AREXX Engineering & JM3 Engineering SKY WALKER SW-007 User manual

-1-
SKY WALKER
©2007 AREXX Engineering
Manual: Model SW-007
Educational Robot System SW-007
SKY WALKERSKY WALKER
©©
2007 AREXX Engineering2007 AREXX Engineering
©© 2007 AREXX Engineering©©
Manual: Model SW-007Manual: Model SW-007
Educational Robot System SW-007Educational Robot System SW-007

-2-
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 specification, shape and size of the product are subject to change without prior notice.
Technical assistance
during the construction
of the robot:
www.arexx.com
Manufacturer:
Jama Co., Ltd.
Tachung TAIWAN
Importer:
AREXX Engineering
ZWOLLE The Netherlands
© 2007 AREXX Engineering
When you have a pre-soldered
Robot (Model SW-007A), please
start with Chapter 6 on page 20.

-3-
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 electro-
nics. 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.
Specifications:
Power voltage : 1.5 Volt
Power source : 1 Penlite battery (not included)
Power consumption (moving) : About 200 mA
Power consumption (at rest) : About 10 mA
Height : 135 mm
Diameter : 105 mm
Warning
uNo return is possible after having opened the bags with components and pieces
u Prior to the assembly read the manual thoroughly.
uBe careful when using tools.
uKeep this kit away from young children during construction and operation.
(They might get hurt by the tools or swallow small components).
uObserve the correct polarity of the battery.
uKeep the battery dry. When the Sky Walker gets wet remove the battery and let the
Sky Walker dry for some time.
uRemove 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.
1. PRODUCT DESCRIPTION SKY WALKER

-4-
Before you start soldering we will give you some advise and instructions: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 thePlease read the complete soldering instructions before you start. Work accurately and follow the
instructions in this manual exactly to avoid problems.instructions in this manual exactly to avoid problems.
2.1 Necessary Tools:2.1 Necessary Tools:
Soldering ironSoldering iron
(15 to 30W)(15 to 30W)
2. SOLDERING
The correct tools already
do half of the job!
Soldering standard with a wet
sponge to clean the tip
Electronic SolderElectronic Solder
0,8- bis 1mm0,8- bis 1mm
Use an electronic soldering iron about 20 toUse an electronic soldering iron about 20 to
30 Watt. A soldering iron with more power30 Watt. A soldering iron with more power
can overheat sensitive components and thecan overheat sensitive components and the
PCB traces. When the power is too low, sol-PCB traces. When the power is too low, sol-
dering is hard and the solder will not flow well.dering is hard and the solder will not flow well.
Normally you also should have a solderingNormally you also should have a soldering
standard to store the iron safely and a spongestandard to store the iron safely and a sponge
to clean the tip of the soldering iron.to clean the tip of the soldering iron.
Use thin electronic rosin core solderUse thin electronic rosin core solder
Use thin electronic rosin core solderUse thin electronic rosin core solder
with a diameter of about 1mm. Do notwith a diameter of about 1mm. Do not
with a diameter of about 1mm. Do notwith a diameter of about 1mm. Do not
use liquid flux or an flux solder paste foruse liquid flux or an flux solder paste for
electronic circuits.electronic circuits.
Use a safe and solid standard Use electronic tools (150 mm).
Electronic screwdriver set
Always use the right type and size screw-Always use the right type and size screw-
driver you need the philips type for M2driver you need the philips type for M2
and M3 screws.and M3 screws.
Desoldering wick
To suck solder from a PCB to remove
components for small repairs.
Electronic cutter &Electronic cutter &
flatnose plierflatnose plier

-5-
Only use lead free ROSIN CORE solder!
Never use any liquid or paste flux!
PASTE
Hold the iron like a pencil and
only heat the component wire
for a few seconds. 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!
2. Add some solder to the
soldering area and
component wire but NOT
TOO MUCH!
3. Remove the solder and let
the hot liquid solder flow.
4. Take away the soldering iron.
DO NOT MOVE the component
or PCB!
5.Cut away the long component
wire just above the soldering spot.
The END RESULT is a nice and
shiny soldering spot which is
attached to the PCB copper and
component wire.
Correct position for professional soldering
Please NOTICE the correct positioning of the components, see the drawings below:
WRONG GOOD
2.2 Soldering techniques:

