Educational Robot System SW-007
SKY WALKER
Manual: Model SW-007
© 2007 AREXX Engineering
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Contents
1. Product description Sky Walker 3
2. Soldering 4
2.1 Necessary tools 4
2.2 Soldering techniques 5
2.3 Troubleshoot soldering mistakes 6
3. Electronic components 7
3.1 List of electronic parts 9
3.2 The soldering job 10
3.3 Electronic circuit test 11
3.4 Electronic trouble shooting 12
4. Information electronic parts 13
5. Electronics 17
5.1 Block diagram 17
5.2 Explanation black diagram 17
5.3 Function description of electronic parts 18
6. Mechanics 20
6.1 List of mechanical parts 22
6.2 Instructions mechanical assemby 23
7. Test of the Sky Walker 29
7.1 Mechanical test 29
7.2 Final assembly 30
8. Information about gears 32
A. Appendix A 33
© English translation (July 2007): AREXX Engineering (NL).
This description is protected by the laws of copyright. Any partial or total reproduction of the contents
is prohibited without prior written authorisation of the manufacturer:
AREXX Engineering - Zwolle (NL).
The manufacturer and distributor cannot be held responsible for any damages occurred by mishandling,
mounting mistakes or misuse due to a non-respect of the instructions contained in this manual.
The specication, shape and size of the product are subject to change without prior notice.
Manufacturer:
Jama Co., Ltd.
Tachung TAIWAN
© 2007 AREXX Engineering
Importer:
AREXX Engineering
ZWOLLE The Netherlands
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When you have a pre-soldered
Robot (Model SW-007A), please
start with Chapter 6 on page 20.
Technical assistance
during the construction
of the robot:
www.arexx.com
1. PRODUCT DESCRIPTION SKY WALKER
The Sky Walker is a striking robot with two sensors. One sensor watches the light
intensity, the other listens to sounds. When there is a sound or light effect, the Sky
Walker reacts on it by walking for a few seconds and then it automatically stops.
High on his four legs, the Sky Walker walks kind of wobbly. It looks as if he is walking
on clouds. Therefore, his name Sky Walker could not be more appropriate.
With this educational robot project, everybody can learn the basic principles of electronics. Building the robot already brings a lot of fun. You feel great building a real working
electronic system out of all separate parts, which responds to changes in light and
sound.
Specications:
Power voltage : 1.5 Volt
Power source : 1 Penlite battery (not included)
Power consumption (moving) : About 400 mA
Power consumption (at rest) : About 130 mA
Height : 135 mm
Diameter : 105 mm
u No return is possible after having opened the bags with components and pieces
u Prior to the assembly read the manual thoroughly.
u Be careful when using tools.
u Keep this kit away from young children during construction and operation.
(They might get hurt by the tools or swallow small components).
u Observe the correct polarity of the battery.
u Keep the battery dry. When the Sky Walker gets wet remove the battery and let the
Sky Walker dry for some time.
u Remove the battery when you are not using the Sky Walker for a longer period.
u Children below 14 should only assemble this product with the help of adults.
Warning
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Before you start soldering we will give you some advise and instructions:
Please read the complete soldering instructions before you start. Work accurately and follow the
instructions in this manual exactly to avoid problems.
2.1 Necessary Tools:
Soldering iron
(15 to 30W)
Electronic Solder
0,8- bis 1mm
Use an electronic soldering iron about 20 to
30 Watt. A soldering iron with more power
can overheat sensitive components and the
PCB traces. When the power is too low, sol-
dering is hard and the solder will not ow well.
Normally you also should have a soldering
standard to store the iron safely and a sponge
to clean the tip of the soldering iron.
Use thin electronic rosin core solder
with a diameter of about 1mm. Do not
use liquid ux or an ux solder paste for
electronic circuits.
Always use the right type and size screw-
driver you need the philips type for M2
and M3 screws.
Electronic cutter &
atnose plier
2. SOLDERING
The correct tools already
do half of the job!
Soldering standard with a wet
sponge to clean the tip
Use a safe and solid standard
Use electronic tools (150 mm).
Desoldering wick
To suck solder from a PCB to remove
components for small repairs.
Electronic screwdriver set
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PASTE
2.2 Soldering techniques:
Only use lead free ROSIN CORE solder!
Never use any liquid or paste ux!
Hold the iron like a pencil and
only heat the component wire
for a few seconds.
Correct position for professional soldering
Only add a little solder
each time
1. Preheat the solder area which
must be soldered AND the
component wire with the tip of the
iron. Do NOT overheat it!
4. Take away the soldering iron.
DO NOT MOVE the component
or PCB!
Please NOTICE the correct positioning of the components, see the drawings below:
2. Add some solder to the
soldering area and
component wire but NOT
TOO MUCH!
5.Cut away the long component
wire just above the soldering spot.
3. Remove the solder and let
the hot liquid solder ow.
The END RESULT is a nice and
shiny soldering spot which is
attached to the PCB copper and
component wire.
WRONG
GOOD
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Repair of a damaged PCB:
When the trace is broken or the path is damaged,
remove the mask on the copper trace with a screwdriver
or a knife and bend the component wire to the trace.
Solder a piece of wire from trace to trace or from
component to trace.
