Kondo KHR-1 User manual

Hardware Manual

2
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Precautions are classified into Warning and Caution according to their bearing on safety.
Read the Warning, Cuation and Note thoroughly before attempting to assemble the kit.
Descriptions of Warning, Caution and Note
Danger: Applied when there s a danger of the user death or severe injury or when there is a severe
damage of property if the approved procedure is not observed.
Warning:
Applied when there is a danger of the user death or being injured or when there is a
damage of both the user being ijured and the equipment being damaged if the approved procedure is
not observed.
Caution: Applied when there is user being injury or there is equipment being damaged.
Following figure calls attention as each description.
Prohibit: Applied to prohibit action
Compulsory: Applied to compulsory action
Danger
Assemble the kit in enough space and in healty condition.
When there is a danger of death or severe injury by accident.
Unplug NiCd battery in the abnormal case.
The battery is broken, Any liquid is leaked. Flame, smoke, smell or heat up abnormally.
It may occur fire or shock.
Please call or send e-mail to our customer service.
Never break battery charger and cables.
Never scratch, remodeling, or melt the cable. Never use under stressed condition.
It may occur fire or shock.
Repair of cables can be supported by custoer service.
Warning
This product is an assemble kit. Almost responsibility of use is belonging to user.Please use the kit
recognizing this point.
K e e p a w a y f r o m s m a l l c h i l d r e n
Alminum frames has sharp edge.
Safety Information
Danger
Warning
Caution
Prohibited
Prohibited
Prohibited

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Caution
Remove battery charger from plug not in use.
To avoid short circuit.
Keep plug clean.
Never disassemble remodeling servo motors and boards.
Probihit disassemble and remodeling besides of instructions in this manual.
Wrong remodeling and disassemble may occur fire or shock.
Call customer service for repair.
Never use in wet environment
The kit consists of precision instruments.It may be in trouble.
It may occur fire, short circuit or shock.
Call customer service if the kit is moistened with water and so on.
The kit is designed for domestic use in Japan.
Depending on country or region, it requires procedure to use obeying to law.
Out of service for abroad.
Handle connector of battery charger and cables with care.
If the line is pulled, the breaking of a wire and short circuit may occur fire or shock.
Never use the robot unstable place.
The robot may fall down on unbalance. User may be injured by hit the robot.
Pay attention to robot performance and safety.
Safety of the robot performance is not guaranteed because of assemble kit. Different
perfromance may occur by misoperation. It may occur user being ijured on finger or being
broken bone.
Pay attention to short circuit of parts.
RCB-1 are made short circuit easily because of no protection. Mis-plug and short circuit
may fire NiCd battery or cables.
Ni-Cd
NiCd battery can be recycle. Please confirm waste of NiCd battery to
your community.Thank you for your cooperation
Prohibited
Prohibited
Prohibited
Prohibited

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Index
Safety information 2-3
Index 4-5
Introduction 6
About manual 7
About Manual
How to handle NiCd battery? 8-9
Fittings 10
Parts List 11
Parts List (figure) 12-13
Install bracket 14-16
Remove screws from KRS-784ICS
Assemble servo bracket B
Assemble servo bracket C
Left thigh bracket
Right thigh bracket
Assemble servo bracket A
Install servo motor to body frame B
Assemble body 17
Assemble body frame B
Assemble body frame F
Assemble Arms and Legs 18
Assemble cross servo arms 19
Get servo axis position 20-21
How to attach servo hone to axis?
How to find neutral position?
Assemble Arms 22

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Assemble leg and foot parts 23
Assemble soles
Attach cross arm to left and right foot
Assemlbe Knee and Foot 24
Attach cross arm to thigh 25
Assemble leg 26
Fix boards on the robot 27
Attach PCB base
Attach boards on the PCB base
Prepare to finish 28-29
Attach shoulder servo arms
Attach servo motor for head
Confirm assembled parts
Finish 30
Setting of RCB-1(ID) 31
Lines for servo motor 32
Connection of RCB-1
Ser v o cable arrangement
Confirmation 33
Trim function 34
What is trim function?
Operation of trim
Problem of trim
Organize cables (1)(2) 35-36
Assemble case 37
Home position setting 38
F A Q 39
Index

