AL5B Arm Assembly Instructions Rev. 2.1

dampening panels as shown. Use four 2-56 x 1/4 inch machine screws. Be sure to add the discs to the correct side and ensure the protective covering has been removed from the Lexan parts.

85

Press down when screwing to ensure there is no gap between the Lexan

86

and the aluminum, as the screw will be threading the Lexan.

</td>

Figure 2.</td>

</tr>

<tr>

</tr>

<tr>

<td align="left" valign="top" >Step 3.

97

Insert the 4-40 x .5" Phillips head screw through the hole in

98

the multi-purpose bracket as shown. Secure with a steel nut.

<tbody>

<tr>

</tr>

<tr>

</tr>

</tbody>

</table>

</td>

Figure 3.</td>

</tr>

<tr>

</tr>

<tr>

<td align="left" valign="top" >Step 4.

121

Slide the large "C" bracket end of the bracket assembly over

122

the screw as shown, and secure with a nylon insert lock nut. The amount

123

of friction can be adjusted by tightening or loosening the lock nut.

124

Start with the nut loose, and if the arm seems to wobble a bit, you can

125

tighten this joint to correct the wobble. Caution

126

- don't over-tighten this! If the arm is operated with the mechanical

127

dampeners too tight, the servo WILL heat up and CAN be damaged!

<tbody>

<tr>

</tr>

<tr>

</tr>

</tbody>

</table>

</td>

Figure 4.</td>

</tr>

<tr>

</td>

</tr>

<tr>

<td valign="top" >Step

151

5.

152

Figure 5 show a typical mega-size servo with its default

153

servo horn at center position. You will need to replace this black

154

servo horn with the round nylon servo horn.

155

Remove the servo horn screw,

156

being careful to not rotate the servo horn itself. Pull the servo horn

157

off, then press the nylon servo horn in place, as close to the

158

alignment shown as possible. Replace the servo horn screw.

159

Make sure your servo looks like

160

the image. The arrows in the image point to the screw holes you will

use.

</td>

Figure 5.</td>

</tr>

<tr>

</tr>

<tr>

<td align="left" valign="top" >Step 6.

171

Attach the HS-755HB servo to the base bracket as shown using

172

the 3mm hardware; follow the diagram below. Use two #2 x 1/4" tapping

173

screws to secure the bracket to the servo horn. Route the shoulder

174

servo wires underneath the servo. Plug the servo into channel 1 on the

175

SSC-32. Carefully rotate the base to an extreme, and use a wire tie to

176

take up the slack in the servo cable.

<tbody>

<tr>

</tr>

<tr>

</tr>

<tr>

</tr>

<tr>

</td>

</tr>

</tbody>

</table>

</td>

Figure 6.</td>

</tr>

<tr>

</td>

</tr>

<tr>

<td align="left" valign="top" >Step 7.

208

Attach two of the tubing connector hubs to the short side of

209

the "L" brackets, using four 2-56 x .250 screws and 2-56 nuts.

<tbody>

<tr>

<td >4 x (two

each)

</td>

<td >4 x (two

each)

</td>

</tr>

<tr>

</tr>

</tbody>

</table>

</td>

Figure 7.</td>

</tr>

<tr>

</tr>

<tr>

<td align="left" valign="top" >Step 8.

236

Connect the hubs to the 2.25" tube using two 4-40 x .250"

237

screws. Tighten these down tightly.

<tbody>

<tr>

</tr>

<tr>

</tr>

</tbody>

</table>

</td>

Figure 8.</td>

</tr>

<tr>

</tr>

<tr>

<td align="left" valign="top" >Step 9.

260

Attach the tubing structure to two Multi-Purpose brackets as

261

shown, using four 2-56 x .250 screws and 2-56 nuts.

<tbody>

<tr>

<td >4 x (two

each)

</td>

<td >4 x (two

each)

</td>

</tr>

<tr>

</tr>

</tbody>

</table>

</td>

Figure 9.</td>

</tr>

<tr>

</td>

</tr>

<tr>

<td align="left" valign="top" >Step 10.

289

Insert the 4-40 x .5" Phillips head screw through the hole in the

290

multi-purpose bracket as shown. Secure with a steel nut.

<tbody>

<tr>

</tr>

<tr>

</tr>

</tbody>

</table>

</td>

Figure 10.</td>

</tr>

<tr>

</tr>

<tr>

<td align="left" valign="top" >Step 11.

