SG5/6-UT Robotic Arm - CrustCrawler Robotics

Transcription

SG5/6-UT Robotic Arm
Kit Assembly Guide
VERSION 3.4
Author – Alex Dirks
WARRANTY
CrustCrawler warrants its products against defects in materials and workmanship for a period of 30 days. If you discover a defect,
CrustCrawler will, at its option, repair, replace, or refund the purchase price. Simply call for a Return Merchandise Authorization (RMA)
number, write the number on the outside of the box and send it back to CrustCrawler. Please include your name, telephone number,
shipping address, and a description of the problem. We will return your product, or its replacement, using the same shipping method used to
ship the product to CrustCrawler.
14-DAY MONEY BACK GUARANTEE
If, within 14 days of having received your product, you find that it does not suit your needs, you may return it for a full refund.
CrustCrawler will refund the purchase price of the product, excluding shipping / handling costs. This does not apply if the product has been
altered or damaged. Please refer to our web site for the latest warranty information.
COPYRIGHTS AND TRADEMARKS
This documentation is copyright 2004 by CrustCrawler, Inc. BASIC Stamp is a registered trademark of Parallax, Inc. If you decided to use
the name BASIC Stamp on your web page or in printed material, you must state that "BASIC Stamp is a registered trademark of Parallax,
Inc." Other brand and product names are trademarks or registered trademarks of their respective holders.
DISCLAIMER OF LIABILITY
CrustCrawler, Inc. is not responsible for special, incidental, or consequential damages resulting from any breach of warranty, or under any
legal theory, including lost profits, downtime, goodwill, damage to or replacement of equipment or property, and any costs or recovering,
reprogramming, or reproducing any data stored in or used with CrustCrawler products. CrustCrawler is also not responsible for any personal
damage, including that to life and health, resulting from use of any of our products. You take full responsibility for your BASIC Stamp and
robotic application, no matter how life-threatening it may be.
INTERNET ACCESS
We maintain internet systems for your use. These may be used to obtain software, communicate with members of CrustCrawler, and
communicate with other customers. Access information is shown below:
E-mail: Support@CrustCrawler.com
Web: http://www.CrustCrawler.com
Table of Contents · Page i
Preface · Page iii
Preface
The SG5/6 robotic arm is an original design from Alex Dirks of the CrustCrawler team.
Experience programming the BASIC Stamp is helpful, but if you need more help in this regard you can
find plenty of robotic programming resources on our web site (www.crustcrawler.com). All of the sensors
we sell include BASIC Stamp program examples which you could readily adapt to the SG5/6 robotic arm.
Great resources for electronics can be found at Mouser www.mouser.com and Digikey
(www.digikey.com). Batteries and chargers can be found at as well as an optional power supply for the
SG5/6-UT arm can be found on the Crustcrawler web site.
Support for your SG5/6 arm, should you need it, is as simple as and e-mail (support@crustcrawler.com) or
phone call away. We have also provided a web forum for each of our product categories if you would like
to ask a question or share information about your robotics project.
The CrustCrawler team assures you that when you successfully complete the SG5/6 robotic arm you’re in
for an exciting series of robotic projects that you will find highly rewarding. Our office staff has
customized the SG5/6 robotic arm by adding, cameras, ultrasonic sensors, pressure sensors and infrared
detectors to make it a truly interactive platform. We are sure that you will find our SG5/6 series robotic
arms to be a truly expandable and functional robotic kit.
Chapter 1: Preparing to Assemble the SG5/6 robotic arm · Page 1
Chapter #1: Preparing to Assemble the SG5/6 Robotic Arm
REQUIRED TOOLS
The following tools will be required to build your SG5/6 robotic arm:

Phillips screwdriver
Drill
1/8” drill bit
Small adjustable crescent wrench or socket set
Wire cutters
A small amount of white grease or equivalent
SG5/6 ROBOTIC ARM FULL KIT INVENTORY
The SG5/6 base kit contains the following components:
Electronics\Software:

