Related Manuals for Robotronics Vehicle Robot
Summary of Contents for Robotronics Vehicle Robot
- Page 1 1610 West 1600 South Springville, UT 84663 Phone: 801-489-4466 FAX: 801-489-8241 Robotronics.com Vehicle Robot Operating Manual ™ Version 6.6...
- Page 2 Vehicle 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 spokesperson for safety and your organization. It is built for ease of operation, maintenance and repair.
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Page 3: Table Of Contents
Contents Warranty Information ....................1 PART 1 General Operating Instructions .......... 3 Chapter 1 Getting Started ..............3 Operating Tips and Safety Information ..............3 Setup and How to Operate The Robot ..............4 Transporting the Robot ..................7 PART 2 Subsystems of the Robot ............ - Page 4 Chapter 12 Optional Accessories Water Squirter System ..................36 Water Squirter System Diagrams................ 36 Pitch Shifter (Voice Modifier)................37 Stop Arm Option – Bus ..................39 Crossing Arm Option – Bus................. 40 PART 3 Assembly & Disassembly ..........41 Chapter 13 Assembly & Disassembly..........41 PART 4 Maintenance ................
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Page 5: Warranty Information
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 If you need to send a part back to Robotronics for repairs • Go to our website, Robotronics.com and under the service tab find the return form. Fill this out and send it back with the part or robot. •...
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Page 7: Part 1 General Operating Instructions
CHAPTER 1 Getting Started Operating Tips and Safety Information 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 1 Read the manual Read and study this manual completely before operating the robot. If you have any questions about operation of the robot, call our service group. 2 Charge the batteries Be certain that the robot battery and radio control transmitter battery are fully charged before operating the robot. - Page 9 CAUTION Before operating the robot or transporting the robot on the cart or in a vehicle, the upper robot must be properly latched to the lower by pushing the latch pins in. Failure to do this could cause damage to the upper robot if it fell off. Body Latches Body Latches Body Latches...
- Page 10 These will help you become familiar with where the parts are located and their function. • For parts that you need for the robot, go to Robotronics.com. This includes radio controls, voice units, headsets, batteries and chargers. •...
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Page 11: 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 12: Part 2 Subsystems Of The Robot
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 Following are explanations of each subsystem, some operating instructions, and trouble shooting hints where appropriate. -
Page 13: Chapter 2 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 14: Radio Control Transmitter (Diagram)
Radio Control Transmitter RC Frequency on back of RC Tape or MP3 Player Option Squirt Flashing Lights (Not used on all robots) Lights/Beacon Siren Drive Eyes & Head Drive Trim Charge Frequency on crystal Power On/Off Power/Signal Wire Plugs in to B/8. RC Receiver located in the robot RX Crystal... -
Page 15: Radio Control Transmitter Controls
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 16 Top Switch Functions Tape player Voice and Siren Squirter Up- Flashing Lights- Red (Buster and Andy) or Red & Blue(K.C./McGruff Cruisers) Down- Flashing Lights- Yellow (Buster) Beacon and Lights Controls for the Integrated MP3 Player Option The MP3 player is located in the robot and has a SD or MM memory card that you can load music onto.
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Page 17: Ni-Mh Rc Transmitter Battery
The NiMH (Nickel Metal Hydride) RC Battery The NI-MH RC transmitter battery will last about 5-6 hours on a full charge. Charge the battery for about 14 hours. A charge jack is provided on the transmitter for recharging its internal batteries. -
Page 18: Charging Of The Ni-Mh R.c. Transmitter Battery (Diagram)
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 need 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 19: Chapter 3 Voice System Overview
CHAPTER 3 Wireless 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 20: Belt Transmitter
How to Operate the Operator’s Transmitter 1. Open the battery door. This may be the front cover of the case that slides open. 2. Use a 9 Volt alkaline battery and insert it according to the diagram inside the battery compartment. -
Page 21: Robot Receiver
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. The other adjustment is the sensitivity. This is factory preset to maximum sensitivity. -
Page 22: 151 System (Robot Tx And Belt 151 Receiver)
How to Operate the 151 Transmitter (in Robot) Located in the front left of the lower robot. The wire from the hood mic connects to it. No adjustment is needed. The switches will be preset to on at the factory. It receives its power from the robot. -
Page 23: 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. This fuse is a round black fuse holder. - Page 24 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.
