Lynxmotion AL5D-PLTW User manual

RobotShop Product Code: RB-Lyn-814
Lynxmotion SKU: AL5D-PLTW
Guide release date / version V1.2 March 2018
RobotShop Inc. 305-18005 Lapointe Mirabel, Quebec, Canada J7J0G2

About 2
Lynxmotion / RobotShop 2
AL5D Robot Arm 2
What’s Included 3
Part Codes 4
Tools Required 5
RC Servo Technology 6
Angle 6
Torque 6
Operation 6
Assembly 7
A. Base 7
B. Arm Assembly 17
C. Servo Installation 27
D. Software / Servo Setup 37
E. Cleanup & Mounting 45
Important Notes 52
Warranty Information 52
RobotShop Inc. 305-18005 Lapointe, Mirabel, Quebec, Canada, J7J0G2
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About
Lynxmotion / RobotShop
Lynxmotion offers a variety of hobby and research level robot kits and parts, most precisely the
modular robotics building system known as the Lynxmotion Servo Erector Set.
Imagine it. Built it. control it.™
Founded in 2003, RobotShop Inc. is proud to put robotics at your service. We specialize in
personal and professional robot technology and offer a wide range of robotic products and
services in this sector. RobotShop acquired Lynxmotion in late 2012.
Putting robotics at your service!
At RobotShop, our vision is to be the World leading source for personal and professional robot
technology that help increase the pleasure, knowledge, liberty and security of individuals. We
are also committed to promoting and advocating the interest and necessity of robotics use
towards positive ends, allowing humanity to attain a better world.
AL5D Robot Arm
The AL5D - PLTW arm is part of Lynxmotion’s series of AL5 robot arms (AL5A, AL5B and AL5D;
the AL5C was discontinued). The AL5D robotic arm delivers fast, accurate, and repeatable
movement. The robot features: base rotation, single plane shoulder, elbow, wrist motion, a
functional gripper, and medium duty wrist rotate. The AL5D robotic arm is an affordable system
with a time tested design that will last.
Standard AL5D Robot Arm
RobotShop Inc. 305-18005 Lapointe, Mirabel, Quebec, Canada, J7J0G2
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What’s Included
NOTE: The assembly guide provided in this document is not the same as the assembly guide
provided online via Lynxmotion or on YouTube. We suggest using this guide only.
If you purchase the AL5D-PLTW (RB-Lyn-814) arm, it will include everything mentioned below.
The arm does not require any additional parts for use with the Project Lead The Way curriculum,
though additional accessories are available separately.
Standard AL5D
● 1x AL5D 4 Degrees of Freedom Robotic Arm (Hardware Only)
● 1x SSC-32U USB Servo Controller
● 1x Power Supply Output 6VDC 5A Input 120-240VAC
● 1x HS-422 Servo Motor (gripper)
● 1x HS-645MG Servo Motor (wrist)
● 1x HS-755HB Giant Scale Servo Motor (elbow)
● 1x HS-805BB Giant Scale Servo Motor (shoulder)
● 1x HS-485HB Servo Motor (base)
AL5D - PLTW
The PLTW version of the AL5D (RB-Lyn-814) includes additional upgrades:
● 1x FlowArm PLTW Software (on CD with licence printed on the invoice / packing slip)
● 1x Medium duty wrist rotate with 1x HS-422 servo
● 1x Servo extension cable
The arm is packaged by sub-sections - for example, the hardware for constructing the frame of
the arm is provided in its own bag, complete with screws and nuts. The base rotate kit is
packaged separately in its own bag with all corresponding hardware. It is up to the customer if
they prefer to keep these packages separate, or to open all packages and combine identical
products.
RobotShop Inc. 305-18005 Lapointe, Mirabel, Quebec, Canada, J7J0G2
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Part Codes
The following diagram illustrates the parts (Lynxmotion codes) used to make the standard AL5D
arm (without the additional parts for PLTW).
Standard AL5D Robot Arm (V1) w. Old SSC-32
Medium duty wrist rotate upgrade
RobotShop Inc. 305-18005 Lapointe, Mirabel, Quebec, Canada, J7J0G2
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Note: We include a variety of additional parts which you will not use in the construction of the
arm. This is because the AL5D-PLTW is nevertheless part of a modular building system, and
parts / kits which make up the arm are also used in other kits.
Tools Required
Several standard tools are needed for the assembly of the arm, most notably:
● 3-30 Hex wrench suitable for the 4-40 screws (included)
● Phillips head screwdriver
● Small pan head screwdriver (for SSC-32U screw terminals)
● Wrench (for 2-56 nuts)
● 400 grit sandpaper (optional)
● Silicon based oil (optional)
Mechanics
The aluminum robotic arm is made using the Lynxmotion Servo Erector Set components for the
ultimate in flexibility and expandability. The kit consists of aluminum brackets, aluminum tubing,
custom injection molded components, and precision laser-cut Lexan components.