SG5 - (3) HiTec HS-475 HB Servos, (1) HS-805 BB servo, HS-645MG
SG6 - (3) HiTec HS-475 HB Servos, (1) HS-805 BB servo, (1) HS-225 MG, HS-645MG
Servo Wire Extensions – (2) 12” , (2) 6”
(1) SPST switch
(1) 6V – 4 Amp power supply (Full kit only)
Aluminum Parts:

(1) Board Holder
(1) Pivot Box
(1) Lower Servo Pivot table
(1) Upper Pivot Table
(2) Servo Table Braces
(1) Servo Pivot Brace
(1) Pem Stud Bicep
(1) Servo Bicep
(1) Pem Stud Forearm
(1) Servo Forearm
(1) Palm Bracket
(2) Left Hand Grippers
(2) Right Hand Grippers
(4) Flat Braces
(1) Gear Brace
(1) Servo Gear Brace
(1) Sensor Bracket
Page 2 · SG5/6 robotic arm Kit

(1) Lower arm brace
(1) Upper Arm Brace
Nuts, Bolts, Washers Screws & Spacers

(4) #2 nuts
(4) #2 lock washers
(4) #2 -5/16”screws
(35) #4 washers
(13) #4 -1/2” screws
(12) #4 –3/8” screws
(26) #4 - ¼” screws
(4) #4 – 1” screws
(1) #4 – 5/8” screw
(3) #4 – 5/16” screw
(19) #4 nuts
(23) #4 lock nuts
(19) #4 lock washers
(14) #4 ¼” nylon spacers
(4) #4 5/16” nylon spacers
(8) #4 3/16 nylon spacers
(14) #6 –3/8” screws
(1) #6 ½” Screw
(8) #6 lock nuts
(8) #6 nuts
(8) #6 lock washers
(1) #6 washer
(6) ¼” SAE flat washers
(4) Support Knobs
Miscellaneous

