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1. 05 15 2005 Botster and Botster Brand are Trademarks of Summerour Robotics Corporation 2004 2005 Pre Construction Information Before assembling your Botster kit get familiar with the material below so you will better understand the nomenclature used in this guide Botster Screw Types and Sizes Button Head Cap Screw BHCS 6 32 x 1 2 For wheel encoder modules and rear caster Flat Head Cap Screw FHCS 6 32 x 1 2 Chassis servos 6 32 x 1 4 Colored trim pieces wheel encoder modules and caster TOOLS You will need the following common hand tools to fully assemble your Botster kit e Combination hex wrench set Specifically 5 64 amp 7 64 size wrenches e Phillips head screwdriver e Razor Blade utility knife or xacto knife 2004 2005 Summerour Robotics Corporation Botster Assembly Manual Version 1 4 05 15 2005 Botster and Botster Brand are Trademarks of Summerour Robotics Corporation 2004 2005 Botster Robot Kit Part Names Quantity each in parentheses Chassis Sides 2 Upper Deck 1 Middle Deck 1 Lower Deck 1 Front Vertical Deck 1 Upper Rear Vertical Deck 1 Lower Rear Vertical Deck 1 Battery Door Colored Trim Pieces 4 Wheel assemblies Wheels Encoder disk Hubs 2 Servos Hitec HS 322HD 2 Traction Bands 4 two extra Hamamatsu Wheel Encoder Modules 2 Rear Steel Ball Caster amp Mount 1 Screw Pack 12. Botster Assembly Manual Version 1 4 05 15 2005 Botster and Botster Brand are Trademarks of Summerour Robotics Corporation 2004 2005 19 20 Now bolt in one of your Sharp GP2D infrared sensors using the 6 32 x 1 4 socket head cap screws included in the infrared sensor kit as shown Once you get it bolted in it s a good idea to connect the sensor wire while you have easy access to the connector 21 Bolt in the front vertical deck as shown using four 6 32 x 1 2 flat head cap screws 2 in bottom deck 2 in middle deck 2004 2005 Summerour Robotics Corporation Botster Assembly Manual Version 1 4 05 15 2005 Botster and Botster Brand are Trademarks of Summerour Robotics Corporation 2004 2005 20 Here s what the Botster should look like at this point NOTE You may have the Generic or CMUcam2 turret bolted in as well 2004 2005 Summerour Robotics Corporation Botster Assembly Manual Version 1 4 05 15 2005 Botster and Botster Brand are Trademarks of Summerour Robotics Corporation 2004 2005 21 22 Bolt on the top and bottom trim pieces using seven 6 32 x 1 4 flat head cap screws per side as shown NOTE Do not insert them into the holes shown below which do not have them We will use 6 32 x 1 2 flat head cap screws in the empty holes in the next step 23 Bolt on the upper deck using four 6 32 x 1 2 flat head cap screws thru each side plate as sho
3. don t worry about the two in the middle yet 2004 2005 Summerour Robotics Corporation Botster Assembly Manual Version 1 4 05 15 2005 Botster and Botster Brand are Trademarks of Summerour Robotics Corporation 2004 2005 12 Bolt each chassis side to the bottom deck as shown Make sure you hold the sides tightly against the bottom when starting the screws with no gaps showing If you happen to have a gap once you ve started threading the screws in simply back the screws out and start over This will allow you to apply very little torque to tighten them down when fully seated 2004 2005 Summerour Robotics Corporation Botster Assembly Manual Version 1 4 05 15 2005 Botster and Botster Brand are Trademarks of Summerour Robotics Corporation 2004 2005 13 10 Start threading two 6 32 x 1 2 flat head cap srews into the two holes in the middle of each side plate as show until the end of the screw is flush w the inside of the side plate 11 Start threading in two 6 32 x 1 2 flat head caps screws into the countersunk holes on the middle deck as shown These are the two holes pictured in the top right of the picture below with the screws in them NOTE Some middle decks may have extra holes as shown In this case simply use the holes closest to the angled notch Ignore the other two holes NOTE 1 If you re not going to be using the Sharp infrared sensor blocks then don t bother threading i