2.3 Troubleshoot soldering mistakes:
Cold PCB
Solder is attached to the
component wire but not to
the PCB copper.
Cold component
Solder is attached to the
PCB Copper but not to the
component wire.
Wire bridge
Two separate components are
connected with a wire to each
other making a short cut
Not enough solder
Solder did not ow
Bridge of solder
Two separate solder spots
are connected to each other
making a short circuit
Perfect solder connection
The soldering surface looks
nice and shiny!
The PCB is made of a copper trace on a non-conductive substrate which connects
the components, who are soldered to solder paths, electrically with eachother. Copper
surfaces which will not be soldered are often coated with a mask to make it solder
resistant. This mask also protects the copper against oxidating. When we overheat the
copper traces or solder paths, the copper may vaporate or loosen from the substrate.
To repair this we must remove the protective mask carefully with a screwdriver or
small knife. See below how you can repair a damaged PCB.
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3. ELECTRONIC COMPONENTS
Variable Resistor
(Potentiometer)
Resistor
Ceramic capacitor
When the component has a marking near the legs the polarity is extreme important !
Assembly with the wrong polarity can dammage the component or the complet circuit!
Component Assembly PCB symbol Circuit symbol
Electrolytic
capacitor (ELCO)
-
Transistor
+
B and E are just an
example, position can
change per type
PNP type
NPN type
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Switch
Component Assembly PCB symbol Circuit symbol
PHTR
E
Transparent
or black
Microphone
Lamp
Red
Terminal pin
C
Bottom
view
sig
Gnd is connected
with the metal body
gnd
E
sig
C
gnd
ECM
Motor
Battery (not included)
MOTOR (terminal) M1, M2
No symbol
SW (terminal) S1, S2
+
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3.1 List of electronic parts:
Wire preparation:
Put the soldering wick
on the solder path.
Heat the wick and the
path with the soldering
iron and the copper
braid of the wick will
suck the solder.
When the wick
removed all the
solder from the
path, pull back the
wick and the
soldering iron simul-
taneously
Resistors 0,25 Watt; 5% Marking: Quantity:
… 15 Ω R13 (Brown, Green, Black, Gold) 1 pc.
… 1 KΩ R1, R3, R7, R8 (Brown, Black, Red, Gold) 4 pcs.
… 3.9 KΩ R2, R4, R12 (Orange, White, Red, Gold) 3 pcs.
… 27 KΩ R11 (Red, Violet, Orange, Gold) 1 pc.
… 47 KΩ R10 (Yellow, Violet, Orange, Gold) 1 pc.
… 100 KΩ R5, R6 (Brown, Black, Yellow, Gold) 2 pcs.
… 2.2 MΩ R9 (Red, Red, Green, Gold) 1 pc.
Variable resistors Marking: Quantity:
… 100 KΩ VR1, VR2 (104) 2 pcs.
Ceramic capacitors Marking: Quantity:
… 22 nF C3, C4 (223) 2 pcs.
… 1 nF C6 * Already soldered to the motor ! *1 pcs. (motor C)
ELCO’s Marking: Quantity:
… 3.3 µF C1, C5 (3.3 µF/50V) 2 pcs.
… 100 µF C2 (100 µF/16V) 1 pc.
Semi conductors Marking: Quantity:
… A1015 or A733 TR1, TR5 (2SA1015 or 2SA733) 2 pcs.
… C1815 or C945 TR2, TR3, TR4 (2SC1815 or 2SC945) 3 pcs.
… D2001 or D734 TR6 (2SD2001/2SD2120 or 2SD734) 1 pc.
… Phototransistor PHTR (SFH309) 1 pc.
Divers Marking: Quantity:
… PCB AREXX DG-SKY (arexx) 1 pc.
… Microphone EMC (Condensor type for PCB) 1 pc.
… Switch SW (Slide switch with wires) 1 pc.
... Termininal pin S1, S2, M1, M2 (1 mm Typ) 4 pcs.
… Motor M (1,5 Volt DC Motor) 1 pc.
… Motor cable With terminals at each end (Blue, Orange) 2 pcs.
… Battery holder VCC (1 pc. AA type) 1 pc.
... Light bulb Lamp1, Lamp2 (red color lamp) 2 pcs.
... Black wire For lamp assembly (About 8 cm wire) 1 pcs.
... Tube White and Black (About 5 cm tube) 1 pcs./ Color
5mm
Remove about 5mm of the
plastic wire insulation
Desoldering
When you made a soldering failure, you can easily remove the mistaken component with wick.
Twist the copper wires
when necessary
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Pre-solder the copper wire. This step
makes it more easy to solder the wire
later on.
3.2 The soldering job:
First please check if all parts are complete
with help of the parts list on page 9 and the
circuit on page 18.
The markings on the PCB show exactly at
which location you should solder the parts. If
you need more information, please check the
drawing of the PCB.
We always start to solder the lowest and non
critical parts, these are normally the resistors
and ceramic capacitors, and nish with the
higher critical parts like Elco's and semiconductors like transistors and LEDs.
We advise to cut the component wires
directly after soldering, so they will not be in
the way when you start soldering other parts.
THE POSITION AND POLARITY OF THE ICs, ELCOs, DIODES, TRANSISTORS, LEDs AND PHTR ARE MOST IMPORTANT,
OTHERWISE THE ROBOT MAY NOT FUNCTION CORRECTLY OR IN THE WORST CASE, COMPONENTS GET DAMAGED!