(1) SG5/6 robotic arm Manual
(10) Cable ties
(1) Long Retention Spring
(1) Short Retention Spring
(2) 60 tooth Gear Sets
(4) Rubber Bumpers
(2) Gripper Padding
Chapter 1: Preparing to Assemble the SG5/6 robotic arm · Page 3
Source Code from the CrustCrawler Web Site (www.crustcrawler.com)
SG5/6 Robotic Arm Source Code
The CrustCrawler web site and the SG5/6 robotic arm page contains sample BS2P24-IC source code, this
installation guide and additional pictures of the SG5/6 robotic arm to aid you during the construction
process.
Projects and Accessories are available from the CrustCrawler web site
(www.CrustCrawler.com)
SG5/6 Robotic Arm Projects / Accessories
Projects that include updated code; electronics and hardware accessories are always being added to the
Crustcrawler web site. Check with our site often for the latest updates.
ADDITIONAL PARTS YOU NEED TO SUPPLY
Like other hobby kits, completing the SG5/6 robotic arm kit requires additional parts that you will need to
supply. This hardware is not included in the SG5/6 kit because it would only drive the cost higher as most
of these items are readily available at hobby stores or www.crustcrawler.com.
•
Zip-ties of the smaller sizes are very useful for securing wires in a tidy fashion. Approximate
cost is probably a few dollars. Available from any hardware store. (10) Zip ties have been
included in your kit.
•
Robot sensors The SG5/6 robotic arm has been designed for sensor integration. Selecting the
appropriate sensor is left up to you, our customer. CrustCrawler (www.crustcrawler.com) has
many acceptable add-on sensors for the SG5/6. Additional sensors can be purchased from
Parallax (www.parallax.com).
•
Light grease A small amount of white grease or it’s equivalent is helpful when assembling the
gripper portion of the arm and the base.
Chapter 2: Pre-Assembly Tips · Page 5
Chapter #2: Pre-Assembly Tips
PAY ATTENTION TO DETAILS
•
Work in a well lit, clean environment with lots of workspace
•
Organize your nuts, bolts and screws so that you have each specific size of lock-nuts, screws, washers
in the same group and are easily within reach.
•
Take your time! The SG5/6 robotic arm kit is a precision made product and requires all parts to be
assembled in the exact order as described in this installation manual.
•
The average time to construct a kit is between 3 to 6 hrs..
•
During the construction process, please refer to the reference pictures in this guide frequently. Refer to
and study the pictures and close-up diagrams carefully before starting the construction of any part of
your kit.
•
Always note the orientation and direction of screws and aluminum parts and which side of your
SG5/6 robotic arm you are constructing! It absolutely makes a difference!
PREPARING THE SERVOS
•
Remove the aluminum body parts from their protective bags and lay them loosely in their respective
groups on your work surface.
•
Gather all (6) servos for the SG6 or (5) of SG5/6 robotic arm servos and remove the servo horn and
screw, setting them aside in a safe place.
Note: (1) of your Hitec HS-475HB servos will not contain a round servo horn. Use this
servo for the palm assembly as it requires a pre-assembled gear head contained in your
kit.
•
Remove the riser tabs from all of the servos (figure 1). The removal of this plastic riser will allow the
servo to sit flush against the servo holder. These servos will be installed in the next few steps of the
construction process. The larger HS 805 BB servo may require some filing of the servo tab after it is
cut as it is considerably thicker than the rest of the servos.
Figure 1
Chapter 2: Pre-Assembly Tips · Page 7
Chapter #3: Building The Base
MOUNTING THE SERVO TO THE PIVOT BOX
#6–3/8”
screws
#6– nylon
lock nuts
Figure 2 – Mounting the servo
1. Using (2) #6 – 3/8” screws and lock nuts, secure the HiTec HS475HB servo to the pivot box as
shown in figure 2. Ensure that the servo is mounted so that the servo horn mount is in the center
of the pivot box as shown in figure 3. Thread the servo wire thru the center slot of the pivot box.
Servo
Wire
Figure 3
2. Using (2) #4 3/8” screws, washers, lock washers and nuts, install the board holder to the pivot box
as shown in figure 4. Before tightening the #4 screws, install the (4) rubber bumpers to the bottom
of the board holder and (if necessary) adjust the board holder so that it sits flush with your work
surface (figure 6). Tighten the #4 – 3/8” screws.
#4–3/8”
screws
Mounting
Slots
Figure 4
Board
Holder
Chapter #2: Program the SG5/6 robotic arm · Page 9
Figure 5
Rubber
Bumpers
3. Using (4) 5/16” #4 nylon spacers and washers, install the support knobs to the (4) integrated pem
nut holes located at the top of the pivot box as shown in figure 6. The #4 washers can be placed
on top of the 5/16” spacer before installing the support knob. Hand tighten the support knobs. Do
not use pliers or other tools to tighten the support knobs.
Support
Knobs
5/16” #4 Nylon
Spacer &
washer
Figure 6
Figure 7 – The completed pivot box assembly
4. Add a liberal amount of grease to the top of the support knobs as shown in figure 7. Temporarily
set the pivot box assembly to the side of your work area.
5. Using a 1/8” drill bit, drill out the holes of the servo horn that match the holes in the lower servo
pivot table as shown in figure 8.
Figure 8
6. Using (4) 3/8” screws and lock nuts, mount the servo horn to the lower servo pivot table as shown
in figure 9. The servo horn should be mounted on the pem nut side of the lower pivot table (see