4. servos in the chassis sides continue threading each of the four 6 32 flat head cap screws up through the servo flange holes into four 6 32 nuts as shown Make sure you have all of the bolts threaded into the nuts before tightening them down othewise it ll be hard to thread them all in Also make sure the servo wire Is pointing toward the bottom of the Botster and that the servo mounting flange is flush with the bottom of the chassis side 2004 2005 Summerour Robotics Corporation Botster Assembly Manual Version 1 4 05 15 2005 Botster and Botster Brand are Trademarks of Summerour Robotics Corporation 2004 2005 4 Next cut the wheel encoder spacers using the include wheel encoder spacer tubing material Using a razor blade or xacto knife slice the tubing into four 1 16 sections as shown below Here s what the four washers will look like when you ve finished cutting them Enough material was included in the kit that if you mess up a couple you ll still have plenty of material to cut more NOTE Do not use metal washers for spacers since they could short the electric circuit on the wheel encoder module 2004 2005 Summerour Robotics Corporation Botster Assembly Manual Version 1 4 05 15 2005 Botster and Botster Brand are Trademarks of Summerour Robotics Corporation 2004 2005 5 Bolt each wheel encoder to the chassis sides using two 6 32 x 1 2 button head cap screws and the wheel encoder
5. Connection com BOLSTERS EESS ESS eee ERAMo Manual 2004 2005 Summerour Robotics Corporation Botster Assembly Manual Version 1 4 05 15 2005 Botster and Botster Brand are Trademarks of Summerour Robotics Corporation 2004 2005 BEFORE YOU BEGIN ASSEMBLING BOTSTER IMPORTANT PLEASE DO NOT USE ANY POWER TOOLS TO ASSEMBLE YOUR KIT Use only the required held phillips head screwdriver and hex wrenches NOTICE We will not warranty any parts with stripped out holes for which you have stripped out using power tools The plastic material that our kits are manufactured out of has been tested to ensure that it provides enough strength to withstand typical hand torquing of screws and provide sufficient wear characteristics for typical insertions and removals of screws Once the screw is seated on the plastic apply a 1 8 turn 45 degrees of clockwise rotation of the screwdriver and STOP DO NOT apply any more torque We define seated as when the bottom of the screw head comes in contact with the plastic Also our kits are designed so as to not require the user to have to frequently remove screws to get to other parts of the kit So once the kit is together leaving it together will help prolong the life of it We believe you will be very pleased with the solidity and rigidity of the assembled kit 2004 2005 Summerour Robotics Corporation Botster Assembly Manual Version 1 4
6. Robotics Corporation 2004 2005 26 2 Install the x 6 32 hex standoffs into the top of the upper deck by inserting the threaded end into the holes in the upper deck which correspond to the controller being mounted NOTE The four outer most holes correspond to the OOPic R and the four innermost holes correspond to the BasicX 24 controller Thread them in until they bottom out as shown below 3 Bolt the OOPic R or BasicX 24 onto the standoffs using the four included 6 32 x 1 4 socket head cap screws as shown 2004 2005 Summerour Robotics Corporation Botster Assembly Manual Version 1 4 05 15 2005 Botster and Botster Brand are Trademarks of Summerour Robotics Corporation 2004 2005 Here s what it should look like when you ve finished mounting your controller That s it 2004 2005 Summerour Robotics Corporation Botster Assembly Manual Version 1 4 05 15 2005 Botster and Botster Brand are Trademarks of Summerour Robotics Corporation 2004 2005 27
7. Sharp GP2D120 infrared sensor mount blocks 2 Front infrared sensor aluminum hex standoffs 2 Generic or CMUcam2 Turret and servos Optional 1 Wheel encoder spacer tubing material PRP RPP RPRPRrPrErFPWOONOUBRWNE SHOGR WN O22 Be 7 7 7 7 ees ee ee oe ee eee el ee SVN Assembling the Botster kit 1 Start by trimming the small ribs protruding just above the surface of the servo mount tab with a razor blade or xacto knife as shown This will allow the servo to mount flush with the inside of the chassis side plates Repeat for both mounting tabs Caution Be very careful on this step and do not cut yourself This should be performed by an adult Fy A 4 TF g ni e a _ a M re ee r d m _ a ad 2004 2005 Summerour Robotics Corporation Botster Assembly Manual Version 1 4 05 15 2005 Botster and Botster Brand are Trademarks of Summerour Robotics Corporation 2004 2005 Here s what the mounting tab should look like when you re finished trimming the tab flush 2 Start threading in four of the supplied 6 32 x 1 2 flat head cap screws as shown into each of the chassis sides Thread them in until about 1 8 of an inch is sticking out of the other side of the chassis side plate 2004 2005 Summerour Robotics Corporation Botster Assembly Manual Version 1 4 05 15 2005 Botster and Botster Brand are Trademarks of Summerour Robotics Corporation 2004 2005 3 To install the