-6-
Cold PCB Not enough solder
Solder is attached to the
component wire but not to
the PCB copper.
Solder did not flow
Solder is attached to the
PCB Copper but not to the
component wire.
Cold component Bridge of solder
Wire bridge Perfect solder connection
Two separate components are
connected with a wire to each
other making a short cut
Two separate solder spots
are connected to each other
making a short circuit
The soldering surface looks
nice and shiny!
When the trace is broken or the path is damaged,When the trace is broken or the path is damaged,
remove the mask on the copper trace with a screwdriverremove the mask on the copper trace with a screwdriver
or a knife and bend the component wire to the trace.or a knife and bend the component wire to the trace.
Solder a piece of wire from trace to trace or fromSolder a piece of wire from trace to trace or from
component to trace.component to trace.
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.
2.3 Troubleshoot soldering mistakes:

-7-
3. ELECTRONIC COMPONENTS
Variable ResistorVariable Resistor
(Potentiometer)(Potentiometer)
ResistorResistor
Ceramic capacitorCeramic capacitor
Electrolytic
capacitor (ELCO)
Transistor
-
+
B and E are just an
example, position can
change per type
NPN type
PNP type
Component Assembly PCB symbol Circuit symbol
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!

-8-
PHTR
Lamp
Motor
Terminal pin
+
SwitchSwitch
Microphone
ECM
gnd
sig
sig
gnd
MOTOR (terminal) M1, M2
SW (terminal) S1, S2
Component Assembly PCB symbol Circuit symbol
Transparent
or black
Red
Battery (not included)
No symbol
Gnd is connected
with the metal body
Bottom
view
C
E
C
E

-9-
3.1 List of electronic parts:
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.
Ceramic capacitors Marking: Quantity:
… 22 nF C3, C4 (223) 2 pcs.
… 1 nF C6 * Already soldered to the motor ! *1 pcs. (motor C)
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.
ELCO’s Marking: Quantity:
… 3.3 µF C1, C5 (3.3 µF/50V) 2 pcs.
… 100 µF C2 (100 µF/16V) 1 pc.
Wire preparation:Wire preparation:
Wire preparation:Wire preparation:
Pre-solder the copper wire. This step
makes it more easy to solder the wire
later on.
Remove about 5mm of the
plastic wire insulation
Twist the copper wires
when necessary
Put the soldering wickPut the soldering wickPut the soldering wick
on the solder path.on the solder path.on the solder path.
Heat the wick and theHeat the wick and theHeat the wick and the
path with the solderingpath with the solderingpath with the soldering
iron and the copperiron and the copperiron and the copper
braid of the wick willbraid of the wick willbraid of the wick will
suck the solder.suck the solder.suck the solder.
Desoldering
When the wickWhen the wickWhen the wick
removed all theremoved all theremoved all the
solder from thesolder from thesolder from the
path, pull back thepath, pull back thepath, pull back the
wick and thewick and thewick and the
soldering iron simul-soldering iron simul-soldering iron simul-
taneouslytaneouslytaneously
When you made a soldering failure, you can easily remove the mistaken component with wick.
Variable resistors Marking: Quantity:
… 100 KΩ VR1, VR2 (104) 2 pcs.
5mm

-10-
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.
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 finish with the
higher critical parts like Elco's and semi-
conductors 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.
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.
3.2 The soldering job:
The last part is the battery holder and also
here the polarity (red + and black wire -)
is realy important.
The battery holder itself is fixed to the PCB
with double sided tape.
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!
are the lamps and the battery holderare the lamps and the battery holder
Bend the lamps 15mm and 10mm length,
same way as shown on the picture.
** 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.
Tube 20mm
The LAMPS must be soldered with 25mm leg length.The LAMPS must be soldered with 25mm leg length.
Lamp preparation:
1) Cut 25 mm wire and remove insulation
5mm (see page 9 wire preparation).
2) Solder the wire to the lamp.
4) Put the tube over the wires so there will
be no shortcut between the wires.
3) cut 2 pcs of
20 mm tube.
Micophone!
Gnd is connected
with the metal body