figure 10).
#4 Lock
Nuts
Servo Horn
3/8” #4
Screws
Figure 9
7. Mount the lower servo pivot table onto the servo of the pivot box assembly and turn the lower
pivot table clockwise and counter-clockwise to spread the grease evenly to the bottom of the pivot
table as shown in figure 10.
Figure 10
8. Remove the lower servo pivot table and spread grease with your finger onto any spot formed by
the circle of grease that may appear thin or uneven as shown in figure 11. Re-apply a small
amount of grease to the tops of the support knobs. Re-install the servo pivot table to the pivot box.
Do not secure the servo pivot table with the servo screw at this time.
Figure 11
9. Temporarily install the lower pivot table to the servo box with one of the pem nuts of the lower
pivot table aligned with the center slot (located on the board holder side) of the pivot box. Rotate
and orient the lower pivot table so that it can rotate evenly 90 degrees in either direction from the
center slot as shown in figure 12.
Rotate 90 degrees
counter clockwise
Pem nut – center
point
Figure 12
Rotate 90
Degrees
clockwise
10. Once the lower pivot table is oriented correctly secure the lower pivot table with the stock servo
screw. DO NOT over-tighten the servo screw. Tighten the servo screw to the point that the round
pivot table can turn freely but is not loose enough in that it does not make contact with all of the
(4) pivot points.
11. Using (8) #4 ½” screws, nuts and 3/16” nylon spacers, install the Parallax micro controller board,
basic stamp, Parallax Servo Controller (PSC), (1) SPST switch (optional) and the male power
supply receptacle (if you purchased the optional 6v, 4 amp power supply – see figure 13b) to the
board holder. Your micro controller board and servo controller should be oriented as shown in
figure 13. The board holder was made for all of the Parallax micro controller boards and the PSC
servo controller. If you have a micro controller board that does not fit the slots on the board
holder, simply drill out the appropriate holds with a 1/8” drill bit.
Note: We have provided (1) single pole, single throw (spst) switch for your convenience.
Power for the servos can be routed directly to the PSC controller or through the switch and
then to the PSC. The switch is optional and is not required for arm operation.
Figure 13
Figure 13b
Connect the
power supply
wires to the PSC
Chapter #4: Building the Bicep’s
12. Using (3) #4 screws, lock washers and nuts, install the servo bracket to the upper pivot table as
shown in figures 14. Ensure that the center hole of the servo bracket matches the center hole of
the upper pivot table before tightening the #6 screws.
Servo
Bracket
#4 – 3/8”
Screw
#4 – 3/8”
Screw
#4 – 3/8”
Screw
Figure 14 – Servo bracket assembly & orientation
Note: For the next step, use the servo horn from the Hitec HS-645MG servo.
13. Using a 1/8” drill bit, drill out the center hole of the 3-hole pattern on the round servo arm for (2)
servo horns (1 horn from the 645 servo and 1 horn from the 475 servo) as shown in figure 15. To
make drilling easier, use an unused servo and attach the servo horn to the servo before drilling.
Figure 15
14. Using (2) ¼” screws and lock nuts, install the servo horn to the right bicep as shown in figures 16
and 17.
Figure 16 – Right bicep
Figure 17
15. Using (1) #6 – 9/16” screw, (3) ¼”SAE washers and (1) lock nut, install the right bicep to the pem
spacer on the servo bracket as shown in figure 18 and 19. Tighten the #6 lock not just enough so
that there is no play or rattle in the assembly but not too tight that the arms movement is stiff.
Ideally, the arm should just barely stand by itself without falling. The servo horn on the pem stud
bicep should be oriented so that it is facing the inside of the servo bracket.
¼” SAE
washer
#6 lock
nut
Figure 18
Note: Ensure that you align the (2) ¼” SAE flat washers on the inside of the assembly to ensure that they
seat properly on the pem spacer by supporting them with your finger when tightening the assembly.
Failure to do so will result in the assembly being loose.
(2) ¼” SAE
washers
#6 – 9/16”
Screw
Figure 19
16. Using a 1/8” drill bit, drill out any (2) opposite holes located on the inner portion of the servo
horn as shown in figure 20. Once the drilling is complete, remove the servo horn from the servo.
Re-install the servo screw to the servo to ensure it does not become misplaced.
Figure 20
Note: Be sure to rotate the servo arm until the holes line up with the holes in the left pem stud bicep.
Although the holes appear to be the same configuration on the servo arm they are not.
17. Using (3) #6 – 3/8” screws, lock washers and nuts, install the HiTec 805BB servo to the servo
bracket as shown in figure 20.
#6 – 3/8”
Screws
#6 – 3/8”
Screw
Figure 21 – HiTec 805BB Servo Installation
18. Using (2) #4 – 3/8” screws and lock nuts, install the servo arm to the inside of the bend in the left
pem stud bicep as shown in figure 22 and 23.
Figure 22
Figure 23
19. The completed assembly should look like figure 24. Before installing the servo horn screw, ensure
that the left pem stud bicep can rotate 90 degrees forward and backward from a perpendicular
position.
Figure 24
20. Place (3) - #4 ¼” nylon spacers on top of the pem nut openings on the lower pivot table as shown
in figure 25.
#4 – 1/4”
Nylon Spacer
Figure 25
21. Using (3) ½” #4 screws, install the assembly from figure 24 to the lower pivot table as shown in
figure 26.
1/2” #4 screw
1/4” #4 nylon
spacer
Figure 26