8. efore installing the turret if you own one you won t be able to unless you remove the turret Also go ahead and insert the cable into the front Sharp IR sensor before bolting it into the front deck below Otherwise you ll face a similar situation 2004 2005 Summerour Robotics Corporation Botster Assembly Manual Version 1 4 05 15 2005 Botster and Botster Brand are Trademarks of Summerour Robotics Corporation 2004 2005 16 16 Optional If you ordered a Generic or CMUcam2 turret note the position of the adjustable turret servo horn on the tilt servo remove it and modify it as shown using a razor blade or xacto knife This will provide clearance with the rear vertical deck when the Botster is fully assembled Make sure you cut the horn as shown below with the serrated side down You ll only need to trim the one side shown Now bolt the servo horn back onto the servo in the same position from which you removed it 17 Bolt the Generic or CMUcam2 turret onto the top of the middle deck as shown with the previously threaded in 6 32 x 1 2 flat head cap screws 2004 2005 Summerour Robotics Corporation Botster Assembly Manual Version 1 4 05 15 2005 Botster and Botster Brand are Trademarks of Summerour Robotics Corporation 2004 2005 17 You can wrap the excess tilt servo wire around the back of the turret a couple of times to keep it out of the way If you re using the CMUcamz2 turret v
9. ersion then you can plug the servo connector into the second servo port which is the one used to control tilt Now you can simply send commands serially to the CMUcamz2 to tilt the servo in the desired direction Please follow the CMUCam2 user manual for instructions on how to connect the CMUcamz2 to your controller NOTE The servo will turn farther than the turret can tilt so you will have to limit it s movement via software Go to our Documents and Downloads web page for examples on how to implement this for the BasicX and OOPic R microcontrollers If the servo makes a humming noise once it moves the turret plate to it s extent in either direction then it s moving to far and should be backed off a little Also insert two 6 32 x 1 2 flat head cap screws into the two front countersunk holes as shown below These will be used to bolt in the front vertical deck Here s what the middle deck with turret assembly should look like at this point 2004 2005 Summerour Robotics Corporation Botster Assembly Manual Version 1 4 05 15 2005 Botster and Botster Brand are Trademarks of Summerour Robotics Corporation 2004 2005 18 18 Bolt the middle deck into the Botster as shown 19 If you ordered the Sharp GP2D infrared sensor pack install the two threaded hex standoffs included in that kit into each of the two holes in front vertical platter as shown 2004 2005 Summerour Robotics Corporation
10. n the flat head cap screws NOTE 2 If you purchased the optional Generic or CMUcam2 Turret for the Botster then thread in the two 6 32 x 1 2 flat head cap screws used to bolt the turret servo pan base into the middle deck as shown These are the two holes in the bottom left of the picture below with the screws in them Also follow the next steps Otherwise Skip down to step 14 to bolt in the middle deck 2004 2005 Summerour Robotics Corporation Botster Assembly Manual Version 1 4 05 15 2005 Botster and Botster Brand are Trademarks of Summerour Robotics Corporation 2004 2005 14 12 Bolt the two Sharp IR sensors to the sensor mounting blocks as shown with the included 6 32 x 1 4 socket head cap screws as shown 13 Bolt both on the Sharp infrared sensor blocks and sensors onto the top of the middle deck as shown using a 6 32 x 1 2 flat head cap screw Unless you re not going to be using these in which case save them and skip this step 2004 2005 Summerour Robotics Corporation Botster Assembly Manual Version 1 4 05 15 2005 Botster and Botster Brand are Trademarks of Summerour Robotics Corporation 2004 2005 15 14 Here s what the top of middle deck should look like at this point NOTE The sensor blocks should be pointed at roughly 45 degrees off of the centerline of the middle deck 15 Now s the time to plug in the Sharp IR sensor cables If you do not do so b
