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Robotronics Toby Tire Robot Operating Manual

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Toby Tire Robot
Operating Manual
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Version 6.5

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Summary of Contents for Robotronics Toby Tire Robot

  • Page 1 ® Toby Tire Robot Operating Manual ™ Version 6.5...
  • Page 2 Toby Tire Operating Manual Congratulations on your purchase of a ROBOTRONICS, Inc. robot. Your robot has been carefully constructed of the highest quality components. Its design is the result of years of experience building robots. You will find it an extremely effective spokesman for your organization.

  • Page 3: Table Of Contents

    Contents Contents Warranty Information ....................1 PART 1 General Operating Instructions .......... 3 Chapter 1 Getting Started ..............3 Operating Hints ..................... 3 Setup and How To Operate The Robot..............4 Transporting The Robot ..................6 PART 2 Subsystems of the Robot ............
  • Page 4 Contents PART 3 Assembly & Disassembly ..........35 Chapter 11 Assembly & Disassembly..........35 PART 4 Maintenance ................36 Chapter 12 Maintenance ..............36 Regular Maintenance Checklist ................36 Recommended Tool Kit..................37 Painting of the Body .................... 38 Repair of the Body ....................39 Storage........................

  • Page 5: Warranty Information

    If you need parts sent by air shipment you will be responsible to pay the additional shipping charges. In no event shall ROBOTRONICS, Inc. be liable for any incidental or consequential damages in connection with or arising from the use of the robot, this manual or any procedures herein.
  • Page 6 Warranty Information and Getting Help • Upon the receipt of your product, save all packing materials to return the product if needed. • If you must return a part or the robot for repair, pack it carefully and send it prepaid according to instructions.

  • Page 7: Part 1 General Operating Instructions

    CHAPTER 1 Getting Started OPERATING HINTS ROBOTRONICS, Inc. robots are a unique and exciting tool in the hands of a skilled and trained operator. The operator provides much of the excitement the robot conveys. The selection and training of the operator should be done carefully, so as to provide a person with good judgment and an outgoing personality.

  • Page 8: Setup And How To Operate The Robot

    Setup and How to Operate the Robot SETUP AND HOW TO OPERATE THE ROBOT Step # 1 Read and study this manual completely before operating the robot. Step # 2 Charge the batteries Be certain that the robot battery and radio control transmitter battery are fully charged before operating the robot.
  • Page 9 Setup and How to Operate the Robot Step # 9 Charge the batteries again Connect the Robot battery to the charger and bring it back to a full charge before leaving the robot. This battery should not be left with a partial charge. The transmitter battery should be charged if it is low.

  • Page 10: Transporting The Robot

    Transporting the Robot TRANSPORTING THE ROBOT Before transporting the robot, remove the robot battery from the robot. The vehicle that you use to transport the robot should have adequate shock absorption. Vans and cars used for passengers would be the best. Transporting the robot in a trailer is not recommended because trailers typically do not have the same level of shock absorption as a car or van.

  • Page 11: Part 2 Subsystems Of The Robot

    Subsystems Part 2 Subsystems of the Robot Functionally, the robot is made up of the following basic subsystems: A. Radio Control System B. Voice System C. Cassette Tape Player D. Siren E. Robot Battery Systems F. Drive Motors G. Eyelids and Eyes Left and Right The systems block diagram found in the Appendix shows how the various subsystems and their components are interrelated.

  • Page 12: Chapter 2 Radio Control System

    Radio Control System CHAPTER 2 Radio Control System The Radio Control System consists of the control transmitter unit held by the operator and the receiver with its associated components in the robot. The Radio Control Transmitter converts movements of the control sticks and switches into a coded radio signal, which is transmitted by radio to the Radio Control Receiver within the robot.

  • Page 13: Radio Control Transmitter (Diagram)

    Radio Control Diagram RADIO CONTROL TRANSMITTER (Hi-Tec)

  • Page 14: Radio Control Transmitter Controls

    Radio Control Functions RC TRANSMITTER CONTROLS Note: The following information on the transmitter controls includes information for a variety of similar robots. Telescopic Transmitter Aerial. Transmitter Battery Voltage Meter (Expand Scale Voltmeter) Right control Stick- Up and Down – Robot drive motors, forward and reverse. Right and Left –...
  • Page 15 Top Switch Functions Tape player Blink eyes Dance and Handshake Unused Siren...