6
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Introduction
Thank you for buying our product.
This is reasonable humanoid robot kit for bipedal locomotion.
Please read carefully to make robot for safety.
We recommend to copy this manual harddisks on your PC or to print out to refer,
if you need.
This product is made to enjoy humanoid robot for various age.
However, some of parts are hard to assemble for children because this is not a toy.
Please help them to assemble or understanding robot and robot performance.
This product is assemble kit. It is no guarantee of performance of robot. Depending on
accuracy of assemble, it is hardly possible to answer to question of robot performance.
Knowledge to use PC and Windows is a precondition to read this manual. It has a software to
set up and to make performance on PC with RS232C port. The software requres Windows 2000
or latest version. (It is impossible to answer about question of your PC and Windows.)
1
2
3
Please prepare PC and tools to assemble a robot which are shown in following list.
PC
OS: MicroSoft Windows2000 or XP
RS-232C Port( )
CD-ROM Drive (for installation software and manual)
Printer (If user want to print out these manuals.)
Tools
Plus driver: This product has 1.7mm, 2mm and 2.6mm screws.
Nippers or Cutter: To remove unnecessesary projection.
Tweezers: It is useful to pick up a small screw.
Before use
Tools
USB/RS232C adapter can be used if your PC doesn't have RS-232C port. Depending on combination of PC, OS and USB, there is a case
not to work software on the PC. Please refer to software manual for details. (Information to attach USB/RS232C adapter to your PC is out of our
support service.)

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About Manual
This product has three manuals.
1.Kit guidance
Paper manual (1 sheet) about description of kit and introduction of manual in PDF file.
2. Hardware manual
This manual. It is in PDF.
This is description to assemble robot hardware.
3. Software manual
Software manual is PDF in CD-ROM.
This describes software to set up and to make performance of robot.
Abstract
This manual describes procedure to assemble robot hardware.
Romove servo case screws
Attach bracket to servo motor
Attach servo hone to servo
motor
Assemble body
Attach arms to body
Attach legs to body
Attach boards to body
Setting up
Organizing cables
Attach board cover to body
Assemble arms and legs parts
1
2
3
4
5
7
6
8
9
10
11
This product can be made by screwed
up each parts. Howerver, procedure 5-9
uses boards to find out servo neutral
position. Therefore, NiCd battery is
required to work board. Please charge
battery before assemble.
Each screw is tightened temporary. All
screws are tightened up at the last.
If you tighten up screw at first, the
position of rest screw is not in the right
place.

8
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How to handle NiCd battery?
This product uses NiCd battery for robot power source.
NiCd battery is rechargeable. Please read carefully this manual to use it
safety.
R e c h a r g e
Cable for NiCd battery
Battery Charger
5N-600 NiCd battery
Battery charger is for AC100V.
It is to link NiCd battery to the battery charger.
Connect NiCd battery to the battery
charger
1
2Connect NiCd battery to cable
Comfirm connection.
Warning
Both pins of terminal of connector supplies
electricity. Never ground orshort circuit.
Handle the ends appropriately.
3Insert the battery charger to AC100V
Power indicator LED turns on and start to charge.
Depending on remainder, empty NiCd battery
takes 12 hours to be full charge.
Pay attention to NiCd battery during charge. Stop
charging battery if you found abnormal tempreture,
sound or smell.
Attention:
Pay attention to the anode. You can know the anode by
the color of cable. Same color cable must be attached
to the same color of the another cable.
Danger

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You must operate following tasks if it may occur.
Profhibit
Do not following action because of danger.
Remove connector from cables or boards, replace or remodeling
of cables.Do not make a short circuit of NiCd battery.
Causes severe eye injury or injury by short circuit of NiCd battery. Short circuit breaks battery or
flames or leaks. Handle the ends such as pins of connector appropriately.
Keep away from other parts during carrying or in strage.
It may fire or leak from the battery if you keep or bring the battery with connector, cables, and other
conductors. For example, coins, key of house or car fired with the battery. Because of short circuit.
A liquid leak has been found. You must wash your hands
if the liquid stuck to your skin. In the case of eye, wash
your eye carefully. After wash, you must consult a doctor.
The liquid is a toxic substance. It is not only human body but also house and furnitures.
In the case of eye injured, the person may lose his/her eyesight in the accident.
You must remove the battery from board or the battery
charger if you leave from the battery or not in use.
Charactoristics
NiCd has less electrical resistance comparing with other batteries. Therefore, NiCd battey can supply high electric
current. When NiCd battery is repeatedly recharged without fully discharging, it progressively loses its ability to run at
full capacity. To avoid the memory effect, we recommend fully discharging a battery before recharging it.
NiCd battery Safety Information
NiCd battery is a toxic waste. According to the article
of your local region, recycle or waste the battery. If you
dump garbate unlawfully, it may occur fire or severe
accident or environmental pollution.
Do not leave it alone. It can't be handled appropriately for fire or flame.