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Page 25: Mouth Operation
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 affected by the level of volume of the voice. This level is affected by the Receiver volume level and the position of the headset microphone to the operator's mouth. -
Page 26: Operator's Voice Headset, Transmitter, And Receiver
Operator’s Voice Transmitter and Receiver Headset style that comes with Mic Plug - 3.5mm 3.5mm Headphones Plug the robot. -
Page 27: Chapter 4 Audio Amplifier
CHAPTER 4 Audio Amplifier System The audio amplifier boosts the all audio from the main circuit board and drives the speakers. The level adjustment adjusts the volume for any audio projected from the speakers. There are individual volumes for the voice, mp3 player, and siren. Set the Filter to middle because this gives you the best mid-range sound. -
Page 28: Chapter 5 Mp3 Player
CHAPTER 5 MP3 Player Option Integrated MP3 Player Features • Ability to play MP3 files through the robot. • Memory Storage Card: SD Card. • Four sound effects stored on the card varies with robot type. • Space on the card to load your own music. •... - Page 29 • There is an additional way to change the volume of the music/effects. It is to go to the Road Rage audio amp and adjust the volume. When you do this, you may also need to adjust the volume of the voice on the voice receiver. Do not turn the amp up too high; not much past 1:00, because you may get some audio distortion.
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Page 30: Chapter 6 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 31: Chapter 7 Siren
CHAPTER 7 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 Circuit Board 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 32: Chapter 8 Robot Battery Systems
CHAPTER 8 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 To recharge the robot battery, first open the trunk or rear door and unplug the battery from the main component board. -
Page 33: 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 6/3 Amps. It will charge the battery in about 8-12 hours depending on how long you have used the robot. After the battery is charged, the green LED will come on and the battery is ready to use. - Page 34 Charge the battery in a dry, well ventilated area. This is why it is important that you leave the trunk or door open. You can also remove the battery from the robot. Do not position your face over the battery, at any time while making connections. Do not smoke, strike a match, or cause a spark in the vicinity of the battery during charging.
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Page 35: Chapter 9 Drive Motor System
• The motor control circuit is likely the cause of this. The problem is in the drive circuit. Send the main electronics to Robotronics for repair or contact our Service Department. The robot is not driving straight (Veering when you drive) - Page 36 Note: Before making this adjustment, be sure that your motor pulley set screws are tight and that both motors appear to be working forward and reverse. To check this prop the back of the robot off the ground. • To locate the adjustment, see the Robot Main Electronics Box diagram in the Appendix. They are labeled Forward Drive adjust and Reverse Drive adjust.
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Page 37: Chapter 10 Character Head Turning Motor System
CHAPTER 10 Character Head Turning System Vehicle robots that have characters driving them will have this system. The main components of this system consist of the head turning motor, 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 Character board. -
Page 38: Chapter 11 Eyelids And Eyes Left And Right
CHAPTER 11 Eyelids and Eyes Left and Right The eyelid and eyes left and right movement is accomplished by three servo motors in the Character or upper robot. When the switch on the radio control is activated, this signal is sent to the radio control receiver in the robot. - Page 39 37 pin connector. Check the wiring here to see if there is a broken wire. On robots with characters driving, these wires go to the Character Control Board in the chest area. Check these connections and look at the Character Control Board in the end of this manual for correct placement on the circuit board.
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Page 40: Chapter 12 Optional Accessories
CHAPTER 12 OPTIONAL ACCESSORIES Water Squirter System The new system has a reservoir in the robot that you remove to refill. It is held by an elastic band. Fill the Water Bottle Remove the water bottle inside the rear of the robot by disconnecting the tube from the water connector. -
Page 41: Pitch Shifter (Voice Modifier)
Optional Accessory: Voice Modifier (Pitch Shifter) The pitch shifter (voice modifier) can change the operator’s voice to disguise it and create a robot character type voice. The operator’s voice signal is received like normal by the voice receiver in the robot. The signal is then sent from the audio out of the receiver to the Input Jack of the pitch shifter. - Page 42 modes give you the ability to adjust the shift of your voice to exactly what you want whether up or down. About 2:00 on the pitch knob gives you a good voice. 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.
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Page 43: Stop Arm Option - Bus
Stop Arm and Crossing Arm for School Bus Robots – Barney and Buster Stop Arm To activate the stop arm function, the operator will hit the switch on the RC that is labeled stop arm/reds. The signal from the RC is sent to the receiver in the robot. This signal goes to the main processor and two signals are in turn sent from the processor. -
Page 44: Crossing Arm Option - Bus
EZ connector 791121 4-40 Threaded Rod End 791144 Crossing Arm metal bracket 930402 Crossing Arm with Ball and Pivot Rod 500405 Crossing Arm Gate Plastic Only 700409 Crossing Arm The same servo signal that opens the stop arm will open the crossing arm. The signal comes from the same place on the main board and then continues on to the 5 Volt Isolation board before it goes to the servos. -
Page 45: Part 3 Assembly & Disassembly
3. Locate the four body latches and push the pins outward into the body to secure the upper robot to the lower. If you have a typical vehicle robot, two are in the middle left and right and two at the back. To latch these you will need to reach in through the rear hatch or door. If you have a character in the top, two of the latches are located in the compartment where the Character sits. - Page 46 Removal of Main Box Remove 2 nuts, lift plate up to clear studs, and slide main box back to remove. Lift Drive Base Removed Removal of Drive Base Remove these 4 nyloc nuts to remove the drive base (7/16” socket) Removing the drive base from the plastic frame (Increases access to the motors): 1.
