MergedFile Assembly Manual

Assembly Manual

Dylan Brenneis

July 2017

i

Contents

Table of Figures ............................................................................................................................................ ii

1 Introduction ........................................................................................................................................... 2

2 Naming and Definitions ........................................................................................................................ 1

2.1 Digits ................................................................................................................................................... 1

4 Assembly Flowchart ............................................................................................................................. 5

5 Material Preparation .............................................................................................................................. 6

5.1 3D Printed Parts (17h 0m) .................................................................................................................. 6

5.2 Potentiometers (1h 45m) ..................................................................................................................... 7

5.3 FSRs (1h 0m) ...................................................................................................................................... 8

5.3.1 Fingertips ............................................................................................................................. 9

5.4 Screws (0h 45m) ................................................................................................................................. 9

6 Thumb Assembly (1h 0m) .................................................................................................................. 10

6.1 Part Assembly ................................................................................................................................... 10

6.2 Mounting to Palm ............................................................................................................................. 11

13 Wiring (1h 0m) ............................................................................................................................... 19

13.1 Testing............................................................................................................................................. 19

13.2 Full Implementation ........................................................................................................................ 20

14 Appendix A: Grip Pattern Template .................................................................................................. I

15 Appendix B: Servo Cover Template ................................................................................................ II

Table of Figures

Figure 1: Digit numbering ............................................................................................................................ 1

Figure 2: Joint names .................................................................................................................................... 1

Figure 3: Example part naming convention .................................................................................................. 1

Figure 4: Dorsal Palm post processing ......................................................................................................... 7

Figure 11: Thumb assembly diagram .......................................................................................................... 10

Figure 12: Assembled thumb prior to MC - P Geared Rotator installation, showing servo position ......... 10

Figure 13: Thumb mounted to dorsal palm ................................................................................................. 11

Figure 14: Index finger (D2) assembly diagram ......................................................................................... 11

Figure 15: Full Forward Position of servo .................................................................................................. 12

Figure 16: Zip-tie installed in servo spool .................................................................................................. 12

Figure 17: Servo spool installation on servo ............................................................................................... 13

Figure 18: Required cut for zip-tie .............................................................................................................. 13

Figure 19: Servo installation and finger tensioning complete, showing servo positions for right and left

hand ............................................................................................................................................................. 13

Figure 26: Finished breadboard hub ........................................................................................................... 16

Figure 27: Pinout for breadboard hub. Breadboard holes to the left of the green line correspond to sensor

signal connections; holes to the right correspond to servo motor command signals. Use this diagram as a

reference when connecting the wiring to ensure proper connection. .......................................................... 16

Figure 28: Installation of aluminum servo covers (left hand) ..................................................................... 17

Figure 29: USB Webcam installed in ventral palm (right hand) ................................................................ 17

Figure 30: Grip diagram .............................................................................................................................. 18

Figure 31: Test Setup Wiring ...................................................................................................................... 19

Figure 32: Full wiring diagram for individual finger potentiometer control .............................................. 20

Figure 33: Full wiring diagram ................................................................................................................... 21

instruction required to construct a fully functional HANDi Hand, and should also give the maker enough

flexibility to make alterations to the design as necessary to suit their own needs. Both left and right hand

versions are available. To contact the original designers, or to receive support for your build, please visit

BLINCdev.ca.

This assembly manual outlines all the information required to print and source parts, and assemble the

HANDi Hand as currently designed. The hand takes an estimated 30 hours to build.

2 Naming and Definitions

2.1 Digits

The digits are referred to by standard numbering, beginning with the

thumb as D1 (See Figure 1).

constructed first with a digit indicator (i.e. D2) followed by a joint

indicator D, I or P, indicating distal, intermediate, or proximal

respectively. Potentiometers are named for the joints that they

measure. The digit D0 refers to thumb rotation.