1) Start with the resistors.
2) Then we solder the potentiometers to the PCB.
3) After that, we solder the 4 terminal pins.
4) In this step we solder all ceramic capacitors.
In the following steps we will solder the more critical parts. It is important to solder the
correct type and the correct polarity. Take care not to overheat these parts with your
soldering iron.
5) Start with the Elcos and notice the correct polarity with the plus and minus marking.
6) Solder the transistors, be sure you solder the correct types and correct polarity.
7) Solder the microphone and pay attention to the correct polarity!
8) At last you can solder the PHTR. The polarity is very important!
Final PCB soldering are the lamps and the battery holder
The LAMPS must be soldered with 25mm leg length.
** IMPORTANT NOTICE FOR THE LAMPS:
Very important is to put a tube (20mm) over each leg of the LAMPS after
you solder it! This tube will protect the LAMPS against a short circuit.
Lamp preparation (only when the lamp wires are to short):
Micophone!
Gnd is connected
with the metal body
1) Cut 25 mm wire and remove insulation
5mm (see page 9 wire preparation).
2) Solder the wire to the lamp.
Tube white 20mm
4) Put the tube over the wires so there will
be no shortcut between the wires.
3) cut 2 pcs of
20 mm white tube.
Bend the lamps 15mm and 10mm length,
same way as shown on the picture.
The last part is the battery holder and also
here the polarity (red + and black wire -)
is realy important.
The battery holder itself is xed to the PCB
with double sided tape.
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3.3 Electronic circuit test
*) Switch on the robot, lamps will glow.
1) Clap your hands.
2) The motor should rotate for a few seconds and then automatically stop.
3) Shade the light sensor with your hand.
4) The motor should rotate for a few seconds and then automatically stop.
Please notice!
We did not draw the lamps on this PCB!
But it is realy important that the lamp legs are
covered with a tube so there will be no shortcut!
Before you start with the mechanical assembly we do a simple test to check the function of the electronic circuit.
PREPARATION
First we have to connect the switch to the PCB. Connect the 2 black wires of the switch to the SW
terminals on the PCB.
Now we have to connect the motor to the PCB. Connect the orange and blue wire to the motor terminals and
connect the other end of the wire to the motor terminals on the PCB. The position of the terminals is not so
important.
Insert the battery.
PLEASE NOTE THE POLARITY! (+ and -).
At last: Adjust the variable resistors into the middle position.
TEST
NOTE!
You can adjust the sound sensor sensitivity with VR1.
You can adjust the light sensor sensitivity with VR2.
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When you adjust the variable
resistors, please use a good tting
screwdriver. Always rotate it very
slowly without any force.
To improve the sensivity of the light
sensor you must put a small piece
(5mm) of tube over the PHTR sensor.
See drawing above
3.4 Electronic trouble shooting
PROBLEM CHECK
The lamps do not light.
• Check the polarity of the battery.
• Check the battery (is it full).
• Check the polarity of the battery holder.
The lamps do light but the Sky Walker does not react
on noises.
The Lamps do light but the Sky Walker does not react
on differences of light intensity.
Transistors get very warm.
• Check the sensitivity of the microphone.
• Check the parts and solderings involving the
microphone circuit: ECM, R1, VR1, R8, C4,
TR3, TR4 and TR5, TR6.
• Check the sensitivity of the lightsensor.
• Check the polarity of the PHTR.
• Check C1, R2, VR2, TR1, TR8, R4-R7 and C3
• Check the transistors type, position and polarity.
- When there is a problem ALWAYS check the battery rst: Is it full?
- Check the wire connections, only in good wire connections the current can ow freely.
- Try to establish if you have a mechanical problem or an electronic problem.
- Use the trouble shoot tables in this manual.
- Check all electronic parts, see if it is the right type on the right position and check polarities too!
- Check all solderings: Do the parts and the PCB traces make good contact?
- When a problem cannot be solved, best way is to disassemble the robot and build it again. Follow the
instructions in the manual very accurately.
Tips and Tricks
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The value of a resistor can be identied by coloured rings. The rst and second
ring describe a number and the third ring is a multiplying factor, of which you
should multiply the previous number. The fourth ring shows the accurancy of the
resistor value, which means the possible deviation of the value in %.
4. Information electronic parts
Lamp
A very common part which you can nd in each household. Because of the low voltage
we are using an incandescent light bulb. This type transfers electricity in light and heat.
The efciency is poor, because the heat is a waste of power which we do not want.
Therefore we use more and more LEDs as a lamp. They have a much better efciency.
Quantity: Symbol: Value (SI unit) :
Some basic
principals and
important
formula's used
in electronics
Current I Ampere (A)
Voltage V Volt (V)
Resistor R Ohm (Ω)
Power P Watt (W)
The relation between them is called "OHMs LAW" :
Current calculation; I = U : R
Resistor calculation; R = U : I
Voltage calculation; U = I x R
VOLTAGE = CURRENT TIMES RESISTOR.
POWER = Voltage times Current
Resistor
The resistor restricts the current in an electronic circuit. When you use Ohm's law, you
also can see that they can reduce the voltage in a circuit. When you imagine the current
as a water ow in a garden hose, the resistor creates the same effect as pressing in the
middle of the water hose. The water does not spray out of the hose so hard anymore.
