Assemble posey strut
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[edit] parts
you will need:
- ABS plastic hub shell
- socky board
- socky battery board
- 4 socky led boards
- ribbon cable
- 4 straight 1x7 2mm male headers
- 6 right angle 2x6 2mm male headers
- 22 ir leds
[edit] fix version 0.3 socky board
if you have version 0.3 of the socky board there are a couple of misrouted traces that need to be fixed to be able to use all 22 i/o pins:
In the picture above, the two red lines show where to cut the blue traces on the back of the board, and the two green lines show where to run green wires between the vias.
[edit] fix version 0.4 socky battery board
if you have a version 0.4 battery board there are several fixes that need to be made to the board
1) cut shorted traces and add green wire:
In the picture above, the red lines in the image show where to cut the traces, and the green line shows where to run a green wire between the vias.
2) Remove battery header and solder battery and power connector directly to board. The battery connector is the white right-angle shrouded header. The people I bought the batteries from sent me the wrong connectors, so I have just been soldering the battery to the board instead. I remove the header, and solder some solid wire or the cut-off posts of an led into the holes the header was soldered to. I leave the wire sticking out on both sides, and solder the battery to one side and the power connector (with some ribbon cable) to the other. Make sure to get the polarity right!
3) remove the two 1x2 2mm female pin headers as they do not fit inside the strut.
4) solder ribbon cable onto the power switch and green led, and then solder the power switch and led directly to the board where the two-pin headers were before.
[edit] assemble circuit boards
plug socky battery board into socky board
[edit] assemble led boards
each strut has four led boards, a bottom board with 5 leds (B5), a top board with 5 leds (T5) and a bottom and top board with 6 leds each (B6 and T6).
1) cut posts off of 22 ir leds just below where post widens
2) cut 22 45mm 2-wire pieces of ribbon cable and solder to the 22 ir leds
3) solder leds to boards as shown in the diagram below. make sure to get the polarity right!
[edit] build led cable assembly
1) cut four 120mm lengths of ribbon cable, two with 6 wires for the 5 led boards, and two with 7 wires for the 6 led boards.
2) solder the four ribbon cables to four 1x7 2mm male headers. make sure the wires of the 6-wire are hooked up to the right pins!
3) solder the other ends of the four cables to 6 2x6 right-angle 2mm male headers as shown below:
make sure the headers are oriented so that the board will fit into the plastic shell, the battery bracket has to fit over the avr microprocessor.
[edit] stuff components into plastic shell
1) stuff leds into sockets and gently slide led boards into slots
2) screw nut onto power connector to attach it to plastic shell.
3) gently snap power switch into mounting bracket
4) stuff green led into hole
5) snap battery into mounting bracket
6) attach cable assembly to led boards and socky board
7) use #4 round head sheet metal screws and nylon spacers to mount socky board and battery board.
8) carve away area of top of plastic shell that hits corner of socky board
9) gently slide top of plastic shell onto bottom and use #4 wood screws to hold them together
[edit] test new strut
1) does the power light come on when you turn it on?
2) run sensor_demon_tester.py with a strut to check that the leds are hooked up in the order shown here:
