9, T10) does not work 30
6.6. A switch does not work 30
6.6.1. Obviously a combination of switches has been activated 31
6.6.2. Display reacts if switches have been interchanged 31
6.6.3. Things still do not work well 31
6.7. The re ected light-sensor (odometer) does not work 31
6.7.1. None of the re ected light-sensors work 31
6.7.2. The left re ected light-sensors does not work 31
6.7.3. The left re ected light-sensors does not work 31
6.8. One motor does not move 32
6.8.1. Both motors do not move 32
6.8.2. Left motor does not move or only in one direction 32
6.8.3. Right motordoes not move or only in one direction 32
6.8.4. One motor rotates in reversed direction 32
6.9. IR-interface 32
6.9.1. ASURO does not send symbols 32
6.9.2. ASURO does not receive symbols 32
6.9.3. Things still do not work well 33
7. Final adjustments 34
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III. Software 35
8. Software installation and initial steps 35
8.1. WINDOWS 35
8.1.1 Installation Flash - the ASURO-Programmer-Tool 35
8.1.2 Installation of the editor and compiler 35
8.1.3. Example programs 39
8.2. LINUX 51
8.2.1. Installation Flash - the ASURO-Programmer-Tool 51
8.2.2. Compiler 52
8.3. Working with Flash 53
8.4. Flash failures 54
8.5. First step in Programming 54
9. C for ASURO 56
9.1. Basics in C-Programmierung 56
9.1.1. Introduction 56
9.1.2. Variables and datatypes 57
9.1.3. Compilerdirektives 59
9.1.4. Conditions 59
9.1.5. Loops 61
9.1.6. Functions 62
9.1.7. pointers and vectors 64
9.2. Overview of the ASURO functions 65
9.2.1. void Init(void) 66
9.2.2. void StatusLED (unsigned char color) 66
9.2.3. void FrontLED (unsigned char status) 67
9.2.4. void BackLED (unsigned char left, unsigned char right) 67
9.2.5. void Sleep (unsigned char time72kHz) 67
9.2.6. void MotorDir (unsigned char left_dir, unsigned char right_dir) 67
9.2.7. void MotorSpeed (unsigned char left_speed, unsigned char right_speed) 68
9.2.8. void SerWrite (unsigned char *data, unsigned char length) 68
9.2.9. void SerRead (unsigned char *data, unsigned char length, unsigned int timeout) 68
9.2.10. void LineData (unsigned int *data) 69
9.2.11. void OdometrieData (unsigned int *data) 70
9.2.12. unsigned char PollSwitch (void) 71
IV. Appendices 72
A. Partlist 72
B. Diagram ASURO 74
C. RS-232 IR Transceiver 75
D. USB IR-Transceiver 76
E. Blockdiagram ASURO 77
F. Blockdiagram PIC Processor 77
G. Contents ASURO KIT 78
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Part I. Mechanics
1. Necessary tools
In order to build the ASURO we need – apart from the kit – the following tools:
• A „third hand“
• Stanley-Knife
• Small hammer
• Sandpaper (for ne work, Nr. 240)
• Long nose plier for electronic work
• Cutter for electronic cable work
• Soldering iron for electronic work (approx. 20-30 W) or a soldering station
• Solderwire (1 mm) for electronic work, optionally leadfree
• Desoldering wick (2-3 mm width), just in case solder has to be removed from the print
• Glue (either an instant 1-component glue, a bicomponent glue or a hot glue pistol)
• Computer: a laptop or personal computer (operated with Windows or Linux)
• Optionally: a multimeter
* For the optional USB IR-Transceiver you may need an USB cable A to B
Figure 1.1:
Necessary tools
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2. Mechanical Preparations
Completeness of the kit must be checked rst. A parts list in appendix A has been provided
as a checklist. Before doing any electronic artwork, we must however do some mechanical
preparations. So let’s start working.
2.1. Motorpinion
Motor power is to be transmitted to the gear by small cogwheels (with drilling holes of 1.9 mm),
which have to be pressed onto the motor axles. Place the rounded side of the cogwheel on a at
surface and press the motor axle gently into the drilling hole of the cogwheel without using too
much force. You may use a small hammer to press the axle of the motor fully into the cogwheel, by
placing the cogwheel on a weaker surface ( eg. cardboard) and applying the hammer gently to the
backside axle of the motor (see g. 2.1).