  • Page 16: Ni-Mh Rc Transmitter Battery

    RC Transmitter Battery THE NICKEL METAL HYDRIDE (NI-MH) RC TRANSMITTER BATTERY The NI-MH RC transmitter battery will last about 5-6 hours on a full charge. Charge the battery for 16 hours. A charge jack is provided on the transmitter for recharging its internal batteries. This round jack is located on the right side of the radio control.

  • Page 17: Adapter For Charging And 110 V Power Supply

    Adapter and 110 V Supply Adapter for Charging an Extra NI-MH RC Transmitter Battery If you have an extra NI-MH RC battery, you can charge this outside the RC. You may want to do this while you are using the robot or if you need to charge both batteries at the same time. The adapter needed to do this is in the control case or it is on your charger.

  • Page 18: Chapter 3 Voice System Overview

    Voice System CHAPTER 3 Voice System The Voice System consists of two separate communication links. One link transmits the operator's voice to the robot. When you speak into the headset mic, this audio goes to a transmitter on your belt. This audio is transmitted to a receiver in the robot. The audio signal then goes from the receiver through a mixing circuit on the main board.

  • Page 19: Belt Transmitter

    Voice System How to Operate the Operator’s Transmitter 1. Open the battery door. 2. Use a 9 Volt alkaline battery and insert it according to the diagram inside the battery compartment. 3. Place the headset on your head and adjust the microphone to approximately 1 inch from your mouth.

  • Page 20: Robot Receiver

    Voice System How to Operate the Receiver (in Robot) There are two adjustments on the receiver. The volume is on the back of the receiver, which you may set to the desired volume. On the UHF UB-10 you can change the volume on your belt transmitter on the fly.

  • Page 21: 151 System (Robot Tx And Belt 151 Receiver)

    Voice System How to Operate the 151 Transmitter (in Robot) No adjustment is needed. The switches will be preset to on at the factory. It receives its power from the robot. No 9 Volt battery is needed. Function of the LED When the robot is turned on, this light flashes and then goes out.

  • Page 22: Voice System Troubleshooting

    Voice System Troubleshooting Warnings 1. Do not unplug or plug in the DC power plug on the robot receiver with the robot power on. If the power is left on, the plug will short out and could damage the receiver. The fuse in line on the power wire that is plugged into this receiver may blow.
  • Page 23 TEST- Connect robot mic to transmitter. If it now works, problem is in headset. Repair or replace. 7. Still not working. Call Robotronics. Send transmitter, receiver, and headset in. Operator cannot hear 1. Low Battery. LED on steady or no LED flash.

  • Page 24: Mouth Operation

    Moving Mouth MOVING MOUTH Function- The moving mouth is a feature where the mouth moves as the operator speaks through the robot. The amount of the movement is effected by the level of volume of the voice. This level is effected by the Receiver volume level and the position of the headset microphone to the operator's mouth.

  • Page 25: Operator's Voice Headset, Transmitter, And Receiver

    Operator Voice Units Operator’s Voice Transmitter and Receiver 3.5mm Headphones Plug Mic Plug - 3.5mm or 3 Pin mini XLR...

  • Page 26: Chapter 4 Cassette Tape Player System

    6. Open the main box and re-connect to board. board. 7. Radio control or tape circuit not working 7. Contact Robotronics for help. No siren, or voice either. 1. Audio fuse blown. 1. Replace the fuse. See fuse block diagram.

  • Page 27: Cassette Tape Player (Diagram)

    Cassette Tape Player Cassette Tape Player...
  • Page 28 Cassette Tape Player...

  • Page 29: Chapter 5 Siren

    Siren CHAPTER 5 Siren The robot siren is operated by remote control from the Radio Control Transmitter. The siren circuitry is located on the main circuit board. See the Main Electronics Box diagram, in the Appendix, for the location of the siren volume, mode select and oscillation frequency adjust. The volume of the siren is controlled by a trim pot on the main board.

