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Mechatronics

for the

Evil Genius

NEWTON C. BRAGA

McGraw-Hill

New York Chicago San Francisco Lisbon

London Madrid Mexico City Milan New Delhi

San Juan Seoul Singapore Sydney Toronto

Library of Congress Cataloging-in-Publication Data

Braga, Newton C.

Mechatronics for the evil genius / Newton C. Braga

p. cm.

ISBN 0-07-145759-3

I. Mechatronics. I. Title.

TJ163.12.B72 2005

2005051094

Copyright © 2006 by The McGraw-Hill Commpanies, Inc. All rights reserved. Printed in the United States of America. Except as permitted under the United States Copyright Act of 1976, no part of this publication may be reproduced or distributed in any form or by any means, or stored in a data base or retrieval system, without the prior written permission of the publisher.

7 8 9 0 QDB/QDB 15 14 13

ISBN 0-07-145759-3

The sponsoring editor for this book was Judy Bass and the production supervisor was Pamela A. Pelton. It was set in Times Ten by MacAllister Publishing Services, LLC. The art director for the cover was Anthony Landi.

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Contents

About the Author

Preface

Acknowledgments

Section OnePreparing the Reader

Section TwoThe Technology Used in the Projects

Section ThreeThe Projects

PROJECT 1 — Mechatronic Race Car

PROJECT 2 — RobCom: A Combat Robot

PROJECT 3 — Using a PWM Motor Control

PROJECT 4 — Ionic Motor

PROJECT 5 — Experimental Galvanometer

PROJECT 6 — Experimenting with Electromagnets

PROJECT 7 — Electronic Potentiometer

PROJECT 8 — Experiments with Eolic Generators

PROJECT 9 — Electronic Cannon

PROJECT 10 — Experiments with Lissajous Figures Generated by a Laser

PROJECT 11 — Analog Computer

PROJECT 12 — Touch-Controlled Motor

PROJECT 13 — Mechatronic Elevator

PROJECT 14 — Stepper Motor Control

PROJECT 15 — Magic Motion Machine

PROJECT 16 — Test Your Nerves

PROJECT 17 — Robot with Sensors

PROJECT 18 — SMA Experimental Robotic Arm

PROJECT 19 — Position Sensor

PROJECT 20 — Light-Beam Remote Control

PROJECT 21 — Mechatronic Airboat

PROJECT 22 — Coin Tosser

PROJECT 23 — The Challenge of the Mechatronic Timer

PROJECT 24 — Experimental PLC

PROJECT 25 — The Mechatronic Talking Head

About the Author

Mr. Braga was born in Sao Paulo, Brazil, in 1946. His activities in electronics began when he was only 13 years old, at which time he began to write articles for Brazilian magazines. At age 18, he had his own column in the Brazilian edition of Popular Electronics, where he introduced the concept of electronics for youngsters.

In 1976, he became the technical director of the most important electronics magazine in South America, Revista Saber Eletronica (published at that time in Brazil, Argentina, Colombia, and Mexico). He also became technical director of other magazines of Editora Saber, such as Eletronica Total, and became the technical consultant for the magazines Mecatronica Facil, Mecatronica Atual, and PC & CIA.

Mr. Braga has published more than 90 books about electronics, mechatronics, computers, and electricity, as well as thousands of articles and electronics/mechatronics projects in magazines all over the world (U.S., France, Spain, Japan, Portugal, Mexico, and Argentina among others). Many of his books have been recommended at schools and universities around the world and been translated into other languages, with sales of more than 3 million copies worldwide.

The author currently teaches mechatronics at Colegio Mater Amabilis, is a consultant for distance learning, and is engaged in educational projects in his home country of Brazil. These projects are directed at the introduction of electronics and mechatronics in middle schools as well as the professional training of workers and teachers who need enhanced knowledge in the fields of electronics, mechatronics, and technology. The author now lives in Guarulhos (near Sao Paulo, Brazil) with his wife and 15-year-old son.

Preface

This book doesn’t pretend to be a complete resource for the mechatronics evil genius, but it certainly offers a large assortment of useful information and ideas for projects not found elsewhere.

The purpose of this book is not only to teach many tricks and techniques used to build mechatronic and electronic devices, but also to provide ideas and complete projects that can be easily duplicated using low-cost and easy-to-find parts.

The audience for Mechatronics for the Evil Genius includes beginner, intermediate, and advanced builders who want new ideas for projects, as well as educators who want to introduce the use of technology to their schools. Of course, the most important reader is the evil genius who can make incredible things using his or her imagination, skills, and some parts gathered from old equipment and appliances, stolen from a younger sibling’s toys, or bought from a local electronics parts dealer.