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Page 47: Part 4 Maintenance
10. Part of your maintenance of the robot may include sending the robot or parts of it back for repair and tune-up. This may include the RC, voice equipment and the main electronics panel. Go to Robotronics.com and service for more information. For a list of recommended tools for a tool kit, see the next page. -
Page 48: Recommended Tool Kit
Recommended Tool Kit Fuses- 1, 3, 5, 15, 20, Amp (AGC Type) #53 Miniature bayonet bulbs (automotive panel type) for eyelights Precision regular Phillips screw drivers Screwdrivers (Regular and Phillips) Socket and ratchet set Needle nose pliers Crimper/Wire strippers Wire cutters (diagonal cutters) 7/16"... -
Page 49: Care Of Character Fur
Fabric and Fur Care General maintenance of your robot should include caring for the robot’s fur. After each use, clean and brush the robot’s fur and clothing so the oils and dirt do not become permanent. This may be done with a cloth or brush. Keep the robot covered when not in use to keep dust and dirt off and to protect the fur and clothing. -
Page 50: Painting Of 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. This is especially true if the surface has had a silicone-based product such as Armor-All put on it. -
Page 51: Repair Of The Body
2. You can use two types of materials for support behind the crack. You can use 1/8” ABS plastic or fiberglass mesh. The plastic pieces provide more strength. Call Robotronics if you cannot get these materials locally. 3. Cut a piece of fiberglass mesh or ABS plastic to cover the crack. -
Page 52: Storage
Storage 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; this will extend the life and help insure proper operation. -
Page 53: Appendix A
APPENDIX A... -
Page 54: 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 55 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 56 Problem Cause Solution Eyelids and Eyes Left and Right 1. Rod linkage came off. 1. Get to eyelid rods and ball links and re-attach. An eyelid or eyes L/R does not operate 2. Servo wire broken or wire came out of eye 2.
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Page 57: Robot Circuit Block Diagram
Robot Block Diagram... -
Page 58: Appendix B Robot Parts Identification
APPENDIX B ROBOT PARTS IDENTIFICATION... -
Page 59: Robot Frame Top View 1
Robot Frame - Top View 1 Headlight/Body Light Connection and Fuse 37 Pin Connection Wire to upper robot 151 Voice Transmitter connects here. RC Receiver Road Rage Voice Modifier Audio Amp Audio Amp Master Volume Speaker Wire Speaker Wire RC Receiver Antenna Voice Receiver Raise Antennas... -
Page 60: Robot Frame Top View 2
Robot Frame - Top View Box Open Main Circuit Board Fuse Block See Fuse Block Detail Active Filter Diagram for Fuse size and circuit Water pump Water connections... -
Page 61: Main Electronics Box/Panel
Main Electronics Box RC Receiver Main Circuit Board Fuse Block Active Filter See Fuse Block Detail Diagram for Fuse size and circuit On/Off Switch Battery Connection MP3 Player Option or Tape Player... -
Page 62: Vehicle Main Electronics Board
Vehicle Main Electronics Board 5 Volt Regulator. Pwr for MP3 Player and Tape Sensitivity Adjust: Player Flashing Lights or Mouth Andy-Reds Buster-Reds & Yellows Cass. 3 Volts Switching Headlight Beacon Reds Flash Reds Flash Yellows Flash Yellows Flash Squirter Output 1 Output 2 Output 4 Output 5... -
Page 63: Led Functions On The Main Board
Main Board – LED Functions Led 2 Led 1 Led 3 Led Bank Stop Arm/Steering Wheel Direction Jumper Led 1- Failsafe and presence of RC signal status. Failsafe-led on and no signal is present from RC RC signal present- led is off Led 2- Moving mouth or flashing eye-lights detection. -
Page 64: Vehicle Fuse Block Detail
Vehicle Fuse Block Detail Use AGC type fuses Blue wire Brown wire Blue wire Purple wire Yellow wire White wire 5 Volt Left Drive Right Drive Switched 5 Volt Reg. Audio Outputs Reg. 3 Amp 20 Amp 20 Amp 15 Amp 5 Amp 3 Amp Super... -
Page 65: Robot Frame Bottom View-Motor Pulley Set Screws
Robot Frame - Bottom View Front Transport Cart Eye Hooks Caster Wheels Note: Speakers will be in wheels or under the frame. Motor Pulley Set Screws Allen wrench sizes Super Motors= 1/8” Standard Motors- 3/32” Motor Pulley Drive Belt Wheel Pulley Rear Transport Cart Eye Hooks... -
