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FIGURE 3.5 A wire-wrapping tool. The long end is for wrapping the wire around the post; the short end for unwrapping (should it be necessary). The blade in the middle is for stripping the insulation off the wire.
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A number of companies offer proprietary alternatives for wire-wrapping; some are better than others. Which system you choose will depend on your own personal preferences as well as the availability of parts and supplies in your area. Visit a well-stocked electronics parts store or catalog Web site and examine their offerings.
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A robot is about 75 percent hardware and 25 percent electronic and electromechanical components. Most of your trips for parts for your robots will be to the local hardware store. The following sections describe some common items you ll want to have around your shop.
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NUTS AND BOLTS
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Number 6, 8, and 10 nuts and pan-head stove bolts (6/32, 8/32, and 10/24, respectively) are good for all-around construction. Get a variety of bolts in 1/2-, 3/4-, 1-, 1 1/4-,
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EXTRUDED ALUMINUM
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and 1 1/2-inch lengths. You may also want to get some 2- and 3-inch-long bolts for special applications. Motor shafts and other heavy-duty applications require 1/4-inch 20 or 5/16-inch hardware. Pan-head stove bolts are the best choice; you don t need hex-head carriage bolts unless you have a specific requirement for them. You can use number 6 (6/32) nuts and bolts for small, lightweight applications. Or for even smaller work, use the miniature hardware available at hobby stores, where you can get screws in standard 5/56, 4/40, and 2/20 sizes.
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While you re at the store, stock up on flat washers, fender washers (large washers with small holes), tooth lock washers, and split lock washers. Get an assortment so you have a variety of nut and bolt sizes. Split lock washers are good for heavy-duty applications because they provide more compression locking power. You usually use them with bolt sizes of 1/4 inch and above.
ALL-THREAD ROD
All-thread is two- to three-foot lengths of threaded rod stock. It comes in standard thread sizes and pitches. All-thread is good for shafts and linear motion actuators. Get one of each in 8/32, 10/24, and 1/4-inch 20 threads to start. If you need small sizes, hobby stores provide all-thread rod (typically used for push/pull rods in model airplanes) in a variety of diameters and threads.
SPECIAL NUTS
Coupling nuts are just like regular nuts except that they have been stretched out. They are designed to couple two bolts or pieces of all-thread together, end to end. In robotics, you might use them for everything from linear motion actuators to grippers. Locking nuts have a piece of nylon built into them that provides a locking bite when they are threaded onto a bolt. It is preferable to use locking nuts over two nuts tightened together.
Extruded Aluminum
If you re making metal robots, you can take advantage of a rather common hardware item: extruded aluminum stock. This stuff, which is designed for such things as building bathtub enclosures, picture frames, and other handyman applications, comes in various sizes, thicknesses, and configurations. The standard length is usually 12 feet, but if you need less most hardware stores will cut to order (you save when you buy it in full lengths). The stock is available in plain (dull silver) anodized aluminum and gold anodized aluminum. Get the plain stuff: it s 10 to 25 percent cheaper. Two particularly handy stocks are 41/64-by-1/2-by-1/16-inch channel and 57/64-by9/16-by-1/16-inch channel. I use these extensively to make the frames, arms, legs, and other parts of my robots. Angle stock measuring 1-by-1-by-1/16-inches stock is another often-used item, which is usually employed to attach crossbars and other structural
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