If you think that it’s impossible to build interesting things using simple materials and technology, you are wrong. Three types of technology are used to build electronic and mechatronic projects:

The simplest, or traditional, technology incorporates electrical parts for motors, cells, and passive components. This technology can be understood even by children in elementary school. You can implement some interesting projects with this technology by simply using your imagination, and we will present some projects using these simple devices in this book.

Intermediate technology is the kind that uses something more advanced than the passive components of the traditional physicist, such as semiconductors (diodes, transistors, silicon controlled rectifiers [SCRs], light-emitting diodes [LEDs]) and some integrated circuits [ICs], but not so advanced as microprocessors, very large scale integration (VLSI) chips, digital signal processors (DSPs), and much more.

    The great advantage of using intermediate technology is that it is accessible to all. Discrete components such as transistors, resistors, and diodes can be easily handled, which is important in order to reveal hidden vocations and talents. You will not need special tools to handle such components, as they are vigorous enough to resist the evil genius who is not experienced with the use of tools.

The advanced technology is the type you can find in all modern appliances such as cellular phones, DVDs, computers, pagers, video games, and global positioning systems (GPSs). Although these appliances use very complex chips, they are all based on the same principles of operation. What differs is the number of functions and components.

You can make a simple radio using three or four components, but a high-tech radio requires a microprocessor with a million components. The most important goal for the evil genius is that he or she can build different things, appliances not commonly found but seen only in movies, on TV, or in science fiction magazines. Using low-cost parts and easy technology, the reader can build simple robots, shock machines, race cars, remote controls, and much more with the same approach shown in TV programs such as those on the Discovery Channel.

You can do all that, and we intend to give you some of the necessary tools, ideas, and techniques in the following chapters. You only have to complete these items with your imagination–the super imagination found only in a true evil genius. This book is divided into three parts:

In the first part, we will prepare the reader to be a real mechatronics evil genius. We will explain what to do and how to handle electronic and mechanical devices used in these projects. We will also dedicate space to educators who want to reveal an evil genius or two among their pupils by building projects and making experiments with them. The educators will see how easy it is to link many of our projects with their science classes, using the projects as cross themes for the science curriculum.

    For readers who want to take a more serious approach in the hope of becoming an amateur scientist, we will discuss the scientific method. This will help the reader to go further with the projects, developing new and more advanced things from the ideas provided in this book. It is an approach that will involve the imagination of the advanced evil genius.

In the second part of the book, we will show the reader how to build electronic circuits, work with electronic components and devices, mount materials, use tools, and solder. Because the evil genius tends to be daring, sometimes going too far with the projects and their use, this book details how to avoid dangerous situations when working with technology and how to work and play safely.

In Part 3, we find the projects, 25 of them, chosen from the author’s large collection of experiments, many specially created for the reader of this book, the real evil genius.

The projects are all complete; they have all the information needed to build a basic version that works. A brief description of the project explains how it is supposed to look and work upon completion. Following this section, the reader will find the operation principles and details of how to mount the materials. A complete parts list makes it easy for the reader to gather all the parts needed for building. After that, we include directions for making any adjustments, adding additional circuits, upgrading the project, building variations, or conceiving new projects based on the same principles.

Rounding out each project are ideas for educators, linking projects to the subjects taught in school, as well as additional information. This approach makes the book easy to use as a large reference for mechatronics projects.

We hope that as a reader and potential evil genius your face will light up and your eyes will be full of mischief from the ideas provided in this book. Enjoy!

Newton C. Braga

Acknowledgments

I would like to thank all the people who helped make this book possible:

Jeff Eckert—my book agent who helped me with all the bureaucratic procedures involving the production of the book.

Carlos Eduardo Portela Godoy and Marcelo Portela Godoy—who gave me support when working with my mechatronics pupils at Colegio Mater Amabilis in Guarulhos (Brazil), revealing among them many an evil genius.

Helio Fittipaldi—who allowed me to use many illustrations and photos from articles I had published in his magazines Mecatronica Facil and Eletronica Total.

Edson de Santis—my great friend who supplied me with many parts of the components I have used in the projects described in this book.

Alexandre Costa Berbel—who helped me monitor how many of the projects described in this book were used by a large number of schools in the city where I live and many others where he supports the use of technology in education.

My wife Neuza and my son Marcelo—who have both been supportive of my efforts.

Newton C. Braga

Section One

Preparing the Reader

What Is Mechatronics?

So you want to be an evil genius in mechatronics? Before you start with the fantastic projects described in this book, can you answer a simple question?

Do you really know what mechatronics is?