Page 66: Vehicle Top 1 Underside View
Vehicle Top 1 – Underside View Rear Body Latches Eye Servo Board (Opto-shift board) Left Body Latch Right Body Latch Left Eyelid Servo Right Eyelid Servo Servo Arm Set Screw (M2.5 x .45 x 8mm Phillips Pan Head Machine Screw) Servo Arm Servo Arm Eyelid Rod... -
Page 67: Vehicle Top 2 Underside View
Vehicle Top 2 – Underside View (P.C. ™ Eyes L/R Servo Eyelid Rod Eyelid Rod Servo Arm Servo Arm Servo Arm Set Screw Right Eyelid Servo (M2.5 x .45 x 8mm Phillips Pan Head Machine Screw) Left Eyelid Servo Right Body Latch Left Body Latch Eye Servo Board (Opto-shift board) -
Page 68: Eyes Servo Board
2 Left Eyelid Reverse Black 3 Right Eyelid Gray 4015 4 Right Eyelid Reverse Yellow 5 Eyes L/R Black (Brown) 6 Eyes L/R Reverse 7 Mouth Servo Robot Typical Connection Location of Board in Robot Vehicle robot 2,3,6,7 In Upper robot... -
Page 69: Character Head-Inside View
Character Head - Inside View Eyes Left/Right Servo Eyelid Rod Servo Arm Set Screw Set Screws Left Eyelid Servo Right Eyelid Servo In-line connectors Mouth arm for each servo Set Screw Servo Mouth with Servo Arm... -
Page 70: Character Top Underside View
Character Top 1 – Underside View (K.C. ™ /McGruff ® Servo Arm (Set Screw) Steering Wheel Servo Steering Servo Connector Head Turning Feedback Pot Head Turning Motor Body Latch Body Latch Character Control Board Eyes Servo Board 37 Pin Connector See Character Board Diagram for detail of connections on the Character board. -
Page 71: Character Top 2 Underside View
Character Top 2 - Underside View ® (Patches ™ /Sparky Steering Servo Connector Servo Rod Servo Arm (Set Screw) Steering Wheel Servo Head Turning Motor Body Latch Body Latch Character Head Turning Control Board Feedback Pot 37 Pin Eyes Servo Board Connector Body Latches See Sparky Control Board Diagram for detail of... -
Page 72: Character Head Turning Parts Detail
Character Head Turning Motor Detail Coupler with set screws. Tube interfaces the feedback pot shaft to the head turning motor shaft. (1"x1/4"x5/16" Coupler) Head Turning Motor Head Turning Feedback Pot Set Screw on Set Screw on 5K 360 degree single turn pot Pot Shaft Motor Shaft Tracks with movement of the... -
Page 73: Character Control Board Type 1
Character Control Board Type 1 Signal to Eyes Servo Board Signal From Lower Mouth Trigger Yell./Gray/Blk/- Robot RC Receiver Purple jumper/purple (Blue/Black/Orange) 5 Volts to Eye Mouth Switching Power Servo Board (Black/Yellow) Black/Red 12V power Head Turn Motor Wire from lower (Blue/Yellow) robot Fuse in line 1.5 Amp... -
Page 74: Character Control Board Type 2
Character Control Board Type 2 Head Turn Motor Wire (Blue/Yellow) Signal From Lower Robot RC Receiver (Blue/Black/Orange) Mouth Trigger Mouth Switching Power Purple Jumper/Purple (Black/Yellow) Signal to Eye Servo Board Yellow/Grey/Black 5 Volts to Eye Servo Board Black/Red Head Turn Feedback 12v Power from Lower Robot... -
Page 75: Led Light Bar (Available On Certain Robots)
LED Light Bar This is an optional feature available on certain robots. The flashing pattern can be changed by pushing a switch that is located in the seat area of robots with a character. It is on the seat back to the right of the character driving the robot for Patches and Sparky. -
Page 76: 37 Pin Connector Pinout
37 Pin Connector Pinout Black Orange Blue Brown/red Beacon RC Signal RC Signal Beacon Power Purple Black Blue Black Mouth Eyelights Eyelights RC Signal Trigger Power Yellow Black Grey Black Eyes Eyes Eyes Eyes Lights Lights Lights Signal Power 5V Signal Signal Flashing... -
Page 77: Appendix C Maintenance Forms
APPENDIX C CHECKLIST AND MAINTENANCE FORMS... -
Page 78: Checklist Form
Pre/Post Checklist for Robot Use Mark the appropriate one: Pre-checklist_______ Post-Checklist_______ Event: ______________________________ Date:__________________ Your Name:__________________________ Inspect the items that are listed below • Check the appropriate column. If something is not operating properly, note it in the comments section. •... -
Page 80: Notes Section
Notes... - Page 81 Technical Tips...
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