Refer to figure 27 to ensure accurate assembly.
Figure 27
Chapter #6: Constructing the Forearm Assembly
1. Using (2) ¼” #4 screws and lock nuts, install the servo pivot brace to the pem stud forearm
ensuring that the large center holes are aligned as shown in figure 28. Ensure to install the
servo pivot brace with the small hole located towards the end of the arm as shown in figure 28
and 29.
1/4” #4 screws
Ensure Hole
Alignment
Single
Hole
#4 lock nuts
Figure 28
Figure 289
2. Using a 5/16” #4 screw, washer, lock washer and nut, install the short retention spring to the
servo pivot brace. Ensure that the washer clears the top of the springs coil and sits flush with
the springs loop as shown in figure 30 and 31.
#4 nut
#4 lock
washer
#4 washer
5/16” #4
screw
Figure 30
Short Retention Spring
Figure 31
3. Install (2) #4 SAE flat washers to the pem stud bicep as shown in figure 32. Apply grease to
the outside of the last washer. Ensure to install the washers so the flat sides of the washers will
be touching the aluminum arm components.
#4 SAE washers
Pem stud
Figure 32
4. Using (1) 9/16” #6 screw, washer and lock nut, secure the assembly from figure 31 to the pem
stud as shown in figure 33. Do not over tighten the 9/16” screw and lock nut. The assembly
should be tightened enough so that there is no play in the assembly but loose enough so the
arm can rotate up and down freely.
Pem Stud
9/16” #6
Screw
#6
Washer
Figure 33