Dimensions
● Shoulder to elbow: 5.75”
● Elbow to wrist: 7.375”
● Wrist to tip of gripper: 3.375”
● Height (arm packed): approx. 7.25”
● Height (reaching up): approx. 19.00”
● Median forward reach: approx. 10.25”
● Gripper opening: 1.25”
● Weight: 31oz
● Range of motion per axis: 180 degrees
● Medium duty wrist rotate ads 1”
Load Capacity
The load capacity of the arm is based on multiple factors:
● Operating voltage: RC servos can accept between 4.8V to 6V
● Distance from the base: This factor is critical since the farther the object is from the
base, the more energy will be required to hold it against gravity
● Length of time the object is held: The longer the object is held against gravity, the more
the servos will heat up.
At median reach (elbow at 90 degrees), the arm can support up to 10 oz. As the arm is
extended, it will support a bit less, and as it is retracted, it can support a bit more.
RobotShop Inc. 305-18005 Lapointe, Mirabel, Quebec, Canada, J7J0G2
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RC Servo
Technology
The AL5D uses Hitec RC servo motor actuators at each joint. These servos are classically used
in the RC hobby industry to control ailerons and landing gear on airplanes, rack and pinion
steering on RC cars and come in a variety of sizes and torque ratings. Given their popularity,
easy of use, low price and absolute positioning, RC servos were adapted for use in animatronics
and robotics.
Angle
Standard RC servo motors only rotate 180 degrees (0 to 180 / -90 to +90). This is the case
because the internal component (rotary potentiometer) which provides the absolute positioning,
cannot provide multiple rotations and is physically limited in the angle over which it can turn.
Torque
“Torque” is not the same as a “force”; a “force” acts as a straight vector, whereas “torque” is
rotational about a point. Torque is defined as force multiplied by distance, or T = F * d, where d
is the distance between the force and the axis of rotation. Although we will not go into the details
of how to calculate torque, it is important to note that not all servos can provide the same torque,
and some are more powerful than others.
Operation
AN RC servo motor has three wires which are always in the same order:
Black = Ground (GND)
Red = Positive (4.8V ~ 6V)
Yellow = PWM Signal / Pulse
An RC PWM signal is a repeated pulse at 5V whose duration lasts between 0.5ms (500us) to
2.5ms (2500us), followed by a delay of between 20ms to 30ms. The servo’s onboard electronics
time the pulse and position the servo at the corresponding angle. The pulse must be repeated
for the servo to retain the desired position.
RobotShop Inc. 305-18005 Lapointe, Mirabel, Quebec, Canada, J7J0G2
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Assembly
Note that there is also an online assembly guide from Lynxmotion for the AL5D (which uses
photos), as well as a YouTube video, however this manual is an updated version, so we suggest
using ONLY this guide for the assembly steps.
A. Base
Step A1 : Insert the 1/16” x ⅜” stainless steel pins into the 6mm black plastic beads as shown
(5x)
● 5x steel pins
● 5x plastic beads
Step A2 : Install the bearings into the base as shown. They will fit snugly. Note, the notch in the
bottom edge of the base (shown below) indicates the back.
● 5x plastic bead assemblies
● 1x base rotate (bottom)
RobotShop Inc. 305-18005 Lapointe, Mirabel, Quebec, Canada, J7J0G2
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Step A3 (optional): Lay a piece of 400 grit sandpaper (not included) on a flat surface and
carefully turn the base assembly from step 2 upside down. Press the base against the
sandpaper in small circles on it to remove any imperfections on the beads.
Step A4 (optional): The image below shows the circle pattern on the sandpaper and the inset
shows the bearings after any imperfections have been removed.
RobotShop Inc. 305-18005 Lapointe, Mirabel, Quebec, Canada, J7J0G2
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Step A5 : The Hitec 485HB servo is shipped with its white plastic horn centered. If the horn is
rotated by accident, ensure it lines up like the image below. It should rotate 90 degrees CCW
and 90 degrees CW. Unscrew the black screw holding the horn in place and KEEP IT for step
A9). Note that this screw is very tight and the appropriate screwdriver (correct Phillips head) is
needed. Apply some downward pressure but do not strip the screw . If the servo horn was
rotated, re-center it as in the image below, then pull the white plastic horn straight off of the
servo.
Step A6 : Place the servo in the base as shown and screw it in using four #4 x ⅜” Phillips head
tapping screws included with the base rotate kit. Note that the holes are not tapped - the screws
need to be turned and pressed to force thread the plastic.
