1. Electronic Case Assembly

Read each chapter before you start work. Catch confusing things early!

Always follow every step in order.

If a step is unclear, use the comment section below it to let us know.

Steps may be color coded and have matching colored symbols on the pictures. A single picture could have more than one symbol.

[3D] Electronic Case Package

Robot Electronics

Alan Keys

Flat Screw Driver

Needle Nose Pliers

Multimeter

Ferrule Crimper (optional)

Prepare the following components:

ABS Junction Box {380x260x105mm}

[3D] - 7E-plug wall adapter

Aviation GX16-8p Cable M/O (wire assembled and numbered)

USB-B M/F Panel Mount Extension

M3x10mm Screws (x3)

M3 Nylock Nuts (x5)

Unscrew the Wall Mount Nuts from each connectors

Each Connectors have 2 sets of 4pin wires soldered in this specific manner

The wires are cut to length as follows:

0 & 1 = 370mm & 370mm respectively

2 & 3 = 370mm & 270mm respectively

4 & 5 = 340mm & 310mm respectively

Not Labelled = Tool --> 190mm

Familiarize yourself with the panel. The back side has a lip and the front side is labelled with each connector.

Feed the Cables through the Wall Adapter as labelled. Make sure the long end of the cable ends up on the back side of the panel.

Tighten the Mounting Nut that was unscrewed from the previous step

Repeat the same process with the rest of the connectors

Be sure the alignment mark on the plug to be in the bottom center

USB Extension Cable comes with M3x10mm Philip Head Screws

Feed the USB Cable through the Case Wall Adapter

Use M3 Nylock Nut to secure USB Extension Cable in place

Only tighten the side furthest from the edge

Insert the Case Wall Adapter into the Case and secure its place using the M3x10mm Screws.

Use the M3 Nylock Nuts on the inside of the case but don't tighten it too much. Case wall Adapter should be able to slide along the wall

Prepare the following components:

Power Supply 24V-20A

Acrylic PSU Mounting Plate

Rocker Switch

M4x14mm Screws (x6)

M4 Hex Nuts (x8)

M4 Nylock Nuts (x2)

Make sure the Power Supply is set to the correct voltage, in Canada, we use 110V

Use two M4 Hex nuts per M4x14mm Screws as spacer on the Acrylic Mounting Plate

Align the PSU and the Acrylic Mounting Plate as shown in the figure exactly

Take a closer look on the Screw Terminal of PSU

Take a closer look on the "Half Moon" cut on the Plate

Flip the Acrylic Mounting Plate on to the PSU

DON'T tighten 1 screw all the way at a time, this will cause the plate to flex and cause it break

Insert the Rocker Switch into the Machined Case.

Some version of Rocker Switch has smaller mounting holes

if this is the case, use the M3x10mm Screws, Washers and Nylock Nuts

If not, use M4x14mm Screws and M4 Nylock Nuts

Secure the Rocker Switch with the fasteners

Notice the Soldering Patterns AND Length

18AWG Power Wires 65mm long

3 Wire Power Cable 365mm long

Secure the Power Cable to the PSU Screw Terminals

Test the Rocker Switch and PSU by connecting the Power Plug and turning the Switch ON

Be careful to NOT touch the screw terminals with your bare hands.

If the Green LED light turns on, it's a good sign

Use the Multimeter to make sure the output voltage is approximately 24V, adjust using the Philip Head Screw

Left 3 terminals are Positive Output

Middle 3 terminals are Ground/Negative Output

Once test is successful, Turn off the Power using the Switch and unplug the Power Plug

This custom Arduino Mega Shield can be ordered directly and contains the following parts:

Screw Terminal 8p - 2.54mm (x3)

Screw Terminal 4p - 2.54mm (x1)

Screw Terminal 2p - 3.5mm (x1)

NPN Transistor 2N2222A (x6-9)

Voltage Regulator MP1584EN (x2)

D-SUB F-Conn right-angle 37p

The voltages in the MP1584EN must be adjusted before we connect this to the Arduino Mega. Incorrect voltage could damage the electronics.

Prepare the following components:

Arduino Mega Shield

2-Wire Power Cable 18AWG - [160mm]

2-Wire Power Cable 22AWG - [335mm & 420mm]

M3x8mm Screws (x8)

Connect the PSU and Mega Shield using the 22AWG 420mm long wires. Connect the plug to the Switch and turn the power ON

Test the LEFT MP1584EN output voltage to be 6V or whichever voltage your gripper servo needs, adjust using the potentiometer

Test the RIGHT MP1584EN output voltage to be 10 -12V for powering Arduino Mega .

Connect the rest of the power Wires

Small Stepper Driver Wires (22AWG 335mm long)

Big Stepper Driver Wires (18AWG 160mm long)

Using a wire cutter to snip two pegs positioned with respect to the Rocker Switch on the top right corner of the picture.

Align the Half Moon slot and secure the mounting plate to the Case using M3x8mm Screws in the available spots around PSU.