  • Page 30: Chapter 6 Robot Battery Systems

    Robot Battery CHAPTER 6 Robot Battery System ROBOT BATTERY The battery in the robot is a rechargeable sealed lead-acid Gel type battery 12 Volt 33AH. This type of battery is very dependable and safe. It can be repeatedly charged and discharged. How to Recharge Connect the charger to the white connector which is next to the on/off switch.

  • Page 31: Robot Battery Charger

    Robot Battery Charger ROBOT BATTERY CHARGER The charger supplied with the robot is designed to both recharge your battery, and extend your battery’s life. It produces 12 Volts DC at a full 6 Amps. It will charge the battery in about 8 hours depending on how long you have used the robot.
  • Page 32 Robot Battery Charger If the Battery is not taking a Charge Make sure that the charger is working by connecting it to a battery that is known to be good. Leave the charger on for a few days and see if the battery starts taking a charge. Turn the robot on and try to operate it.

  • Page 33: Chapter 7 Drive Motor System

    Drive Motor System CHAPTER 7 Drive Motor System Your robot is provided with two high quality industrial grade drive motors. Each motor controls a drive wheel-left and right. Steering of the robot is accomplished by varying the speed and direction of these motors. For example, when the left motor runs faster than the right, the robot turns to the right.
  • Page 34 If this is the case, check for broken or shorted wires and if nothing is found, contact the Robotronics' service department for assistance. One drive motor operates only in one direction: The motor control circuit is likely the cause of this.

  • Page 35: Chapter 8 Character Head Turning Motor System

    Arms System CHAPTER 8 Arms The main components of this system consist of the arm motors, motor control circuit, and the feedback pot. When you move the joystick on the radio control, a signal is sent to the receiver in the Robot. The receiver sends this signal to the microcontroller on the robot. The motor control circuit is on the Character board.

  • Page 36: Chapter 9 E Yelids And Eyes Left And Right

    Eyes CHAPTER 9 Eyelids The eyelids movement is accomplished by one servo motor just behind the eyes. When the switch on the radio control is activated, this signal is sent to the radio control receiver in the robot. The micro-controller in the robot decodes this signal and a new signal is sent to the eyes servo board.

  • Page 37: Chapter 10 Optional Accessories

    Voice Modifier CHAPTER 10 OPTIONAL ACCESSORIES OPTIONAL ACCESSORIES: VOICE MODIFIER (PITCH SHIFTER) INSTRUCTIONS The pitch shifter (voice modifier) can change the operator’s voice to disguise it and create a robot character type voice. The operators voice signal is received like normal by the voice receiver in the robot.
  • Page 38 Voice Modifier The shifter gets power from the robot battery; no internal battery is needed. If the cover of the main electronics box ever needs to be removed, do not allow the shifter power wire plug, to contact the metal box. The metal box surface has a ground connection. The fuse related to the shifter is the audio fuse located on the fuse block.

  • Page 39: Part 3 Assembly & Disassembly

    Assembly & Disassembly PART 3 CHAPTER 11 Assembly & Disassembly Removing the body: 1. Remove the tread to access the battery. 2. Twist the latches. 3. Disconnect any wires that are connected. 4. Lift the body off the frame. Removing the hubcaps 1.

  • Page 40: Part 4 Maintenance

    Maintenance: Checklist PART 4 CHAPTER 12 Maintenance Regular Maintenance Checklist Periodically the robot should receive a thorough inspection. Examine the exterior of the robot and make repairs as necessary. See the robot body repair instructions if needed. Remove the upper robot. Check all bolts and nuts for tightness. Examine electrical wiring and connectors for looseness and wear.

  • Page 41: Recommended Tool Kit

    Maintenance: Recommended Tool Kit Recommended Tool Kit Fuses- 1, 3, 5, 15, 20, 30 Amp (AGC Type) 4" cable ties #53 Miniature bayonet bulbs (automotive panel type) Precision regular Phillips screw drivers Screwdrivers (flat head and Phillips) Socket and ratchet set Needle nose pliers Crimper/Wire strippers Wire cutters (diagonal cutters)

  • Page 42: Painting Of The Body

    Maintenance: Painting the Body PAINTING OF THE ROBOT BODY The following information is only suggestions of painting methods. Contact a professional for assistance. Preparing the surface: The robot body is an ABS plastic and should be cleaned before painting to remove oils and dirt.