10
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Fittings
KRS-784ICS
RCB-1
KRS-784ICS is the digital FET servo motor. It has been developed to drive joint of robot.
It is the basic robot servo which is inherited know-how of the servo motors for a radio control car and KRS-2346 servo
motor.
Characteristic change and position capture
It can set parameters from outside using ICS.
The motor can be fixed from both side of axises.
Specifications
Size 41x35x21(mm) excluded projections
Weight 45g
Torque 8.7kg/cm (using 5N600 power cell)
Speed 0.17sec/60degree (using 5N600 power cell)
Reasonable Voltage 6V
RCB-1 has been developed for this robot kit as the robot control board. A board can control 12 servo
motors. It can control using all functions of our robot servo motors as KRS-784ICS (included this robot kit)
and all red versions.
Specifications
Size: 45x35(mm)
Weight: 12g (1 board)
Possible number of servo motors: 12 (2 boards can be linked to control 24 servo motors.)
Reasonable Voltage: DC6V (Booster circuit keeps voltage if NiCd battery would stop discharging by low voltage.)
Scenario memory of 4 bank: You can replay 1 scenario as 200 motion replay from combination of 40 kinds of
motion in maximum 100 poses.
Fully supported Red Version functions: Our robot servo motor "Red Version" can be fully controled such as
characteristic change, position capture and power reduction.
Teaching function: You can make performance by teaching function using Red Version.
You must use software on PC to use all functions.

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PartsList
Parts/Item Number bag amount
Servo motor KRS-784ICS -17
Battery Charger -1
NiCd battery 5N600AE -1
CD-ROM CD-ROM (Software and manuals) -1
Servo hone for KRS-784 -17
Free hone for KRS-784 -17
Washer M3 -34
RCB-1 main board -2
Link cable RED (attached to both boards) -1
RCB-001 PCB base -1
Screw for RCB-1 Nickel 2-4 pan screw PartsBag G 8
Screw for PCB base 2-5 chrome pan screw PartsBag H 5
Screw for RCB-002 (Board case) 2.6-6 BH Nickel tapping screw PartsBag H 4
RCB-002 Board case -1
HR-001 Top cover -1
HR-002 M3-6 thumb screw -1
HR-003 body frame F -1
HR-004 body frame B -1
HR-005 shoulder frame -2
HR-006 servo bracket A -2
HR-007 body frame L -1
HR-008 hand R -1
HR-009 hand L -1
HR-010 servo bracket B -6
HR-011 servo arm -14
HR-012 foot R -1
HR-013 foot L -1
HR-014 Servo bracket C -2
HR-015 foot sole -2
Screw for hone 2.6-6BH Nickel tapping screw PartsBag A 35
Screw for body 2-4 Nickel pan screw PartsBag B 130
Nyron clip AB-3N PartsBag C 14
Screw for Nyron crip 2-6 BH black tapping screw PartsBag C 14
Washer for Nyron crip M2 Nickel PartsBag C 14
Expanding cable(200mm) PartsBag D 2
Expanding cable(100mm) PartsBag D 6
Link Cable (gray) PartsBag D 1
Battery link cable PartsBag E 1
Extend cable for AC adaptor PartsBag E 1
Adaptor for battery charger PartsBag E 1
Interface cable ICS-PC Interface II PartsBag F 1
Nyron band SKB-80M -5
KHR-1 sticker -1
Product parts list
Please refer part name to figures of parts in next pages.

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HR-003 body frame F
HR-004 body frame B
HR-005 shoulder frame
HR-006 servo bracket A
HR-010 servo bracket B
HR-011 servo arm
HR-012 foot R
HR-013 foot L
RCB-1 main boards
Servo motor
KRS-784ICS
2.6-6 BH Nickel tapping screw
M3 washer
2-4 Nickel pan screw
2-6 BH Black tapping screw
M2 washer
ICS-PC Interface II
Battery link cable
Link cable (gray)
Link cable(red)
It is attached to boards.
Parts List
some of screws are added in bags for
spare.
These parts consists of the product.
Please confirm number of each part.
Nyron crip
Nyron band
M3-6 thumb screw
CD-ROM
KHR-1 sticker
2-5 Chrome pan screw

13 goto Index
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HR-001 Top cover
HR-007 body frame L
HR-008 Hand R
HR-009 Hand L
HR-014
Servo bracket C
HR-015 foot sole
Free hone
Servo hone
Board case
PCB base
Expanded cable for servo
motor (200mm) 2
Expanded cable for
servo motor (100mm) 6
NiCd(5N600AE)
Expanded
c a b l e f o r
battery
Adapter for
battery charger
Battery Charger