Color Value Multiplication
Black 0 1
Brown 1 10
Red 2 100
Orange 3 1000
Yellow 4 10000
Green 5 100000
Blue 6 1 Million
Violet 7 10 Million
Grey 8 100 Million
White 9 1000 Million
Gold x 0,1 of 5 % accurate
Silver x 0,01 of 10 % accurate
Example: A resistor with colored rings Brown (1), Black (0), Orange (thousand) and Gold has a value of
10000 Ohm (10KΩ) and 5 % accurancy.
TIP:
A trick to remember the the resistor colorcode is;
Buy Better Resistance Or Your Grid Bias May Go Wrong (The rst letter mentions the color letter)
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1 2 3 4
Variable resistor
Besides the normal resistors we also have the variable resistor which is also called
potentiometer (potmeter).
The variable resistor is available in many types and shapes. One of the most familiar
variable resistors is the volume regulator in a radio. The type which is used in our robot
is directly placed on the PCB. The maximum value of a potmeter is always given. The
potmeter in our robot is used to change the amplication of the sound and light sensor.
Capacitor
Capacitors can store electronic energy and when you require it they can offer it back
without great lost. An other characteristic is that they can block a DC current and let an
AC current pass. They will have a certain resistance for AC currents. The symbol for
a capacitor is C. The value of a capacitor is named capacitance and the unit is Farad
(F). Normally the value of a capacitor is very small and is expressed in Nano-, Micro- or
Picofarad:
Abreviation Meaning Value
1µf 1 micro Farad 0,000001 Farad
1nf 1 nano Farad 0,000000001 Farad
1pf 1 pico Farad 0,000000000001 Farad
There are many coding systems for capacitors. Ceramic and mylar capacitors which we
normally use, have value numbers printed on it.
Electrolytic capacytor (ELCO)
The Elco is a polarized (meaning; direction-depending) capacitor. The manufacturers
put several markings on this capacitor to recognize the Plus and Minus pin of this
capacitor. Normally one pin is longer (plus) than the other. The minus pin shows a
white marking on it.
Diode
The diode allows the current to ow only in one way (from Anode to Cathode). When
the current wants to ow in the other direction, it will be blocked.
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Transistor
The transistor is a semiconductor which can be used as a switch and for amplication.
The transistor has three terminals: Basis, Emitter and Collector. These three terminals
are normally marked with the rst letter; B, E, and C. The transistor is supplied in many
types and shapes. There are 2 important main types: the PNP- and NPN-Transistors.
The ow in the NPN-Transistors is different than it is in the PNP-Transistors.
You can also imagine the transistor as a water tap
(Basis) in a waterstream, which ows between
A (Collector) and C (Emitter). The water ows;
• from Collector to Emitter in a NPN-Transistor
• from Emitter to Collector in a PNP-Transistor
With the tap regulator which you can imagine as the Basis,
we can regulate the Flow between A and C.
It is even possible to switch the ow on and off.
When you imagine above waterow, you can understand that with a small current on
the Basis, we can regulate the ow of a big current between Emitter and Collector.
Now you can also imagine that we can switch off the ow between Emitter and
Collector completely so it will act like a switch.
A and C can be the Transistors
E (Emitter) or C (collector),
depending on the NPN or PNP
type.
Battery
We already mentioned the battery on page 13. The one we are using in the Sky Walker
has a voltage (V) of 1.5 Volts. Voltage means the difference of the electrical potential
between the PLUS and MINUS pole of a battery. When you see electricity in
analogy with water, you can imagine that voltage is almost the same as pressure.
When the battery is in a closed circuit, the electrons will ow from - to + and generate a
current (I) which will ow in the circuit. The current value is measured in Ampere.
The Power consumption (P, in Watts) in a circuit is Voltage x Current: P=UxI
When the Sky Walker is moving, it will use a current of 200 mA (0.2A). The battery
voltage is 1.5 Volt.
P = U x I P = 1.5V x 0.2A
So the Sky Walker's power consumption is 0.3 Watt = 300 mW
See also Appendix A
for more information.
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IC = Integrated Circuit
"Integrated Circuit" means a complete electronic circuit on a silicon chip. With the name
IC we describe a complete circuit which normally contains several transistors and other
electronic parts like resistors and capacitors in one building block. There are many different types and shapes of ICs. A few ICs together often build a complete product. For
example only one small receiver IC and a small amplier IC can make a very small but
complete radio.
This electronic part is so important in modern electronics that we have to mention it
even though we do not use it in the Sky Walker robot.
Phototransistor (PHTR)
E
C
The PHTR is a light sensitive device. It works a bit like a transistor but instead of a
basis which controls the ow with a current it has a light sensitive basis. With a PHTR,
the current ow between Emitter and Collector is controlled by the intensity of light.
Microphone
The microphone is maybe the most familiar part in the Sky Walker. Almost everybody
knows what a microphone is. We see it often on TV and all radio makers and pop-
stars have to use it. But do you also know how it works? The microphone changes
soundwaves into electronic signals. These electronic signals can be used in electronic
circuits for example in an amplier. In the Sky Walker, the microphone detects sounds
and when the Sky Walker detects a sound, the electronic circuit will be activated.