Prepare the following components:

Arduino Mega 2650

[3D] Arduino Tray and Standoffs

4-Wire Signal Cable 22AWG {for Motor}

M3x10mm Screws (x4)

M3x16mm Screws (x5)

M3 Hex Nuts (x2)

M3 Nylock Nuts (x2)

Length of each 4-pin 22AWG wires are listed as below:

0 -> 210mm

1 -> 210mm

2 -> 200mm

3 -> 165mm

4 -> 185mm

5 -> 225mm

Insert M3 Hex Nuts in the side slot of the Arduino Standoff

Partially screw in M3x16mm Screws for easier assembly

Secure the Standoff to the Case by tightening the Screws in place.

Notice the Orientation of the Standoff as well as the position of the cables relative to the pegs of the Standoff

Align the Holes on the Tray and the Arduino Mega

Use the M3x10mm Screws and M3 Nylock Nuts to secure the Arduino to the Tray

Make sure to tighten the screws just enough to hold them together, No more, since over-tightening the screws can damage the board.

Insert the Mega Shield to the Arduino Mega

Make sure you have set the voltage regulator in Step 11 before going forward

Remove the hex head screw from the Right Angle D-Sub Connector

Start with Motor 0 signal cable to the Right most connector labelled "M0"

M0, M1 and M2 follows the same color pattern

from the right, Black, Red, Green, Blue

M3, M4, M5 follows a different color pattern from M0-M2,

from the right, Red, Black, Green, Blue

Insert the "TOOL" Cable in the specific order:

from the top, Green, Black, Red, White

Insert the USB Extension Cable in the Arduino

Secure the Right Angle D-Sub Connector to the Case Wall Adapter slot using the Hex Head Screws

Align the Tray to the Standoff and secure it using the M3x10mm Screws

Once everything is aligned, secure this alignment by tightening the screw and the nut on the Case Wall Adapter

Prepare the following components:

Stepper Drivers [DM320T & DM542T & DM556T]

[3D] Stepper Driver Adapters

M3x10mm Screws (x12)

M3x8mm Screws (x9)

M3 Nylock Nuts (x12)

Starting with the Smaller "DM320T" Drivers, screw in M3x10mm Screws in the Adapter with 3 small slots

One driver at a time, secure the drivers to the adapter using M3 Nylock Nuts, use Needle Nose Plier to hold the nuts.

Repeat the process for the rest of the DM320T Drivers

There are two DM542T Drivers and one DM556T Driver, DM556T Driver is the one with a big Heat Sink in the back

Repeat the same process as previous step:

Adapter with 2 Slots, fits each DM542T and DM556T

Adapter with a single slot fits one DM542T Driver

Pull all the Screw Terminal Blocks off from the Drivers

Starting with a single DM542T Driver Adapter, secure each drivers to the Case

Make sure the adapters are aligned as shown in the picture, Label on the DM542T and DM556T Drivers are facing away from the PSU

For DM320T Drivers, 4 pin side is closer to the Label of DM542T Driver

Set the switch to the following mode, it'll follow the Binary scheme, 1 = On, 0 = Off, starting from switch 1 in ascending order

DM542T -> 10001111

DM556T -> 00001111

DM542T -> 10001111

DM320T-Right -> 000111

DM320T-Middle -> 000111

DM320T- Left -> 100111

Prepare the following components:

Screw Terminal Blocks from the Drivers

2-pin Power Wires 18AWG 90mm

2 pin Power Wires 18AWG 130mm

2 pin Power Wires 22AWG 65mm (x2)

22 AWG solid Wires Black 30mm (x6)

[Opt] - Ferrule Crimp Pins (x4)

Grab one of the Bigger Driver's 4-pin Screw Terminal and wire it as shown in the first picture, Screw Head is pointing UP

Starting with M0 Cables that's already attached to Arduino Mega Shield, secure the wire as shown in the second picture.

notice there are 2 black solid wires in the right most pin of the 2-pin connector

Repeat the same process for the M1 and M2 Drivers, and plug them as shown in the third picture.

Starting with the M3 signal cable, attach them and plug them in the corresponding driver as shown in the first picture,

Repeat the process for M4 and M5 drivers, notice the labels

Use the shorter 18AWG 2-pin power cable and attach it to big 6-pin screw terminal

Attach the other end of the shorter 18AWG cable and one end of the longer 18AWG to another 6-pin screw terminal

Now repeat the second step with the longer 18AWG cable and the 18AWG cable that's already in the PSU with the last 6-pin screw terminal

Start with M0 cables from the GX16 Aviation Plug and the screw terminal that's directly connected to PSU.

Start with Black, Green, Red, White

Repeat the same process for M1 and M2 as shown in the second picture.

Optional Step:

Use the Ferrule Crimp Pins to connect 22AWG power wires as shown in the first picture, do this for cable from PSU as well.

The same color code as bigger drivers applies to DM320T, just repeat step 30 with M3-5 Motor Wires

Congratulation! you've successfully finished assembling the Electronic Case! Go You!