Overview
Parts
- Zumy Rev. F PCB
- Zumo Chassis Kit
- ODROID U3+
- ODROID power adapter
- 32GB Micro SD card
- USB WiFi Adapter
- mbed LPC1768
- Power Module
- Motor Driver Module
- Accelerometer Module
- LifeCam
- Camera Bracket
- 2x 100:1 Pololu Gearmotor
- Right angle USB mini cable
- Battery
Electrical Components
- Battery Cable
- 6 conductor ribbon cable with keyed connector
- Power Switch
- 1x 2x6 female header
- 1x 2x5 female header
- 2x 2x3 shrouded female header
- 2x 1x20 female header
- 3x 1x8 female header
- 1x 1x5 female header
- 1x UVLO Chip
- 1x 1uF capacitor
- 3x 0.1uF capacitor
- 1x 200k resistor
- 1x 100k resistor
- 2x 2.2k resistor
Mounting Hardware
- 8x 2-56 x 3/16" screw
- 4x 2-56 hex nut
- 8x 2-56 M/F aluminium standoff
- 2x 2-56 X 7/16" F/F nylon standoff
- 8x 4-40 x 3/8" screw
- 2x 4-40 x 7/8" F/F nylon standoff
- 2x 4-40 x 5/8" F/F nylon standoff
- 2x Rubber bands
Tools needed
- Solder, soldering iron (at least 700F for heavy ground plane soldering)
- Philips head screwdriver
- Wire strippers
- Ribbon cable stripper
- X-Acto knife
- Ruler
- Hot glue gun
- PCB shear/hacksaw
- belt sander/diamond stone
- 3mm allen wrench
- 4mm (0.157") drill bit and drill OR pinch
Main Board
- Cut boards from panel using hacksaw/shear.
- Sand edges to white outline with belt sander/diamond stone.
- Solder surface mount components and jumper positions as shown (4x jumpers for magnetic encoders, MOT_PWR = V_BATT, mbed_PWR=5V). Do not add the 1uF capacitor for low hysteresis voltage detection.
- Solder straight pin headers to power module, accelerometer, and motor driver. Mounting the modules in the main board first will help align the pins.
- Solder power switch and battery cable (red wire to + via)
- Solder through hole components. For module headers (mbed, power, motor, accelerometer), insert the module and attach with 2-56 standoff and screws (power and accelerometer) before soldering to make sure the headers are at right angles to the board. Pay attention to the key direction for the motor shrouded headers.
- Cut right angle power connector plug from ODROID power adapter to a total length of ~6.5cm.
- Strip ~8mm of outer insulation from power connector with X-Acto knife, being careful not to cut ground braid conductor underneath.
- Separate and twist ground braid to right side of cable.
- Strip ~5mm of inner insulation with wire strippers.
- Solder power connector to main board with inner conductor going to the positive via, and the ground braid going to the negative via.
- Hot glue around the power connector to provide strain relief, being careful not to get glue near the camera mount hole. Remove excess glue with an X-Acto Knife
- Test the main board by plugging the ODROID into its power cable (being careful not to let the underside of the board touch anything on top of the main board), and plugging the in to a power supply or battery. The mbed lights should come on, as well as the ODROID lights.
- Now is a convenient time to install the mbed image.
Motors
See Pololu magnetic encoder page for reference.
- Cut ribbon cables to ~6cm total length.
- Strip ~2mm from ends of cable using ribbon cable stripper. It will also help to separate the ribbon cable about ~3mm at the stripped end with an X-Acto knife.
- Solder encoder PCB to back of motors with red lot number facing up (flat side of encoder board)
- Solder ribbon cable to encoder PCB, making sure red wire goes to pin 1 of encoder (has a square solder pad).
- Press magnetic disk onto motor shaft. The side with two circular indentations should be facing out.
Chassis
See Pololu Zumo Chassis kit page for reference.
- Attach rear wheels with included shoulder bolts and screws. Make sure to include the steel washer between the wheel and chassis.
- Press front wheels onto motor output shafts. The tip of the motor shaft should be flush to the wheel plastic.
- Insert motors into front of chassis with wiring facing up, making sure that the outer gearbox plate is flush with the chassis housing, and that the motors cannot slide left and right.
- Slip treads over front and rear wheels.
- Place 2-56 nuts in 4 indicated positions in chassis.
- Remove protective paper from top cover.
- Slip top cover over chassis.
- Screw 2-56 standoffs into hex nuts from step 5 through top cover.
- Secure top cover with 2-56 screws and nuts included in Zumo chassis kit in indicated position.
Camera
- Remove label from LifeCam cable with X-Acto knife.
- Laser cut bracket pieces from 3mm Delrin (Laser Cut File).
- Tap camera mount holes in bracket upright with M4x0.7 thread.
- Drill or punch 4mm (0.157") diameter holes 20mm apart in bottom section of LifeCam mount as shown.
- Attach LifeCam to bracket upright with M4x5 bolts as shown.
Robot
- Slot a camera bracket to the bottom of the camera upright.
- Attach standoffs and lower camera bracket to main board using 4-40 x 3/8" bolts. The 7/8" standoffs go on the rear of the board, and the 5/8" standoffs go on the front with the screw going through the lower camera bracket.
- Slip battery cable through slot in front of chassis to battery compartment.
- Attach main board to chassis with 2-56 bolts.
- Attach right angle Mini-B USB cable to mbed.
- Attach motor cables to main board.
- Sand tab-route nubs off of rear of ODROID.
- Insert SD card in ODROID slot (you will probably want to image it first).
- Slot a camera bracket to the top of the camera upright.
- Loop Mini-B USB cable so that it will be inside the standoff when the ODROID is attached.
- Attach ODROID to top of standoffs with 4-40 x 3/8" bolts.
- Plug USB Mini-B cable, WiFi adapter, LifeCam USB cable, and ODROID power cable into ODROID.
- Secure battery in under robot with rubber bands.
- Plug battery into battery cable.