313

Slide the screw on the forearm assembly through the dampening

314

discs as shown, and secure with a nylon insert lock nut. The amount of

315

friction can be adjusted by tightening or loosening the lock nut. Start

316

with the nut loose, and if the arm seems to wobble a bit, you can

317

tighten this joint to correct the wobble. Caution

318

- don't over-tighten this! If the arm is operated with the mechanical

319

dampeners too tight, the servo WILL heat up and CAN be damaged!

<tbody>

<tr>

</tr>

<tr>

</tr>

</tbody>

</table>

</td>

Figure 11.</td>

</tr>

<tr>

</tr>

<tr>

<td valign="top" >Step

342

12.

343

Figure 12 illustrates a typical standard-size servo with its

344

output horn (the round white part) at center position. Make sure your

345

servo looks like the image. The arrows in the image point to the screw

346

holes you will use.</td>

Figure 12.</td>

</tr>

<tr>

</td>

</tr>

<tr>

<td align="left" valign="top" >Step 13.

356

Attach the HS-645MG elbow servo to the bracket as shown using the 3mm

357

hardware; follow the diagram below. Use two #2 x 1/4" tapping screws to

358

secure the bracket to the servo horn. Route the shoulder servo wires

359

over the servo. Plug the servo into channel 2 on the SSC-32.

<tbody>

<tr>

</tr>

<tr>

</tr>

<tr>

</tr>

<tr>

</td>

</tr>

</tbody>

</table>

</td>

Figure 13.</td>

</tr>

<tr>

</tr>

<tr>

<td align="left" valign="top" >Step 14.

390

Attach the Little Gripper connector to the short "C" bracket

391

using two 2-56 x .250" screws and 2-56 nuts.

<tbody>

<tr>

</tr>

<tr>

</tr>

</tbody>

</table>

</td>

Figure 14.</td>

</tr>

<tr>

</td>

</tr>

<tr>

<td align="left" valign="top" >Step 15.

415

Attach the short "C" bracket to the other Multi-purpose

bracket as shown.

</td>

Figure 15.</td>

</tr>

<tr>

</tr>

<tr>

<td align="left" valign="top" >Step 16.

428

Attach the HS-485HB wrist servo to the bracket as shown using

429

the 3mm hardware; follow the diagram below. Use two #2 x 1/4" tapping

430

screws to secure the bracket to the servo horn. Route the shoulder

431

servo wires over the servo.

<tbody>

<tr>

</tr>

<tr>

</tr>

<tr>

</tr>

<tr>

</td>

</tr>

</tbody>

</table>

</td>

Figure 16.</td>

</tr>

<tr>

</td>

</tr>

<tr>

<td rowspan="2" align="left" valign="top" >Step 17.

463

Attach the Little Grip to the lexan as shown, using three

464

4-40 x .375" button head screws and acorn locking nuts. Only three

465

screws are used (shown in the image) as the body of the gripper servo

466

is in the way for the fourth.

467

Make sure the HS-422 (a HS-322HD

468

may be substituted) servo is aligned to mid-position, and the gripper

469

is halfway open. Now the servo and gripper will be aligned correctly.

470

Remove the servo screw and horn. Slide the servo into the gripper from

471

the bottom. You may need to wiggle it a bit to get it seated properly.

472

Use the servo screw to attach the servo. Tighten this down, but then

473

unscrew it half a turn. Too much friction can bind the servo.

<tbody>

<tr>

</tr>

<tr>

</tr>

</tbody>

</table>

Step 18.

Add a 12" servo extender cable to the gripper servo, and a 6" extender

490

cable to the wrist servo.

</td>

Figure 17.

</td>

</tr>

<tr>

Figure 18.</td>

</tr>

<tr>

</tr>

<tr>

<td align="left" valign="top" >Step 19.

505

Carefully bend the wrist servo back as far as it will go, and

506

use wire ties to secure the servo cables as shown. Make sure to leave

507

slack in the gripper servo cable, don't pull it too tight.</td>

Figure 19.</td>

</tr>

<tr>

</td>

</tr>

<tr>

<td align="left" valign="top" >Step 20.

517

Carefully stretch the arm forward as far as it will go, and

518

use wire ties to secure the servo cables as shown. Make sure to leave

519

slack in the cables, don't pull them too tight. Plug the servos in

520

according to Table 20.