If you are not sure about the correct answer to this question, it would be better to first learn something about this new fantastic science.

When you saw the word mechatronics on the cover of this book, the first thing that probably came to mind was building robots. Robots are the main products of mechatronics, and robots are very popular these days. Just look at their presence in movies, toys, and books. Character names like R2-D2, Asimo, Aibo, and movie names like Asimov’s I, Robot are known by everyone.

These increasingly popular mechanical creatures are part of a branch of science known as robotics, and robotics is part of mechatronics. So, to know more about mechatronics we must return to the origin of robotics and even the automatic machine using no more than common mechanics.

History

The idea that machines can perform difficult and repetitive tasks, acting as servants (and freeing humans from the tasks), originated in ancient Greece. Traces of movable statues were found in the first century B.C. One individual in particular to be acknowledged is Hero, who was from Alexandria and conducted experiments with mechanical birds. Accounts of Cresibus, a Greek engineer, claim he built organs and water clocks with movable figures.

In 730 A.D., the Swiss clock maker, Pierre Jacquet-Droz, built three mechanical tools that could play music on an organ, draw simple figures, and write. Later, but not so long ago, Tesla built a remote-controlled submarine.

But it was the Czech novelist Karel Kapec, in his book R.U.R., Rassum’s Universal Robots, who first used the term robot. In the book, he describes mechanical servants doing all the things a man could do. The word robot simply means worker in Czech.

Looking further ahead in time, the idea of mechanisms, though not necessarily humanlike mechanisms, performing tasks for humans has not disappeared. With the development of new technologies such as electronics, cybernetics, and artificial intelligence, a new science named mechatronics appeared.

Mechatronics can be defined as the synergistic integration of mechanics, electronics, and computer technology. It can be classified as a subject of cybernetics. Figure 1.1 shows a graphic where we place mechatronics as an independent science.

Mechatronics and robotics have many points in common. Both depend on electronic and mechanical parts, and their projects operate following the same principles.

Looking at the curriculum of many mechatronics courses (also called industrial automation), we can see that the main subject is robotic technology, focusing on industrial robots or automatic manufacturing machines.

Figure 1.1How mechatronics interacts with other sciences.

This book doesn’t intend to be a course in mechatronics, but it is a practical approach to the subject. What we intend to do with this book is show the reader how to have fun and learn about such traditional sciences as physics, biology, and others by using mechanics and electronics or, if you prefer, mechatronics.

Mechatronic Tools and Principles

At this point, we believe that if the reader wants to build the projects described in this book, it is necessary to be prepared to handle tools and know the basic principles behind the two sciences comprising mechatronics. It is also clear that by visiting many model, toy, and virtual stores the reader can find complete mechatronic projects ready to be used. These store-bought projects may be even more complicated or less expensive than the projects described in this book.

However, the real evil genius makes discoveries through his or her own efforts, inventing new devices and learning the theory necessary to build them. The real evil genius doesn’t buy an operating robot or a kit; he builds his own robot. The real evil genius doesn’t look for an ionic motor in science stores; she creates her own version. That is the great difference in what makes this book ideal for a true evil genius.

Barriers to Be Crossed

Building mechatronics projects is a challenge. When observing such projects, one will note that many levels of difficulty exist. An experimenter can try simple projects using very easy-to-handle and easy-to-find parts, or one can take on very complicated ones that require special components, special tools, and a highly specialized knowledge of the technology involved.

Many readers are familiar with the use of delicate components such as the ones found in electronic circuits or small mechanical devices, whereas other readers are not. For those who are not familiar with the technology used in the projects, some barriers must be crossed. Starting with simple projects, the inexperienced reader can acquire the necessary skills to graduate to more complex projects in relatively little time. This means that we will present the reader with both easy and intermediate projects, from the simplest for anyone with a minimum knowledge of technology and tools to others that require much more experience to build. Information about each project’s degree of difficulty will be given.

The reader must also have the necessary tools to work with these delicate parts. When working with electronic and mechanical parts, the reader must have specialized tools as well as sufficient knowledge of how to use them. In the next few pages, we will give some important information about these tools.

To complete this section, the reader must answer a final question: Can I use the projects for any purpose other than simply having fun? The projects described in this book are not simply toys. They can be used for other ends. The amateur scientist can use the ideas given by these projects to discover new things. Practical circuits and configurations can be implemented to build simple research tools used in experiments involving chemistry, physics, and even human sciences.

Educational Electronics, Robotics, and Mechatronics

One of the most interesting applications of the projects in this book is developing an evil genius. The projects can easily be included as technological cross-theme material complementing school curriculum and adding to students’ routine activities. Remember that elementary schools are currently trying to include technology in their curriculum.