The completed assembly.
Figure 34 – right side
Figure 35 – left side
5. Using a 1/8” drill bit, drill out the center hole of the 3-hole pattern on the servo arm as shown
in figure 36.
Figure 36
6. Using (2) ¼” #4 screws and lock nuts, install the servo arm to the inside of the servo forearm
as shown in figure 37. (Flat side of the servo arm mounted to the servo forearm)
¼” #4
Screws
#4 lock
nuts
Figure 297
7. Using (2) #6 – 3/8” screws, lock washers and nuts, install the HiTec HS-645MG servo to the
servo pivot brace and the servo forearm as shown in figure 38 and 39.
Warning! Failure to mount the servo on top of the servo pivot brace will result in the
rest of the assembly not fitting together correctly
#6 Screws
#6 lock
washer
#6 nut
Servo Forearm
Servo Pivot Brace
Figure 308
Figure 319
8. Once the assembly is complete, install the completed assembly from figure 39 into the servo
horn of the pem stud bicep assembly and ensure that the forearm assembly can rotate freely
forward and backward as indicated in figure 40 and 41 from the 90-degree position (straight
up in the air). Secure the servo with the stock servo screw.
Free Rotation
Figure 40
Figure 41
Chapter #7 – Constructing the Gripper Assembly
1. Using (2) ¼” #4 screws, assemble the (2) gripper assembly’s as shown in figure 42.
¼” #4 Screws
Figure 42
2. Install the 1/16” rubber padding to the insides of the gripper assemblies. Be sure to cut out the
slots on the insides of the grippers. Also, ensure that you cut as close to the edge of the grippers as
possible to obtain a clean finish. Place the gripper assemblies to the side of your work area.
Tip: To ensure a clean cut of the rubber padding, a small hobby cutter is the best tool.
3. Using (2) 3/8” #6 screws and lock nuts, install the HiTec HS475HB servo to the palm as shown in
figure 43. Do not tighten the #6 screws completely as this will be completed later in the construction
process.
Palm
3/8” #6 Screws
#6 Lock Nut
Figure 43
• Complete steps 4 & 5 for the SG5 wrist assembly
• Complete steps 6 thru 11 for the SG6 wrist assembly
4. Using (2) ¼” #4 screws and lock nuts, install the servo pivot brace to the palm assembly as shown
in figure 44. Ensure that the vertical slot of the palm aligns with the slot in the servo brace as
shown in figure 44 and 45.
#4 Lock
Nuts
Servo
Brace
Assure
Alignment
¼” #4
Screws
Figure 44
Figure 45
5. Using (2) #6 screws, lock washers and nuts, install a HiTec HS-475 servo to the servo pivot as
shown in figure 46. (Note: Figure 46 depicts (4) #6 screws, lock washers and nuts. Only install (2)
#6 screws diagonal from each other).
Warning! Failure to mount the servo on top of the servo pivot brace will result in the
rest of the assembly not fitting together correctly
#6 nuts
3/8” #6
Screws
#6 lock
washers
Figure 46
6. Using a 1/8” drill bit, drill out the holes shown in figure 47 of the HiTec HS225 MG servo.
Figure 47
7. Using (2) #4, 5/16” screws, lock washers and nuts, install the servo horn to the palm as shown in
figures 48 and 49.
Figure 49
Figure 48
8. Using (2) #6, 3/8” screws, lock washers and nuts, install the HiTec HS-225MG servo to the servo
brace as shown in figure 50. Please ensure that you note the orientation of the servo when
mounting it to the servo brace.
Figure 50
9. Install the HiTec HS-225MG servo to the palm as shown in figure 51 and 52. Ensure that the
servo can rotate equally from center in both directions before proceeding to the next step.
Figure 51
Figure 52 - Side view
10. Using (1) #4 washer and lock washer, install the servo arm screw as shown in figure 53. The
washer should be installed first followed by the lock washer and then the screw.
Figure 53
11. Using (4) #6 – 3/8” screws, lock washers and nuts, install a HiTec HS 475 servo to the palm
and (1) HiTec HS475 servo to the servo bracket as depicted in steps 3 and 5 of this section.
The completed assembly should look like figure 54 and 55.
Figure 54
Figure 55
12. Using (2) #2 lock washers and nuts, install the servo arm to the pre-assembled 60-tooth gear
and the servo gear brace as shown in figure 56. (Use the servo brace that has the slightly
larger, offset, center hole in the middle of the 3 hole pattern). Repeat the exact assembly
sequence for the opposite gear brace.
Servo Gear
Brace
#2 nuts
#2 lock
washers
Gear
Servo arm
5/16” #2 Screws
Figure 56
13. Install the servo gear brace assembly (The one with the larger, slightly offset center hole of the
3-hole pattern) to the palm servo as shown in figure 57. Ensure that the servo gear brace
assembly can swing freely from the far, upper left corner of the palm to the point of the palm
before securing it with the stock servo screw as illustrated in figure 57, 58 and 59.
Figure 57
Figure 58
Figure 59
14. Using (1) 1” #4 screw, (2) washers, (1) lock nut and (1) ¼” nylon spacer, install the gear brace
assembly to the palm assembly as shown in figure 60. Ensure that the gear brace assembly is
aligned (“in line”) with the opposite servo gear brace assembly (see figure 61). Tighten the 1”
#4 screw enough so that there is no “play” in the assembly yet loose enough to the assembly