11. spacers you just cut Use two 6 32 nuts to captivate the encoder module button head cap screws both chassis sides as shown 2004 2005 Summerour Robotics Corporation Botster Assembly Manual Version 1 4 05 15 2005 Botster and Botster Brand are Trademarks of Summerour Robotics Corporation 2004 2005 Here s what the wheel encoders and chassis sides should look like at this point of assembly 6 Bolt the steel ball caster assembly to the bottom deck as shown Start by placing the steel ball into the plastic housing and the place the steel rollers on top of the ball be careful they ll fall out 2004 2005 Summerour Robotics Corporation Botster Assembly Manual Version 1 4 05 15 2005 Botster and Botster Brand are Trademarks of Summerour Robotics Corporation 2004 2005 10 Next place the bottom deck onto the ball housing the deck has three slots that the tabs on the ball housing will fit down into as shown Use three 6 32 x 1 2 button head cap screws to bolt the housing to the bottom deck as shown 2004 2005 Summerour Robotics Corporation Botster Assembly Manual Version 1 4 05 15 2005 Botster and Botster Brand are Trademarks of Summerour Robotics Corporation 2004 2005 11 7 Captivate the caster bolts with three 6 32 nuts as shown 8 Start threading six 6 32 x 1 2 flat head cap screws into each of countersunk holes along the bottom of the bottom deck
12. tretch and tug to get the band centered perfectly Once it s centered it should easily stay in that position even while driving 28 Bolt on the Botster s wheels using the black servo screws in the ends of the splined servo shafts 2004 2005 Summerour Robotics Corporation Botster Assembly Manual Version 1 4 05 15 2005 Botster and Botster Brand are Trademarks of Summerour Robotics Corporation 2004 2005 23 29 That s it You re now ready to bolt on your controllers and other sensors and make Botster perform some cool tasks Good luck Please let us know if you encountered any issues which weren t explained clearly in this manual so we can improve it for our future customers Thank you OOPic R and BasicX 24 installation Optional Follow these steps to install an OOPic R or BasicX 24 board onto the top deck of the Botster with the included mounting kit only included w Botster controller combo 1 Drill out the four mounting holes in either the OOPic R or the Basicx 24 microcontroller depending on which one you have using a 28 drill This drill is about 0 140 in diameter Be SURE to hold the controller firmly and flat when drilling so as to not lose control of it THIS STEP SHOULD BE PERFORMED BY AN ADULT of 18 years or older 2004 2005 Summerour Robotics Corporation Botster Assembly Manual Version 1 4 05 15 2005 Botster and Botster Brand are Trademarks of Summerour
13. wn below 2004 2005 Summerour Robotics Corporation Botster Assembly Manual Version 1 4 05 15 2005 Botster and Botster Brand are Trademarks of Summerour Robotics Corporation 2004 2005 22 24 Bolt the upper rear vertical deck onto the back of the Botster s chassis as shown using four 6 32 x 1 2 flat head cap screws The upper rear vertial deck is a perfect place to mount our plug n play breadboard for the BX 24 or OOPic R 2004 2005 Summerour Robotics Corporation Botster Assembly Manual Version 1 4 05 15 2005 Botster and Botster Brand are Trademarks of Summerour Robotics Corporation 2004 2005 25 Thread in one 6 32 x 1 2 flat head cap screw per side in the countersunk hole Shown and bolt in the lower rear vertical deck battery door NOTE DO NOT tighten these screws up to allow the rear vertical deck to rotate up and down for access to Botster s inner cavities 2004 2005 Summerour Robotics Corporation Botster Assembly Manual Version 1 4 05 15 2005 Botster and Botster Brand are Trademarks of Summerour Robotics Corporation 2004 2005 23 24 26 Thread in two 6 32 x 1 2 flat head cap screws into the two countersunk holes in the top of the lower rear vertical deck and bolt it into the upper deck as shown You an simply takes these out to insert remove batteries as needed 27 Stretch the included traction bands around the Botster wheels You ll have to s
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