<tbody>

<tr>

<td >

<tbody>

<tr>

<td bordercolor="#808080" align="center" bgcolor="#c0c0c0" width="25%">SSC-32

533

I/O</td>

534

<td bordercolor="#808080" align="center" bgcolor="#c0c0c0" width="75%">Servo</td>

</tr>

<tr>

</tr>

<tr>

<td bordercolor="#C0C0C0" align="center" bgcolor="#ffffff" width="75%">Shoulder</td>

</tr>

<tr>

<td bordercolor="#C0C0C0" align="center" bgcolor="#ffffff" width="75%">Elbow</td>

</tr>

<tr>

<td bordercolor="#C0C0C0" align="center" bgcolor="#ffffff" width="75%">Wrist</td>

</tr>

<tr>

<td bordercolor="#C0C0C0" align="center" bgcolor="#ffffff" width="75%">Gripper</td>

</tr>

<tr>

<td bordercolor="#C0C0C0" align="center" bgcolor="#ffffff" width="75%">Wrist

559

Rotate (Optional)</td>

</tr>

</tbody>

</table>

</div>

</td>

</tr>

<tr>

Table 20.

</td>

</tr>

</tbody>

</table>

</center>

</div>

</td>

Figure 20.</td>

</tr>

<tr>

</tr>

<tr>

<td align="left" valign="top" >Step 21a (SSC-32 / Lynxterm). If

584

you have the SSC-32U, please proceed to step 21b. If you have the

585

SSC-32, as in the Base Assembly Instructions, we'll use LynxTerm to

586

test the

587

servos and confirm that they're all plugged into the proper channels.

588

If not done before, download and install <a href="https://wiki.lynxmotion.com/info/wiki/lynxmotion/view/ses-software/lynxterm/" target="_blank">LynxTerm</a>. Connect the SSC-32 to

589

the serial port and apply power. The green LED should light and stay on

590

until it receives a valid serial command. Run the LynxTerm program. If

591

LynxTerm cannot connect, please consult the <a href="https://community.robotshop.com/forum/t/serial-usb-to-serial-port-troubleshooting/17938" target="_blank">serial

592

and USB-to-serial troubleshooting guide</a>.

593

Step 22.

594

Now test the servos and connections by selecting a channel, and moving

595

the servo carefully using the slider bar. Verify that the servos are

596

plugged into the channels as listed in Table 20. Easy does it; this is

597

real time control, so be careful!

</td>

Figure 21a (Lynxterm).

</td>

</tr>

<tr>

</tr>

<tr>

<td style="vertical-align: top;">Step

609

21b (SSC-32U / Servo Utility).

610

Just like in the base instructions, we will use the SSC-32 Servo

611

Sequencer Utility to test the servos and confirm they are all plugged

612

into their proper servo channels and oriented correctly. If not done so

613

before, download and install the <a href="https://wiki.lynxmotion.com/info/wiki/lynxmotion/view/ses-software/ssc-32-sequencer/" target="_blank">SSC-32 Servo Sequencer Utility</a>. Connect the USB

614

cable and power the board using the on/off switch. Run

615

the program.

616

617

The SSC-32U is shipped with a baud rate of 9600. Ensure the baud rate

618

towards the bottom right of the window is set to 9600 (not 115200). The

619

software should automatically detect which COM port is connected to the

620

SSC-32U, and have installed the <a href="http://www.ftdichip.com/Drivers/VCP.htm" target="_blank">FTDI

621

(USB to serial) drivers</a> automatically.

622

623

Ensure Servos 0 4 are checked off in the software (and therefore accessible). You can now move the sliders to see each servo rotate. Verify that the servos are

624

plugged into the channels as listed in Table 20. Easy does it; this is

625

real time control, so be careful.

626

627

For more information, please consult the <a href="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/ses-software/ssc-32-sequencer/WebHome/SSC32%20Servo%20Sequencer.pdf" target="_blank">SSC-32 Servo Sequencer Utility manual</a>. </td>

628

629

630

Figure 21b (SSC-32 Utility).</td>

</tr>

<tr>

</td>

</td>

</tr>

<tr>

<td align="left" valign="top" >Step 22a (SSC-32 / Lynxterm).

640

Click on the "All = 1500" button in LynxTerm. This will command the

641

servos to hold center position. Your arm should look like Figure 22. If

642

any joint is off by more than 15°, then you may have made an error in

assembly.

If you did not purchase the RIOS software, please proceed to step 27.

</td>

Figure 22.

</td>

</tr>

<tr>

</td>

</tr>

<tr>

<td style="vertical-align: top;">Step 22b (SSC-32U / Servo Utility).

661

Click on the "Calibrate" button in the SSC-32 Servo Sequencer Utility.

662

A knob next to each servo will appear (figure 23b). This knob is used

663

to fine tune the servo's center position. The knob is not intended to

664

be rotated: click the knob you wish to rotate, keeping the mouse button

665

down, and drag up and down to rotate the knob. Do this for each servo

666

until the arm looks like figure 22, and angles are 90 and 180 degrees.