14
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Remove screws from KRS-784ICS
Attach bracket B to KRS-784ICS with removed screws.
Assemble servo bracket B
HR-010 servo bracket B
Servo motor
KRS-784ICS
Caution: screws are tightened
appropriately to avoid broken cases.
Assemble servo bracket C
Each different direction servo
bracket C is attached to each servo
motor.
Cable from the servo motor is
passed the bracket through the
hole.
Left
Right
HR-014 servo bracket C
6 units are made in left figure.
Bracket is fixed to a servo motor by these removed
screws. Screws are removed from 16 servo motors.
Install bracket First of all, servo motors are attached to brackets.
6
6
2
S e r v o m o t o r
KRS-784ICS
2
Servo motor
KRS-784ICS
16
64 screws are removed from servo
motor cases.
1.7-32 black screw
1.7-32 black screw
24
1.7-32 black screw
8

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Left thigh bracket
Right thigh bracket
HR-012 Foot R
HR-013 Foot L
2-4 Nickel pan screw
2-4 Nickel pan screw
2-4 Nickel pan screw
2-4 Nickel pan screw
2-4 Nickel pan screw
These two parts are used for thigh.
Attach bracket
S e r v o m o t o r
KRS-784ICS
2
1
2
Servo motor
KRS-784ICS
2
1
2
1.7-3 black screw
8
1.7-32 black screw
8
At first, all screws are tightened
temporary for plural screws on
the part. All screws are tightened
up after each screw hole placed
with screw.
2-4 Nickel pan screw

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Assemble servo bracket A
Servo bracket A are installed to body. 2 same units are
made in this procedure.
HR-006 Servo bracket A
Install servo motor to body frame B
HR-004 body frame B
Two servo motors are installed to body frame B.
It is difficult to recognize suface of body frame B. Because of a symmetrical
shape.Please select smooth surface for front.
Remove projection of servo case to attach
to servo bracket A.If it remains, the robot
can't have battery in the body.
Assemble brackets
S e r v o m o t o r
KRS-784ICS
2
2
1.7-32 black screw
8
1
S e r v o m o t o r
KRS-784ICS
2
1.7-32 black screw
8
1.7-32 black screw

17 goto Index
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Assemble body frame B
HR-003 body frame F
HR-005 shoulder frame
2-4 Nickel pan screw
Surface with projection of this hole
is reverse side of body frame F.
HR-007 body frame L
Assemble body Body (torso) parts.
Body frame and part units are attached each other.
1
2
10
Assemble body frame F
Bracket A unit
2
1
2-4 Nickel pan screw
10
Servo motor units which are attached to brackets
are installed to body frame B.
Cover body frame B unit with body frame F.
At first, all screws are tightened
temporary for plural screws on
the part. All screws are tightened
up after each screw hole placed
with screw.

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Install hand parts
2-4 Nickel pan screw
Hand parts are installed to KRS-784ICS and servo bracket B unit.
These parts are left and right hand.
Assemble servo arms
Servo arm is attached to KRS-784ICS and servo bracket B unit.
Four same units are made for arms and legs.
Pay attention to right direction of
servo arm and servo bracket unit.
2-4 nickel pan screw
HR-008 hand L
HR-008 hand R
HR-011 Servo arm
Assemble Arms and Legs
1
1
Servo bracket unit B
2
6
4
16
Servo bracket unit B
4

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Assemble servo arms
Two different direction units are assembled here. Two
sets of two kinds of parts are made here.
2-4 Nickel pan screw
HR-011 servo arm
Assemble cross servo arms
For left leg
For right leg
Pay attention: watch screw hole to attach two
servo arms.
Wrong assembled parts effect to locomotion.
8
16
Assemble two sets
Assemble two sets
At first, all screws are tightened
temporary for plural screws on
the part. All screws are tightened
up after each screw hole placed
with screw.

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How to set axis position?
Servo hone must be attached after servo axis setting on neutral position. And also, the
same procedure is required to fix servo hone and servo arm.
Procedure of board and servo motor connection is described here.
In this step, it is not required that board is on the robot. servo motors, NiCd battery
and RCB-1 are prepared.
Attach servo motor cable to RCB-1
Don't remove link cable. This cable is attached to two board
from shipment.
In this example, ser vo motor cable will be
attached to connector on the right side of the
board. Please pay attention connector position.
Because other side connector output different
anode.
A l l s w i c h e s o n t w o
boards must be set to
turn off (down direction)
put RCB-1 on an insulator such as vinyl to avoid
short circuit.
Get servo axis position
How to attach servo hone to axis?
Servo motor axis and other parts are fixed by a servo hone. Servo motor rotates limited
degree (about 180 degree.) It is important to make robot performance that it is found
out better axis position on the servo case. Control board RCB-1 output neutral position
signal at initial setting. Using this function, we can found neutral axis position easily.
If RCB-1 is used once, it is set up another position settings. In this
case, please initialize RCB-1 using PC software. If RCB-1 output
different output, it is difficult to make performance with the robot.
Put black cable
on the outside
of the board.
1