LED = Light Emitting Diode
The name LED already says it all, "Light Emitting Diode" which means a diode who
produces light. This diode has the same features as a normal diode but it will light when
a current ows from Anode to Cathode. There are many different colored LEDs and
there are all so many different shapes, sizes and brightnesses. LEDs are often used in
control panels but also in trafc lights because their power consumption is very low.
A
C
A
C
Motor
A motor transforms electrical energy into mechanical
energy. A well-known technical frase for mechanical
energy is kinetic energy. Kinetic comes from Greek
(kinesis) and means motion.
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5. ELECTRONICS
5.1 Blockdiagram
Power supply &
Lamps section
Motor
section
Filter
section
Big electronic schematic diagrams can be very complicated. To simplify such a complex diagram we often use
a blockdiagram. In a blockdiagram we imagine several electronic circuits as a block with their own function. So
with the above blockdiagram we can see the function of the Sky Walker electronics. We will explain each block
more detailed now.
Timer
section
Lightsensor
section
Microphone
sensor section
5.2 Explanation blockdiagram
Power supply and Lamp section
Provides all electronic circuits with power. The Lamps are an ON/OFF indicator
Light sensor section
Detects a difference in light intensity
Sound sensor section
Detects sounds
Timer section
An RC network, regulates the walking time
Filter section
Filters the disturbing power supply signals from the motor
Motor section
Switches the Motor ON and OFF
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5.3 Function description of electronic parts:
Above you can see the complete circuit diagram of the Sky Walker. As you can see it is
much more complex than the blockdiagram we discussed on the previous page.
Microphone section
The microphone section consists of an electronic condensor
microphone ECM which detects the soundwaves. The electronic
signal goes through a volume regulator VR1. The capacitor C4
has 2 functions. First it blocks the DC voltage from the power
supply. Second and together with resistor R8 it is a lter so the
sound of a handclap can be detected better. A condensor microphone can only work with a power supply. This power is supplied
by R1.
Power & lamps section
This is the most simple, but also the most important section. In
the blockdiagram you can see that the power section is connected with all other sections. The reason is simple, all electronic
circuits need power to work. The power of the Sky Walker comes
from a 1.5 Volt battery and can be switched on and off with SW.
The 1.5 Voltage is too low to use LEDs, so instead we have used
2 small light bulbs. So the only function of the lamps is to see if
the Sky Walker is switched ON or OFF. So, here the lamps are
used as an indicator light.
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Lightsensor section
Signal
Power voltage
The phototransistor can see the difference between light and dark. When it is light,
there is a small current ow through the PHTR and the Collector to Emitter is almost
fully open. When it is dark, there is a very small current ow, and C/E is almost closed.
The current (and the sensitivity of this circuit) can be adjusted with VR2. The elco C1
takes care that it will not react on very little and short light changes. Because the
current ow difference between light and dark in the phototransistor is so small, we
have to amplify this signal in two transistor stages, TR1 and TR2. The capacitor C3
and Resistor R7 both have the same function as C4 and R1 in the microphone sensor
circuit.
Timer section
The signals from the sound and light sensor will activate
the timer circuit. If there is no sound and not a big light
difference detected, the input signal on the base of TR3
is low. This means that the signal on the collector of TR4
is high. Because of a positive feedback from C5, the TR3
base will stay low for a while and the collector output of
Input
TR4 stays high. The duration of this positive feedback is
called RC time. The RC time can be calculated R9xC5 =
time; so 2200000 x 0,0000033 = 7.26 seconds
Motor section
In the explanation of the timer section we just calculated that
there will be a low signal for about 7 seconds. This low signal
will activate TR5. This is an amplier because the current
of the timer section is too small to drive the transistor TR6
directly. TR6 will function like a switch and the motor will start
to rotate for these 7 seconds.
Filter section
This important section takes care that no disturbing signals
from the motor will enter the other sensitive electronic circuits.
Often there are disturbing signals with RC networks and small
capacitors. We can lter the power supply lines from disturbing signals.
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6. MECHANICS
IMPORTANT: First read all the instructions about the mechanics !
Follow the step-by-step instructions for the mechanical assembly as shown in this
manual. Read and work very accurately. This is the best way to avoid assembly
failures. When you follow these instructions and study the drawings and comments
carefully, you have a big chance the robot will work directly and without any problems.
Also a great help is the picture on the package. You can see very clearly how the robot
should look like. Best is that you only take out the parts from the packages and frames
when you need them! Sometimes parts or bags are numbered. All parts t perfectly so
you do not need to use force to assemble this robot! Do not hurry and once more, best
is to read all instructions rst before you actually start to assemble.
Possible extra tools which can be handy:
Hobby knife
How to cut the plastic parts
Assembly of a gear to an ax
When you install a gear or a pinion to an ax or shaft, like
the pinion to the motor shaft, you must be very careful. Be
100% sure you put the right gear onto the right ax. Best way
is always to press the gear on the shaft with your hands.
When you cannot manage it this way, use a very small plastic hammer. When you use a hammer, you can protect the
gear or the shaft by putting a piece of wood or carton
between the hammer and the part you will hit on.