2.3 Finger Parts

Each phalanx of the finger is made up of multiple parts. The parts are named with convention in Figure 3:

by their function (pivot, main, lock, tip, etc).

4: Handedness indicator. R = Right Hand, L = Left Hand

3 Required Materials

3.1 3D Printed Parts

blincdev.ca in addition to the grouped parts in Table 1.

Table 1: 3D printed parts

3.3 Tools

A particular order of operations must be followed when assembling the hand, and is outlined in the

5.1 3D Printed Parts (17h 0m)

Print parts as specified in section 3.1 The parts are designed to involve as little post-processing as

possible; however a few things should be done.

1. Dorsal Palm: Remove print supports using needlenose pliers, then sand smooth using dremel tool

with sanding wheel. See Figure 4. The inside faces of the connections with the fingers should also

be sanded using 120 grit sandpaper, to ensure a smooth running fit.

5. Thread the zip-tie through the finger from the distal to

the proximal end, staying ventral to each of the joint

9 Breadboard Hub (3h 0m)

Creation of the breadboard hub is by far the most technically difficult and labor intensive operation in

assembling the HANDi Hand, and is not required to have a fully functional hand. The breadboard hub

reduces the number of wires leaving the hand from 60 to 22, which is important when interfacing with a

movable arm since a large bulk of wires will tend to bind and restrict motion of the arm. Work is

and cut/solder them together to obtain 4 clips

21).

4. Press-fit each of the receptacles into the bottom

of the printed breadboard, making sure no part of

any receptacle extends past the base of the

board.

5. Solder jumper wires between the power

receptacles and ground receptacles as in Figure

22.

6. Test the board for proper conductivity at each

receptacle. Adjust receptacle positioning if

necessary.

7. Superglue the molex connectors to the connector

9. Solder the power and ground connections to the header pins. Refer to Figure 27 to ensure power

and ground are soldered to the correct header pins.

appropriate receptacle pins as shown in Figure 25:

11. Cover and protect all connections using Sugru or

similar methods. See finished breadboard hub in

Figure 26.

10 Aluminum Servo Cover (0h 45m)

The servo covers are made of aluminum. They act as a heat

sink and reduce the tendency to overheat the servos, and as

well have less tendency to warp than the 3D printed plastic.

They can be cut from the aluminum sheet given in the Bill

Refer to Figure 28 for orientation of the servo covers for

installation.

11 Ventral Palm Cover; USB

Webcam (0h 20m)

The webcam used currently is a mini webcam from Seeed

Technology. Remove the PCB and lens from the camera

housing, and mount it to the ventral palm using the extra

small black screws that came with the HS-35HD servo

motors. Figure 29 shows the USB webcam mounted to the

ventral palm.

The USB cable from the camera will be routed out of

the wrist cavity via the USB wire channel noted earlier

hand)

12 Palm Grips (1h 15m)

To increase the friction on the palm, palm grips made of neoprene extra strength rubber are superglued to

the palm plate and the finger phalanxes. A template for the grips is found in Appendix A: Grip Pattern

Template. The locations for the grips can be found in Figure 30.

The radial palm grip should be glued to both the ventral palm and the dorsal palm, covering the seam.

Once glued in place, cut along the seam with a hobby knife to make the ventral palm removable again.

13 Wiring (1h 0m)

13.1 Testing

each degree of freedom), 5 position sensing potentiometers, 5 FSRs, 6 servos, and servo power switch.

This wiring setup is intended for use with the Arduino sketch Potentiometer_Control.ino.

The wiring diagram in Figure 33 outlines the complete wiring setup for 9 potentiometers, 5 FSRs, 6

servos, thumb joystick control, and servo power switch. This wiring setup is intended for use with the

The custom in-wrist breadboard removes a lot of the complications for wiring; if the sensors and servos

are connected to the breadboard hub as per Figure 27 on page 16, the circuit above will be created when

the following connections are made to the Arduino Mega (see Table 5):

Table 5: Pin connections to Arduino Mega