Alternatively you may press the cogwheel to the motor axle by using the benchvice. Take care to
press the axle and not to apply any force to the case or the bearings.
Fig. 2.1.: Motorpinion assembly
2.2. Table-tennis ball
ASURO has been designed to slide on the halve of a table-tennis ball, which has to be prepared.
The best way to do this is to take a complete ball and to cut it in two halves with a saw or a
Stanleyknife. The cutting edges can be cleaned up with a le or sandpaper.
That’s all!
Fig. 2.2. Table-tennis ball
Do not use electrical aids like an electrical saw or electrical knife.
Table-tennis balls may be set a re very easily.
Mechanics
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2.3. Axles
Axles are manufactured from a brass rod. Two pairs of axles are needed, each with a length of
24.5 mm and 42.0 mm respectively. These axes are suplied in correct length with this kit.
2.4. Wheel sensors
The odometer, consisting of a light emitting diode and a phototransistor, looks forward to the black
and white markers on the 50/10 cogwheel.
A complete set of adhesive odometer markers is supplied with this kit. Place them on to the
50/10 gear as shown in g. 2.3. Using the sensor-markers with 6 black and white segments is
recommended for compatibility for compatibility with other ASURO’s (demo programs).
The more segments you draw, the better the cogspeed may be registrated and the better speed
control will work. However, a great number of segments reduces the difference between light and
dark (see g.2.4).
g. 2.4.: Examples for the cogwheel markers
You now have completed the mechanical preparations.
Take a short break ...
We will now continue with the electronics.
Mechanics
g. 2.3.:
RECOMMENDED
cogwheel markers
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Part II. Electronics
3. Soldering instructions
ASURO has been designed with wired parts (in contrast to the much smaller surface mounted
devices). Fig. 3.1
demonstrates the smallest available package for the ASURO processor IC and
the wired device we have incorporated. The chip inside these devices however is the same!
Although soldering wired devices is much more comfortable and easier, especially untrained
persons have to consider some precautions.
Of course the printed circuit board must be unplugged at any time while soldering.
Switching off is not enough !!
REMOVE batteries
and power supplies!!!
3.1. Tip, solder and temperature
Fig. 3.2
demonstrates
the basics for soldering. The hot spot of the soldering equipment should
reach ca. 360ºC with lead-solder and ca. 390ºC for lead-free solder, while soldering axles may
be done at higher temperatures (420ºC). Electronics are to be soldered with a miniature tip, while
axles must be soldered with a larger tip area.
Use a slightly humid soldering sponge and apply some solder to the hot soldering tip. Shortly
before using soldering equipment, for the rst time or after a break, old solder must be removed by
wiping off soldering remains from the tip.
Do use solder for electronic work with a diameter of 0.8 or 1 mm.
Fig. 3.1.: Comparison of the largest and smallest case in which the ATmega8L chip is available.
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Fig. 3.2.: Basics for soldering
While soldering, some smoke will be generated which may cause damage to your health.
Avoid breathing gases or work under a cooker hood. Using solder for non-electronic use and
using resins may destroy components.
3.2. Preparing parts
While soldering small parts you will need some tricks and tips to reach the soldering area. When
you already have soldered before you already may have noticed that there is always one hand
short (a tool called third hand can solve a part of this problem).
Some parts (transistors, LEDs, ICs, switches, capacitors and jumper) are already prepared to t
into the PCB (printed circuit board), but diodes and resistors have to be prepared to do so.
Resistors are to be placed vertically in ASURO. To do so, one leg remains in its original position,
the other one is to be bent 180 degrees. Bending must de done at a curvature of 2.5 mm diameter
at a distance of a few millimeters from the resistor body to avoid damage to the part.
Diodes are inserted for horizontal position. To do so both legs have to be bent (eg. by pincers) at a
distance to t into the holes of the PCB.
Processor IC1 ATmega, IC3 CD4081and the IR-receiver IC2 SFH5110-36 are sensitive to
ESD (electrostatic damage). They may be damaged by simply touching or even reaching for
these parts if you have been charged with electricity (eg. by walking on a carpet).
Before handling these parts you should discharge yourself with a discharging bracelet,
connected to ground or at least by touching a grounded heater system or a metallic case of
equipment.
Electronics
DANGEROUS END !
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