Tweezer
Small plastic hammer
To take out the plastic parts from a
frame, use a sharp hobby knife or a
cutting plier. Cut carefully and take
of the bosses with a knife to make it
smooth.
Do not cut parts from a frame
when you do not need them
directly!
-20-
Self-tapping screws (Parker)
Lock nut fixation
A self-tapping screw looks similar to a wood screw.
When you screw it in a hole, it can cut the threads at
the same time. Never try to screw it down all the way
for a first time, because it may easily become stuck or
you will damage its head.
Tapping screws always have a sharp point,
sometimes with a small carve. They look
almost the same as screws which we use for
wood, only the thread is more fine. The best
way is to screw it in and out a bit.
1. Screw in
2. Screw out a bit
3. Screw in further and continue
step 1 and 2
Do not screw a tapping screw in and out too often because the screw hole may become
enlarged and the screw will loose all grip and proper function.
Screws and nuts
In a moving environment, screws and nuts must be tightened properly. A lock nut is a
special nut with nylon inside which will lock itself automatically.
Another easy way to lock a screw is to use ordinary fingernail polish. A big advantage
of nail polish is that you always can loosen it quite easily again. A professional way to
lock a screw is to use for example locktite a sort of glue especially made for screws,
but it is very difficult to unlock such a screw afterwards.
The size of a screw is expressed by thickness and length. A screw with the marking
M2 x 10 means 2mm thick. The length of the thread is 10mm. A M2 nut means it is
used for a M2 screw so the nut always corresponds with the screw thickness.
Thickness
Length
Lock nut
Wrench
This kit includes a small wrench. Please
use this wrench to t the M2 and M3 nuts
in a proper way. You can use it instead of
a plier.
To lock the lock nut in a proper way, use a
plier or the wrench which is supplied in this kit.
See drawing on the left!
-21-
Nut
6.1 List of mechanical parts:
Please check all parts before you start assembly!
Screw long Screw short Nut M3
M3x30 4 Pcs.
M3x20 2 Pc.
Rubber Washer
2 Pcs. M3
L Bracket
4 Pcs.
Pinion gear
1 Pc.
Assembled PCB
M3x12 6 Pcs.
Joint strip
Crank
2 Pcs.
2 Pcs.
Crown gear Gear shaft
Flat spur gear big Flat spur gear small
1 Pc. 1 Pc.
18 Pcs.
Washer M3
4 Pcs.
Pipe spacer
ø3x12 2 Pcs.
ø3x5 10 Pcs.
Spring washer
8 Pcs. M3
Screw M2
14 Pcs. M2x5
1 Pc. 1 Pc. 1 Pc. 1 Pc.
Metal Washer M3
2 Pcs.
Nut M2
6 Pcs.
Spring washer M2
4 Pcs.
SwitchWrench M2/M3Motor holderMotor
1 Pc. 1 Pc. 1 Pc.
Leg set
1 Pc.
Sidepanel right
1 Pc. 1 Pc.
Cover
1 Pc.
Sidepanel left
Chassis panel
Rubber tube
1 Pc.
1 Pc.
Self-tapping screw
M2.3 x 5 1 Pc.
M2.6 x 6 3 Pcs.
-22-
6.2 Instructions mechanical assembly
For the assembly of the motor you need;
First always collect all the parts, as mentioned
in the "parts you need list", before you start
the assembly!
Install the motorbase and switch
On this side there
are 2 bosses !
Install the motor to the motorbase and x it with
the 2.3x5mm selftapping screw. See drawing.
Push the motor wires on the motor terminals.
Use a plier to insert and remove the wires.
1 pc. Motor
1 pc. Pinion gear (for motor)
1 pc. Switch
1 pc. Chassis panel
1 pcs. Motorbase
1 pc. Self-Tapping screw M2.3x5
6 pcs. Screw M2x5
4 pcs. Nut M2
4 pcs. Spring washer M2
Assembly motor pinion
Hit slightly with the hammer,
do not hit the terminals!
OR BETTER:
Push the gear on the shaft
with your hands.
The shaft must
be fully pushed
into the gear !
Orange (+)
Flat part is faced down
Be sure the motor is fixed properly
with the 2.3 x 5 mm tapping screw.
Blue (-)
Insert the wires into the holes of the chassis panel.
See drawing.
-23-
Assembly of the left and right sidepanel:
To assemble the sidepanels you need;
Assemble in numerical order:
Sidepanel
Left
Sidepanel
Right
Important!
Axes on this side!
NOTICE! The L Brackets should be assembled
very straight to the side panels.
Install gear shaft and crank:
1 Pc. Sidepanel Left
For this assembly you need;
1 Pc. Pipe spacer Ø 3x5
1 Pc. Gear shaft
1 Pc. Crank
2 Pcs. Sidepanel L & R
4 Pcs. L Bracket
4 Pcs. M2x5 screws
Ø 3x5
Cranck
Hit slightly with the hammer, do not hit the
terminals! OR BETTER, Push the gear on
the shaft with your hands.
-24-
2 Pcs. Front leg
2 Pcs. Back leg
2 Pcs. Joint strip
8 Pcs. M3 nut
4 Pcs. Washer M3
2 Pcs. M3x30 screw
2 Pcs. M3x12 screw
2 Pcs. M3x20 screw
2 Pcs. Ø 3x12 pipe spacer
6 Pcs. Ø 3x5 pipe spacer
2 Pcs. Metal ring
2 Pcs. Rubber ring
Assembly of the sidepanels:
For the assembly of the sidepanels you need;
Push the right sidepanel, pipe spacer and crank on the gearshaft.
