dome

Disaster, Recocery and moving along…

Last week, I took R2 out to a gaming/cosplay convention in Uppsala, Birdie Expo!

Birdie is also one of very gracious sponsors of the VERY nice R2 Builders backdrop we (now) have!

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Anyway, day 1 went by well, I managed to get some time in hooking up a servo, rerouting some cables (the quick and dirty version) and doing some code on both my receiver and the new arduino I placed inside R2.

Since I was doing most of this on the fly, with a lot less tools that I usually use, the result was… well .. let’s call it “less than optimal”.

Sure, I got R2 working GREAT with both the new code and the new panel and some of the extra tidbits in it (still not finished with the code, but that will be done at a later time), but .. the results are quite horrible.

The insides of my R2 body now look like this!

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The extra amp, speakers, arduino and servo, without any properly done cabling at all, has turned my once so tidy R2 inside to a gigantic web!

So what was the results? .. well … this!

So, end user result is great, and I’m really happy. It is also the FIRST motorized servo in R2 I’ve done code for, so it marked a milestone!

For well over a year, I’ve had servos in the dome hooked up with no place to go. Now, this will change..

Second day of the Expo started out great.

I thought I’d get some time doing some tweaks in the control board when times were slow, but after a quick update, something went terribly, TERRIBLY wrong!

R2 started jerking, moving by himself and seemed really weird!

A little debugging told me that the communication between the bluetooth wireless Wii Nunchuck I was using, and my controller board had gone bananas. Instead of receiving real world values, it started receiving random signals.

Turns out that the old libraries used (third party) had not been upgraded in the past 3.5 years, and the later versions of arduino seemed to rupture something. (I did try and reinstall an old version to no avail).

So, I had to sit down and focus and see if I could fix the issue.

It ended up with me programming an arduino library for the nunchuck myself from scratch. I had no idea how or what to do when starting out.

About two hours later, R2 is back and moving again! PHEW!

Good thing though, is that now I can throw out the buggy code, and maybe even get more third party nunchucks working with better resolution!

Back at home after the ordeal, I’ve spent a few evenings looking in to the updated controller code, and will soon move over to the whole new branch of code I’ve written and improved upon from the original R-Series code to various contributions form other people.

Not wanting to sit and just do coding, I decided to get the hooked up servos in the dome moving.

I decided to not use the small Adafruit breakout board for 16 servos that I had, mostly because I cannot detach the servos at will, like I can with normal Arduino coding.

Said and done, I found a Servo shield at a local hobby place, bought it, took it home, only to realize that it was the shield version of the same Adafruit PWM board.

Now, that board could work great, if only I knew how to detach a servo in it, and unfortunately I don’t.

Instead, I purchased an empty shield and did some soldering. An hour or so later it was time to make the cables for it (which is a really fidgety job that takes way longer than people think, cutting, peeling, crimping, removing bad crimps, peeling, crimping again, realize it is not sitting tight, remove the second bad crimp and make a third one… and so on.

Once that was in the head, I started hooking things up and got really weird results from the first servo. First servo alone. It wasn’t supposed to be doing anything… yet.

I removed all code that would make any servo move, and still I got really weird results from a servo. Why? what’s going on?

I pulled everything out again and started writing from scratch… turns out that after a bit of googling on what I found, pins 0 and 1 on the Arduino are earmarked for Serial connection, so you have to disable the serial in order for them to work as a normal pin….

Once I found that out, I managed to get a sketch going, and started setting max and min values on the servos.

Not having a lot of time, I did not have time to investigate why one of the servos are not moving. The pie panel not moving in the video is not moving since the nut and bolt that was holding the piano wire that connects to the servo, fell out. Something to fix later on when I investigate why my servo on the 3rd panel doesn’t work.

Here’s a quick video I took after setting the max and min values. I’m not done yet by a long shot, but at least it is a start!

That’s all for now!

more updates next week!

By |2016-12-06T00:00:18+01:00May 19th, 2015|R2-D2|Comments Off on Disaster, Recocery and moving along…

New Dome Logics installed

As the avid reader might have noticed, a while ago, I decided to upgrade my logic displays in the droid from just standard LED’s to using fiber optics, something that was also used in the original droids.

I ran into an issue when I was almost all done, and part of the plastic bezel that held it all in place broke.

A new bezel was ordered, arrived quickly, and I then set out to reroute 96 new small fibre optic cables.