RobotShop Inc. 305-18005 Lapointe, Mirabel, Quebec, Canada, J7J0G2
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Step A7 : Attach the large ASB-204 multipurpose bracket onto the base top using four 2-56 x
.250" phillips head machine screws and four 2-56 nuts as shown. Note, the bracket and
hardware are included in the arm kit, not the base kit. Ensure the orientation looks like the
image below.
Step A8 (optional to reduce noise): Add a drop of silicone-based oil to each bearing (not
included)
RobotShop Inc. 305-18005 Lapointe, Mirabel, Quebec, Canada, J7J0G2
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Step A9 : Install the base top using the horn screw from step A5. The hole pattern of the top
plate should line up with one row of holes pointing to the servo wire hole at the rear, and all of
the lines pointing between the mounting tabs. Note, this top piece is manufactured to be a tight
fit to the servo horn, so be sure to align them well and you might have to press hard.
Step A10 : Pass the servo's cable through the hole in the back of the base. This will keep the
base level to the mounting surface.
RobotShop Inc. 305-18005 Lapointe, Mirabel, Quebec, Canada, J7J0G2
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NOTE: There are now two options for mounting the electronics. Choose one of the two.
Option 1: Lynxmotion Base Rotate / Heavy Duty Base to VEX Adapter
Option 2: Lynxmotion Base Electronics Carrier Kit
OPTION 1 (AL5 to VEX plate)
Step A11 : Screw four 4-40 x 1” long standoffs included with the Lynxmotion to VEX Adapter to
the plate using four 4-40 x ⅜” long hex screws.
RobotShop Inc. 305-18005 Lapointe, Mirabel, Quebec, Canada, J7J0G2
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Step A12 : Use two 4-40 x ⅜” hex screws and two 4-40 x ¼” lock nuts to fix the
RobotShop Inc. 305-18005 Lapointe, Mirabel, Quebec, Canada, J7J0G2
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RobotShop Inc. 305-18005 Lapointe, Mirabel, Quebec, Canada, J7J0G2
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Step A13 : Install the power plug wiring harness as shown (servo controller greyed out). To do
so, you need to remove the nuts and spacers which come installed on both the switch and
barrel connector. You can use a tie wrap or tape to hold the wires in place. The SSC-32U only
needs the one wiring harness.
Note that the On/Off switch has three pins, of which two have wires. When the switch points
towards these two connectors, electricity can flow. In the image below, the switch would be OFF.
The orientation when inserted into the hole can be vertical (as shown in the image above) or
horizontal); just know which is ON and OFF.
Switch in the OFF position
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Step A14 : Install the SSC-32 (shown) or the SSC-32U using four more 1/4" x 3/8" hex socket
screws. Do not make the electrical connections yet. The base rotate is shown just for reference
so you know where it will be placed later.
RobotShop Inc. 305-18005 Lapointe, Mirabel, Quebec, Canada, J7J0G2
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Step A15 : Twist each end of the multi-strand wires to ensure there are no loose wires which can
cause a short circuit. This will also make the multi-strand wires easier to insert into the screw
terminal.
Unscrew the VS1+ and VS1- terminals so the wires can be inserted. This means rotating the
screw so that the inner metal touches the bottom of the plastic (see visually). Screwing in the
opposite direction will create a bottom-up“clamping” effect which will hold the wire in place.
Screw terminal Clean Wires Bad Wires
Insert the wires to the VS1 input as shown, between the top bent metal and the bottom metal,
making sure the black wires goes to (-) and the red wires goes to (+). Tighten the screws to
ensure the wires are secure, and verify that there are no loose strands which may cause a short
circuit.
If you find it difficult to insert all of the wire strands, or they are too “messy”, use wire cutters (or
sharp scissors) to remove some of the shielding at the end (~0.5cm) and then carefully cut
some of the wire, ensuring all of the wires are straight and compact.
NOTE: Once again, ensure no wires touch between the red and black leads at the screw
terminals!
RobotShop Inc. 305-18005 Lapointe, Mirabel, Quebec, Canada, J7J0G2
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OPTION 2
Step A11 : Attach four 4-40 x 3/8" hex spacers as shown using four 1/4" long hex socket screws.
Note that the lexan plate can be in either orientation - whichever works best for you. The
orientation below is “standard”.
Note: If you have purchased the Lynxmotion Base Rotate / Heavy Duty Base to VEX Adapter,
you will not need this plate and must use that adapter plate instead for these steps.
RobotShop Inc. 305-18005 Lapointe, Mirabel, Quebec, Canada, J7J0G2
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Step A12 : Install the power switch bracket using two 4-40 x 3/8" hex socket screws and two
4-40 nylon insert lock nuts, ensuring the bracket is on the same side as the standoffs. The
bracket can be on the left or the right side - whichever works best for your application.
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