can be turned by hand.
1” #4 Screw
#4 Washer
¼”#4 nylon spacer
#4 Washers
#4 lock nut
Figure 60
Tip: Applying a small amount of grease between the washers and the aluminum parts of the
gripper assembly will help to ensure smooth, friction free operation.
Figure 61
Note: Move the palm servo to the right to ensure that
the gear trains engage fully and then tighten the
palm servos (2) #6 screws .
15. Using (1) 3/8” #4 screw, (2) washers and (1) lock nut, install the gripper assemblies to the gear
brace assemblies as shown in figure 62 and 63. Tighten the lock nut just enough so there is no
play in the assembly but loose enough so the assembly can be moved by hand.
3/8” #4 screw
#4 Washers
#4 lock
nut
Gripper
assembly
Figure 62
Figure 63
16. Using (1) 1/2” #4 screw, (4) washers and (1) lock nut , install the flat braces as shown in
figure 64 and 65. Once again, tighten the lock nut just enough so there is no play in the
assembly but loose enough so the assembly can be moved easily by hand.
1/2” #4 Screw
Flat Braces
#4 Washers
#4 Lock Nut
Figure 64\
Figure 65
•
Refer to figure 66 after this step is complete.
Figure 66
17. Using (1) 1” #4 screw, (2) washers, (2) ¼” nylon spacers and (1) lock nut, install the flat
braces to the inside of the palm as shown in figure 67.
Note: The image below has been stripped of the prior assembly sequences for greater clarity.
1” #4 Screw
¼” #4 Nylon Spacers
#4 Washers
#4 Lock Nut
Figure 67
18. Perform the same assembly routine as outlined in the previous step for the opposite side of the
gripper assembly as shown in figure 68 and 69.
Figure 68
Figure 69
19. Using (2) ¼” #4 screws and lock nuts, install the sensor bracket to the gripper assembly as
shown in figure 70.
Sensor Bracket
#4 Lock Nut
¼” #4 Screw
Figure 70
•
Refer to the next 6 images as a reference for the gripper assembly.
Figure 71 – SG5 Gripper
Figure 72
Figure 73
Figure 74 - Open gripper
Figure 75 - Closed Gripper
Note: If the gripper ends do not align as shown in figure 75, simply loosen the palm servo, slide the servo
to the left to disengage the gear assembly and rotate one or both of the gear sets to align the gripper
properly.
Figure 76
Chapter #8 – Installing the Gripper Assembly to the
Forearm Assembly
1. Install (1) ¼” SAE Flat washer to the pem stud of the forearm assembly as shown in figure 77.
Apply a small amount of lubricant over the entire surface of the outside of the washer. The flat
part of the washer should be flush against the forearm.
¼” SAE Flat Washer
Figure 77
2. Remove the forearm brace and install the gripper assembly to the forearm assembly. Ensure that
the gripper assembly can rotate freely at least 45 degrees in either direction from the straight
position (level with the forearm) before securing the assembly with the stock servo screw as
shown in figure 78.
Pem Stud
Forearm Brace
Stock Servo Screw
Figure 78
•
Install the small forearm brace.
Chapter #9 – Retention Spring Installation and Servo Wire
Routing
1. Adjust the lower arm brace so that it is 1” away from the servo pivot brace as shown in figure 79.
Lay the arm assembly flat before measuring. Installing the longer spring is optional but is required
for lifting heavy loads or if you are using the arm continuously for long periods of time.
1” separation
Figure 79
2. Using (1) 1.5” #4 screw, (1) washer and (4) ¼” nylon spacers , secure the long retention spring to
the upper pivot table as shown in figure 80. Ensure that the retention spring is aligned with the
bicep assembly before tightening.
Figure 80
3. Using (1) #4- 5/8” screw, washer, lock washer, nut and ¼” nylon spacer, install the other end of
the long retention spring to the lower arm brace as shown in figure 81. When tightening the screw,
ensure that the spring coil is not twisted to the left or to the right of center of the screw.
Figure 81
4. Using (1) 5/16” #4 screw, washer and lock washer and nut, secure the small retention spring to the
lower arm brace using the opposite hole as shown in figure 82. When tightening the screw,
ensure that the spring coil is not twisted to the left or to the right of center of the screw. This
spring is not optional and is required for proper arm operation. This spring helps to cancel the
forward weight of the arm and allow the elbow servo to run cool and to its maximum lifting
capability.
Figure 82
5. Route the servo wires through the hole in the upper and lower arm braces. Before securing the
servo wires with the black tie wraps, ensure to rotate the arm joints through their normal
movement to ensure wire clearance. Laying the arm flat is a good way to ensure proper servo wire
length before fastening.
6. After the servo wires have been routed, use the (2) 12” servo wire extensions and the (2) 6” servo
wire extensions to ensure that the stock servo wires can reach the Parallax Servo Controller
(figure 83). The servo wire connections to the Parallax Servo Controller will be illustrated in the
last few pages of this guide.
Figure 83
SG5/6 Robotic Arm Safety and Operational Tips – Please
Read!