  • Page 43: Repair Of The Body

    Maintenance: Repair of the Body REPAIR OF THE ROBOT BODY Materials Super glue ABS or PVC clear medium bodied glue Fiberglass mesh Rubber gloves 1. Hold the crack together tightly so that the glue you put on the inside of the body does not run through the crack on to the outside of the body.

  • Page 44: Storage

    Maintenance: Storage STORAGE Storing your robot for any length of time. Charge the robot battery. (Storing the battery for any length of time without being fully charged will permanently damage the battery.) Charge the RC battery as per instructions. Remove batteries from operator’s transmitter and receiver. The RC Transmitter and voice pieces should always be stored in the carrying case;...

  • Page 45: Appendix A

    APPENDIX A...

  • Page 46: Quick Reference Troubleshooting

    TEST- Connect robot mic to transmitter. If it now works, problem is in headset. Repair or replace. 7. Still not working. Call Robotronics. Send transmitter, receiver, and headset in. Operator cannot hear 1. Low Battery. LED on steady or no LED flash.
  • Page 47 1. Move drive stick sliders to center or position to when the stick is in the center. neutral the robot. 2. Joystick potentiometer broken. 2. Send to Robotronics for repair. Robot not driving straight. 1. One motor pulley set screw loose. 1. Tighten set screws.
  • Page 48 Appendix A: Quick Reference Troubleshooting Chart Problem Cause Solution One of the eyelids is at a different level 1. Eyelid rod bent or eyelid out of adjustment 1. Straighten bent rod or change eyelid position by removing the servo arm. Then shorten or lengthen the rod by twisting the servo arm.

  • Page 49: Robot Circuit Block Diagram

    Appendix A: Robot Functional Block Diagram...

  • Page 50: Appendix B Robot Parts Identification

    APPENDIX B ROBOT PARTS IDENTIFICATION...

  • Page 51: Inside View

    Appendix B: Inside View Inside View Microphone Voice Voice Transmitter Receiver Tape Player Voice Modifier Fuse Block Battery strap Battery Connector On/Off Switch...

  • Page 52: Main Box Inside

    Appendix B: Main Box Inside Main Box Inside Main Circuit Board Arm Board Signal Wires Left Arm/5Volt/Right Arm Main Fuse Block Active Audio Filter...

  • Page 53: Battery Compartment

    Battery Compartment Battery Compartment-Inside View Battery Connector Drive Motors On/Off Switch Robot Battery...

  • Page 54: Main Board

    Appendix B: Main Electronics Board Main Electronics Board Cass. 3 Volts Switching Cass. 3 Volt Regulator Output 1 Output 2 Output 4 Output 3 Output 5 Output 6 Output 7 Output 8 9V To Voice Modifier Cassette 3V Power 5 V to Eye Servo Board (Vehicle) Siren...

  • Page 55: Fuse Block Detail

    Appendix B: Fuse Block Detail Fuse Block Detail Use AGC Fast Acting Type Fuses 3 white wire 4 yellow wire 0 brown wire 2 blue wire 5 purple wire 1 blue wire LEFT RIGHT 5 VOLT AUDIO DRIVE 5 VOLT DRIVE SWITCHED REG.

  • Page 56: Side Arm View

    Appendix B: Side Arm View Side Arm View Arm Feedback Speaker Arm Motor Arm Motor Connector...

  • Page 57: Eyes Servo Board

    Appendix B: Eyes Servo Board - Character Eyes Servo Board (Opto-Shift Register Board) Version With Two 4 Pin Connections White Black Red 4 Pin Connectors COPYRIGHT 1993 COPYRIGHT 1993 ROBOTRONICS ROBOTRONICS Gray 1 Eyelids Black 2 Eyelids Yellow 4015 4015...

  • Page 58: Eyes

    Appendix B: Eyes Eyes Eyelid Rod Eyelid Servo Servo Arm Servo Board...

  • Page 59: Arm Control Board

    Appendix B: Arm Control Board Arm Control Board Left Arm Signal 5 Volt Power Right Arm Signal Right Arm Circuit Left Arm Circuit...

  • Page 60: Notes Section

    Notes...

  • Page 61: Technical Tips Section

    Technical Tips...

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