Hit slightly with the hammer, do not hit the terminals! OR BETTER,
Push the gear on the shaft with your hands. See drawing.
WARNING!
Make sure that the cranks are 100% parallel.
1 Pc.
Sidepanel left
1 Pc.
Sidepanel
1 Pc. Pipe spacer Ø 3x5
1 Pc. Crank
right
Ø 3x5
Cranck
Leg assembly:
Assemble the legs as shown on the drawing
Back leg
M3 nut
Joint
strip
Ø 3x5
M3 washer
M3 nut
M3 nut
Ø 3x5
M3x20
Assemble 2 pcs!
It is important that the joint
strip can move freely over
Big feet
the pipe spacer!
M3 nut
M3 washer
Rubber ring
Metal ring
-25-
Ø 3x12
For the assembly you need;
Front leg
Ø 3x5
M3x30
Small feet
M3x12
Assemble 2 pcs!
Install the back legs to the sidepanels:
M3 nut
To install the back legs you need;
M3 spring washer
Notice the correct
position in the crank!
!
Top
!
Below
1 Pc. Assembled side panels
2 Pcs. Assembled back legs
2 Pcs. Spring washer M3
2 Pcs. M3 nut
Right back
Left back
Install front legs to the side panels:
To install the front legs you need;
WARNING!
Make sure that the rear
legs are installed into the
cranks 180º apart (see
drawing).
Top
Below
1 Pc. Assembled side panels
2 Pcs. Assembled front legs
2 Pcs. Spring washer M3
2 Pcs. M3 nut
M3 springwasher
M3 nut
Install the front legs as shown on the drawing.
-26-
Install the joint strip of the front legs:
Right back
To install the joint strip you need;
M3x12
Ø 3x5
1 Pc. Assembled side panels
2 Pcs. M3x12 screw
2 Pcs. Spring washer M3
2 Pcs. M3 nut
2 Pcs. Ø 3x5 pipe spacer
Ø 3x5
Assemble the joint strip as shown on the drawing.
Left back
Final assembly rear legs:
For the nal assembly you need;
1 pc. Assembled side panels
2 Pcs. M3 x 30 screw
2 Pcs. M3 nut
2 Pcs. Spring washer M3
Side panels
Nut M3
Leg
Spring washer M3
Screw M3x30
M3x12
-27-
Installing the gears:
To install the gears you need;
Crown gear
1 Pc. Assembled side panels
1 Pc. Chassis panel
1 Pc. Crown gear with pinion
1 Pc. Flat spur gear with pinion BIG
1 Pc. Flat spur gear with pinion small
4 pcs. M2x5 screw
Flat spur gear BIG
Flat spur gear small
Side panel left
Install chassis panel to the side panels
Install the gears in numerical
order 1-2-3.
To make this assembly step more
clear we have omitted the right side
panel from this drawing.
-28-
Assemble the chassis panel to
the side panels as shown on the
drawing. Join the panels with the
4 pcs. M2x5 screws.
When the legs are not moving correctly, please use the
table below to nd the problem.
7. TEST OF THE SKY WALKER
The motor shaft rotates but
the gears are not rotating.
The gears are possibly not
correctly assembled.
Install all gears again.
Legs do not move.
Legs installed in the wrong way.
Install the legs again.
Loosen the selftapping screw
from the motorbase and move
the motor to the right.
The rear panel screw M3x28
will come off the opening guide
in the rear leg.
The L Brackets are not
installed correctly.
See chapter 6 page 24
Be sure that the L Brackets are
correctly assembled in a 90
degree angle!
7.1 Mechanical test:
This is a very simple test to see if
the legs are moving.
Connect the battery directly to the
blue and orange motor wire, as
shown on the drawing.
In this step the POLARITY is
not really important!
PROBLEM CHECK SOLUTION
NOTICE!
GOOD ALIGNMENT of the GEARS
and a smooth rotation of the gears is
very important for a good function!
You can put some plastic grease on
the gears to make the rotation more
smooth!
-29-
7.2 Final assembly:
Wire color Terminal marking
Blue
(Motor) M-
Orange
(Motor) M+
Black
(Switch) SW
Black
(Switch) SW
Check the battery polarity, see
drawing.
Adjust the variable resistors to the middle position.
For the nal assembly you need;
1 pc. Assembled Chassis
1 pc. Assembled PCB
3 pcs. M2,6x6 selftapping screw
Insert the four wires to the hole in the
PCB and install the PCB with the
3 selftapping screws to the chassis.
Connect the wires according the table below
USE A PLIER TO CONNECT THE WIRES!
Insert battery:
Adjustment variable resistors;
-30-
NOTICE!
When the Sky Walker walks backwards instead
of forwards, change the motor wires.
The POLARITY on the motor decides in which
direction the motor is rotating and the
Sky Walker is walking
FINAL TEST AND ADJUSTMENT OF THE SKY WALKER;
To install the cover you need;
*) Switch on the robot, the lights start glowing.
1) Clap in your hands.