Although many believe that technology means using a computer, today’s technology is present in all parts of our world. Technology starts with the simple lamp you turn on and off, and it includes such electronic and mechatronic domestic appliances as VCRs, TVs, telephones, and high-tech devices such as robots, radars, cellular phones, and wireless computer links. Technology is even more prevalent in some locations. Just visit an airport, a shopping center, or a bank.

The basic idea of educational electronics, robotics, and mechatronics has been adopted here in my home country of Brazil (and in many other countries). Using technology with many of the projects described in this book, I not only entertain readers, but provide the educator with the opportunity to use the projects in order to link the basic sciences (physics, chemistry, and biology) with higher-end technology.

Throughout this book, I show photos of my mechatronics pupils using the projects, such as those that mount a combat robot or mechatronic race car. Students not only have to do research in physics (mechanics) to reduce friction, create the fastest cars, and explain how they work, but they are also challenged to put all their evil genius skills to work.

The projects in this book are created using a central part that can stand alone as a complete device, and parts may be added to create new projects. Experienced and innovative teachers can use additional circuits and creativity to produce new projects and to complement or supplement a curriculum.

Cross Themes

Teachers and educators are very familiar with cross themes. When working with the items of a common science curriculum, it is a good idea to insert activities that are not directly indicated in the curriculum but can be used to reinforce the topic being studied.

Cross themes are very important in today’s education and are highly recommended by educational authorities. They make it easier for students to understand many scientific principles that are not very clear when simply using a blackboard or other traditional teaching tools.

The Scientific Method

Technology is the practical application of science. In earlier times, technology grew out of direct experience with the properties of things and the techniques for manipulating them. Today technology also depends on a vast array of formulas and theories.

Engineering (like mechatronics) is the systematic application of scientific knowledge in developing technology. Engineering has grown from a craft to a science in itself. Therefore, when creating projects in mechatronics, you need to follow the rules of science and technology research. These rules are described in the scientific method.

The scientific method is the process by which scientists construct a reliable, consistent, and nonarbitrary representation of the world. The scientific method has four steps:

Observation and description of a phenomenon

Formulation of a hypothesis to explain the phenomenon

Use of the hypothesis to predict the existence of other phenomena

Testing the predictions through independent means

To do an experimental science project, these steps must be followed:

Make the initial observation.

Gather information.

Name and rationalize a purpose for the project.

Formulate a hypothesis.

Design an experimental procedure to test your hypothesis.

Gather material and equipment.

Do the experiment and record the data.

Make calculations and semmarize results.

Try to answer the original questions.

It is important to observe that the scientific method has different forms. Physical scientists do experiments to gather numerical data from which relationships are derived. From the results, conclusions are made. Descriptive scientists, such as anthropologists, use information gathered by observation and interviewing.

In mechatronics, the reader must follow the procedures used for all experimental science projects. One must collect data, form a hypothesis, gather material, and create a project that can be used to confirm one’s hypothesis and/or that can be used in some practical application.

Choosing a Project

The projects found in this book have different levels of difficulty. It is up to the reader to analyze all the projects and decide if the original version or an upgraded version can be done. Take into consideration the following when choosing a project:

Is the project at an appropriate level of difficulty in respect to your knowledge of mechatronics?

Are the parts clear enough to prevent difficulty when mounting?

Do you have the necessary tools to handle all parts of the project?

Do you know how to use the tools needed to build the project?

Are you sure that you can find all the parts at your supplier?

If you need the help of a more experienced person, is this person readily available?

Take into account these points so you don’t have any unpleasant surprises when mounting a particular project.

Section Two

The Technology Used in the Projects

Most of the projects described in this book can be used individually. Wherever possible, the circuits have been designed so that they can be grouped with one or more other projects. By replacing some components, they can be altered to execute new functions with other aims.

How to Mount

Consumer appliances use machines to assemble small parts, starting with a technology called surface mount technology (SMT), which employs very small parts. Without the use of special tools, we could not handle these parts, and it is very difficult to mount any project using them. Today’s technology is different from the basic technology that used old parts as tubes and only electric components as lamp switches, fuses, and other parts.

For the typical reader, the ideal is to begin by using intermediate technology. The components are a bit larger and can be handled with common tools. You might think these devices would be slower, but this is actually not the case. Larger components do the same tasks done by the small surface mount devices (SMD). They simply need more space in a board to be placed. They are ideal to work with, particularly if you are not familiar with the tools and do not yet have the skills to handle very small parts. These are the size of the components we intend to use in the projects described in this book.

So, the first thing you