667

If

668

any joint is off by more than 15°, then you may have made an error in

assembly.

Once all servos have been properly positioned, click the icon

673

"Calibrate" once again, and the offset values will be stored on the

SSC-32 / SSC-32U.

If you did not purchase the RIOS software, please proceed to step 27.</td>

678

679

680

Figure 22b (SSC-32 Utility).</td>

</tr>

<tr>

</td>

</td>

</tr>

<tr>

<td align="left" valign="top" >Step 23 (RIOS Users Only).

690

To use the RIOS Arm control software, you need to make one

691

minor modification. Remove the servo horn screw from the elbow servo.

692

Pull the servo horn off the servo, lift the arm two 'clicks' (30°) at

693

the elbow and reattach the servo horn and screw. Note, the Hitec spline

694

has 24 grooves, so each groove is 15°.</td>

Figure 23.</td>

</tr>

<tr>

</tr>

<tr>

<td align="left" valign="top" >Step 24 (RIOS Users Only).

703

At this point the arms is assembled and tested using LynxTerm. Now we

704

need to install RIOS and calibrate the arm to the software. Use the

705

RIOS Help File to calibrate and use the arm.

706

Install RIOS, following the

707

on-screen installation prompts. The serial number is on the back of the

708

CD sleeve.

709

Use the RIOS Help File to

710

calibrate and use the arm, following Steps 1-7. When you get to Step 8

711

in the help file, please use the following instructions instead.

712

Please take the time to do an

713

accurate calibration. The performance of the arm will only be as good

714

as the calibration. If the on screen virtual arm does not match the

715

real arm this is a sign of an inaccurate calibration. After calibration

716

please study the RIOS manual carefully to learn how to store and

717

playback sequences for the arm.

</td>

Figure 24 (RIOS).

</td>

</tr>

<tr>

</tr>

<tr>

<td align="left" valign="top" >Step 25 (RIOS Users Only).

730

To calibrate the arm's Shoulder servo, click the "SSC-32" button.</td>

Figure 25 (RIOS).

</td>

</tr>

<tr>

</td>

</tr>

<tr>

<td align="left" valign="top" >Step 26 (RIOS Users Only).

743

Start the servo configuration with the Shoulder, servo #2. Move the

744

shoulder slider up to move the shoulder forward so that it looks like

745

Figure 27-2. Set the Min Deg angle -90°. Right click on the slider to

746

set this as the Min Position. Now the servo will not go past this

747

value, and the program now knows this value is exactly 90° from

748

centered.

749

Now move the slider down to move

750

the shoulder backward so that it looks like Figure 27-3. Set the Max

751

Deg angle to 90°. Right click on the slider to set this as the Max

752

Position. Now the servo will not go past this value, and the program

753

now knows this value is exactly 90° from centered.

754

The next step is to read and

755

study the RIOS users guide. It is accessible by clicking on the help

756

icon on the main screen or by navigating to the install directory

757

(c:\Program Files\RIOS_SSC-32\) and opening the Help.pdf file. This

758

manual explains in great detail how to use the arm.

</td>

Figure 26-1 (RIOS).

</td>

</tr>

<tr>

</tr>

<tr>

Figure 26-2.

</td>

Figure 26-3.

</td>

</tr>

<tr>

</tr>

<tr>

<td align="left" valign="top" >Step 27.

784

To connect springs for load-balancing, replace the servo

785

attachment hardware in the locations shown, following the diagrams

786

below. Hook the springs together after they're secured.

</td>

Figure 27.</td>

</tr>

<tr>

</td>

</tr>

<tr>

<td align="left" valign="top" >Step 28.

799

The arm assembly is complete.  The arm is robust mechanically,

800

but the servos can be damaged by improper use. An example would be if

801

the arm was told to move to an unobtainable position, like the surface

802

the arm is mounted to, or by crashing the arm into itself, or other

803

objects. The elbow servo is the most vulnerable because it holds the

804

entire weight of the forearm. Load balancing springs should be added to

805

reduce some of this load.

806

807

If you purchased FlowBotics Studio,

808

FlowStone or FlowArm, you can proceed with the instruction guide(s)

809

associated with those programs.

People do

not like holding heavy objects with their arms outstretched in front of

814

them. Servo based robot arms don't like it much either. Remember, the

815

most important rule for servo based robot arms: Park the arm when not

816

in motion! When it's moving or at rest it's usually ok. When it's

817

holding an object it should do so for the minimum amount of time

818

required to do the job. You can always touch the servo case to see if

it's getting hot.

</td>

</td>

</tr>

</tbody>

</table>

</body>

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