ALWAYS secure the SG5/6 robotic arm to a solid platform before operating the unit (use the (3)
pivot box tabs to secure the arm to a solid platform).

ALWAYS stay clear of the robotic arm when you are programming and operating the unit. A 3
foot diameter circle away from the arm is ideal.

When turning off the robotic arm, always ensure the arm is either held with your hand or that
the arm is laying flat across the board holder first (via your program) before power is
removed .

Always use a 5v – 6v power pack. Using more voltage than the servo’s require on the SG5/6 can
result in servo overheating and failure. Regulated 5V – 6V power is ideal for any robot using
servos. A regulated 5v to 6v power supply or a voltage regulator rated at 5v, 4.0 amps is ideal.
CrustCrawler sells 6v, 4 amp regulated power supplies for the SG5/6 series of arms. Check our
web site for details.

When operating the arm for the first time, always check the servos for overheating. Always
check the gripper servo to ensure that it is not hot. If it is, check the gripper mechanism for tight
screws as this is almost always the cause.

Ensure that you do not use a value in your program that has the gripper closed or open to the point
that the gripper hardware is at its limits. Constant torque on any servo will result in
overheating and eventual failure.

Never leave the SG5/6 arm in the forward position for a long period of time as the constant
weight of the arm on the shoulder servo will overheat the servo and lead to servo failure (figure
84 and 85). When the arm is “parked” or resting during operation, the shoulder of the arm should
be as vertical as possible and the elbow servo should not be pulling against the spring.

Use the documentation that came with the Parallax BOE and the Parallax Servo Controller to
ensure the correct connection for these (2) components. Also, use the diagram provided on the last
several pages as a guide.

Never use power from the Parallax Board of education to power the servos. Always use a
separate power supply or battery that has a minimum rating of 5 -6 volts and can provide at least 4
amps of current. Failure to do so will result in erratic servo performance.
Figure 84 – Incorrect parking
Figure 85 – Correct Parking
Board of Education and Parallax Servo Controller
Connections
Alkaline Battery
Powercell
The following diagram depicts typical connection between the Parallax Board of Education (BOE) and the
Parallax Servo Controller for the SG5 and SG6 series of robotic arms. Use figure 87 on the next page for
servo specific connections to PSC.
P15
15 14 Vdd 13 12
6-9VDC
9 Vdc
Battery
Red
Black
X4
Pwr
STA
MPS
in
CLA
SS
TM
1
Sout
Sin
ATN
Vss
P0
P1
P2
P3
P4
P5
P6
P7
U1
Vin
Vss
Rst
Vdd
P15
P14
P13
P12
P11
P10
P9
P8
Vss
P1
P3
P5
P7
P9
P11
P13
P15
Vin
Vss
P0
P2
P4
P6
P8
P10
P12
P14
Vdd
X1
Reset
Vin
Vss
X3
P15
P14
P13
P12
P11
P10
P9
P8
P7
P6
P5
P4
P3
P2
P1
P0
X2
0 1 2
www.parallax.com/sic
Vdd
X5
+
Board of Education
Rev C
© 2000-2003
+
Serial In
Rev B
- +S
S+ Ch15
Ch13
Ch11
Ch9
Ch7
Ch5
Ch3
Ch1
Vertical
Ch14
Ch12
Ch10
Ch8
Ch6
Ch4
Ch2
Ch0
Horizontal
© 2004
7.5 VDC max
H
F
D
B
Black
A
C
E
G
Red
Battery 3000 NiMH
Figure 86 - Typical servo / battery connections
•
The 9v battery that is used for the Parallax Board of education can be replaced with our 9v wall
mounted power supply.
•
The 3000 NiMH battery can be replaced with our 6v, 4amp power supply with the included barrel
connector in our full kit option.
•
Ignore the “horizontal” and “vertical” markings above the servos in the diagram above.
•
For the SG5 there will only be (5) servos connected to the PSC (channels 0 – 4), for the SG6 there
will be (6) servos connected to the PSC (channels 0 – 5).
PSC Ch4
PSC Ch3
PSC Ch5
PSC Ch2
PSC Ch1
PSC Ch0
Figure 87 – SG6 – PSC Servo Connections