Here’s a video of what it looked like before upgrading. The LED’s blink and a little too fast, and it is really only white and blue LED’s going on and off.

The original droid used fibre optics connected to a colour wheel, so it more morphed in between white and blue. This is what it looks like now:

Much better, I think.

What’s your opinion?

By |2016-12-06T00:00:25+01:00March 21st, 2015|R2-D2|Comments Off on New Dome Logics installed

Domeworks, part II

On the 9th of April, I posted a lot about how I was fixing up my dome for the first time.

I have, now and then put up posts of more work, but nothing has been as groundbreaking as what I’ve done lately!

A little while ago, I put up a post about cutting up the panels in the dome, well this is partly that, and partly what I’ve done with the opened panels..

First off, I’ve had a surveillance camera laying about for a while that I got from a friend of mine, Magnus Bodin, and I wanted to put this inside R2’s head, so we can actually see what he sees. An “R2-Cam”, if you will! =)

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So, the camera will go behind R2’s “radar eye”. For those of you not well versed in Astromech terminology, this is where it goes:

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So, the place that looks like an eye, will literally become an eye. How imaginative!

First off, remove the surrounding blue aluminium radar eye housing, and expose the dome underneath. Please notice that I’ve added screws to the screw holes, since the dome is actually two domes inside each other, and I want to keep them as close to each other as possible when cutting through the almost 3 mm thick aluminium.

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I’ve tried to find the center of the circle as close as I can. In this case, it doesn’t matter if I’m not exact, as I have at least 5-6 mm on each side that I can be off, and it will still give more than enough opening inside the dome, yet still be totally invisible from the outside.

Let’s start with just using a punch to make a serious dent in this, so my drill can have something to cling on to!

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Ok … no turning back now!

One small hole, followed by a larger, followed by an even larger hole, to act as pilot hole for my hole saw.

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Yes, it is made for drilling in wood, but really, all I need is a serious enough groove in the aluminium…

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…. and a serious groove, that is!

Next up, bring out the trusty dremel and start cutting slices in a cross-wise fashion..

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No, that is not the death star laser. I had to pause here for a while, as my dremel was on the verge of burning up. White smoke emerged from within, and it did not smell good. Once all slices have been cut proper, I started with the outer layer, bent the pieces outwards and after bending back and forth, they snapped right off, as planned.

Next step was the inner layer. I used the dremel to cut along the edge, and bend the inner layer inwards back and forth until they snapped. Follow that up with a sanding disc, and you’re left with…

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A gaping hole! Fortunately it is in the exact right place. Funny enough, when cutting with the dremel, I took great care not to slip and accidentally score the surface of the dome. Why didn’t I take the same care when sanding the edges? my sanding disc slipped…. but not a big issue. Easy enough to sand that area and work away the rough pieces until I got a smooth surface again…

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This is just a test fit with the camera inside. Since the camera is booting up, you see the amber light surrounding the lens, but without that, it should be fairly invisible. However, since the lens is see-through, I did not want anyone to be able to see any of the LED’s on the inside of the head, or use the eye as a device to peek into the droid.

So, I needed a half-round object. Did not have anything at home that worked. I tried cutting up an old christmas ornament, but it was way too fragile (even though it was plastic) and I had to  make my own ..

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… made from duct tape. (No, I didn’t have any black duct tape at home, only the silver kind… so I spray painted the inside!

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Now, since the camera is light gray, I decided it was best to paint hat as well…

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A quick look at the mounting system inside, with the blocking shield in place…

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So a new look from the outside, looks like this:

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So much for the radar eye! What else can one do in a day? .. well .. time to work on getting the servos in place for the dome panels, of course!

After some trial and error I have determined that some of the hinges needs straightening up, and since they are only glued in place with E-6000, I can absolutely move them.

I have 3d printed a block of plastic with a curved surface that matches the inside curve of the dome, and I’ve super-glued them to my servos, and then used a very high bond tape (120 kg draw per meter) to stick these to the insides of the dome. At first I was a bit worried that they might not be enough, but after having to reposition them slightly, I am no longer worried. took me 5 minutes with the help of a scalpel to be able to pry one of the servos loose!

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So, servos in place … time to connect them to a small servo board…

(powered by an arduino), add a bit of test code…

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The end result? … well … check for yourself!

 

 

 

By |2016-12-06T00:00:28+01:00January 14th, 2014|R2-D2|Comments Off on Domeworks, part II
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