2) The Sky Walker should walk forwards for a few
seconds and then stop automatically.
3) Shade the light sensor with your hand
4) The Sky Walker should walk forwards for a few
seconds and then stop automatically.
You can adjust the sound sensor sensitivity
with VR1.
You can adjust the light sensor sensitivity
with VR2.
If the Sky Walker does not function correctly because of a gear problem, you should check the
mechanical test again on page 29. As a last option, disassemble the robot and build it again.
Study each step and all drawings very accurately. This is the best way to nd the failure. When
there is an electronic problem, do the electronic test on page 11 again and use the trouble shoot
table on page 12.
Install the cover:
Finally, we will install the Sky Walker cover:
Before you x the cover, be sure that the two
lamps are put into the front holes of the cover
correctly.
Install the cover to the chassis with the
2 pcs. M3 screws and nuts.
1 Pc. Cover
2 Pcs. M3x12 Screw
2 Pcs. M3 nut
1 Pcs. Robot Chassis
First insert the two
lamps carefully into
the holes in the
Sky Walker cover!
-31-
8. INFORMATION ABOUT GEARS
The mechanics of the SKY WALKER ROBOT consists of two parts. The first part is
the gear box, which takes care that the power from the motor shaft is converted to the
crank. The second part is to convert the rotation of the crank into a movement of the
feet.
The transmission of power
Gears, transmission belts, shaft, crank, chains: They all can transmit power. In the
Sky Walker, four gears transfer the motor power into the crank. Such a transmission
is called a gear box. The Sky Walker motor rotates very fast with only a little torque.
However, for the crank we need low rotation speed and high torque. The power is
transmitted by the teeth of the gears. At the same time, three conversions take place:
a. Change in rotating direction
b. Change in rotating speed
c. Change in torque
a. Change in rotating direction
When two gears are connected, there will be a change in rotation
direction. One gear will rotate clockwise, the other gear will rotate
counterclockwise.
b. Change in rotating speed
The change in rotating speed depends on the relation of the teeth in the gear. As an
example we describe a gear with 10 teeth and a gear with 40 teeth.
When the first gear (10 teeth) makes a full rotation, the second
gear 40 (teeth) only makes a quarter of a rotation. So before the
second gear makes a full rotation, the first gear already makes four
rotations. You may understand that this effect also changes the
rotating speed.
Right rotation
10
Teeth
Left rotation
40
Teeth
c. Change in torque
The torque can be seen as a lever construction with a
fulcrum. Imagine a person who lifts a stone with a lever.
The person who lifts the lever
must use more force when the
distance A gets shorter or when
A
Lever
Fulcrum
the distance B gets longer.
B
-32-
Motor rotation
Gear ratio =
Number of
last gear rotation
Fulcrum
B
A
Appendix A
AC AND DC POWER SOURCES
1.5 Volt battery
Type AA or AAA
On page 15 we already gave some information about the battery power source, but...
there is more to explain about this item. The voltage of a battery is a quite low DC
voltage. It is not dangerous when you touch it. The mains power voltage on a wall
socket in our homes however is a VERY DANGEROUS AC voltage of 120 or 230 Volts
(depending on the country you live in). You already know and may understand that
you must never make contact with this dangerous household voltage (mains
power).
We introduced 2 new terms, AC and DC, which are abbreviations of Alternating Current
and Direct Current (also called continuous current).
AC MAINS power is often called household power or household electricity. The direction
(polarity) of the AC voltage changes periodically. Mostly, the shape of such voltage is a
sinus waveform.
Picture of a sine wave voltage:
The dotted line shows a DC voltage
The DC power is a constant voltage with a constant polarity. DC voltage is supplied by
all kind of batteries like radio, MP3 player and even big car batteries. They all have a
DC voltage.
SI-Prex
In this manual and in electronics in general, we use the SI-prex a lot. It is a way to
present the unit of measure of a quantity or value with a lot of zeros.
For example weight; Kilo (K) means 1000 so 1 Kg means 1000 grams.
Important prex are;
M = Mega = 1000 000
K = Kilo = 1000
m = milli = 0.001
µ = micro = 0.000 001
N = Nano = 0.000 000 001
P = Pico = 0.000 000 000 001
-33-
PERSONALIZE THE SKY WALKER
If you like, you can personalize the
Sky Walker. You can cut symbols and
characters from paper (or colored tape)
and x it with transparent tape or glues,
This way you can simply make a
personalized Sky Walker. You can also
use a special paint which is suitable
for plastics!
You will have a lot of fun making your
own unique robot!
The personalized Sky Walker on this picture was made
by Mara from Nijmegen the Netherlands.
Visit our Website:
www.arexx.com
Besuchen Sie unsere Website:
www.arexx.com
Visiter notre Website:
www.arexx.com
Bezoek onze Website:
www.arexx.com
Manufactured by:
JAMA Co., Ltd.
Taichung, TAIWAN
IMPORTANT:
1. AREXX Engineering and JAMA are registered trademarks.
2. All rights reserved. Reprinting any of this instruction manual without our written permission is forbidden.
3. The specications, form and contents of this product are subject to change without prior notice.
4. We do not accept any responsibility for disadvantage or damage caused by improper use or assembly.
European Importer:
AREXX Engineering
ZWOLLE, THE NETHERLANDS
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