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There are a variety of other prototyping systems besides wire-wrap. You may wish to visit a well-stocked electronics store in your area to see what they have available. Because the tools and supplies for prototyping systems tend to be expensive, see if you can get a handson demonstration first. That way, you ll know the system is for you before you invest in it.
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Making Your Own Printed Circuit Boards
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The electronic construction technique of choice is the printed circuit board (PCB). PCBs are made by printing or applying a special resist ink to a piece of copper clad (thin copper sheet over a plastic, epoxy, or phenolic base). The board is then immersed in etchant fluid, which removes all the copper except those areas covered with resist. The resist is washed off, leaving copper traces for the actual circuit. Holes are drilled through the board for mounting the components. You ve probably built a kit or two using a PCB supplied by the manufacturer. You can also make your own printed circuit boards using your own designs as well as the board layouts found in this book and a number of electronics magazines.
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Understanding Wire Gauge
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The thickness, or gauge, of the wire determines its current-carrying capabilities. Generally, the larger the wire, the more current it can pass without overheating and burning up. See Appendix E, Reference, for common wire gauges and the maximum accepted current capacity, assuming reasonable wire lengths of 5 feet or less. When you are constructing circuits that carry high currents, be sure to use the proper gauge wire.
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Robots are often constructed from subsystems that may not be located on the same circuit board. You must therefore know how to connect together subsystems on different circuit boards. Avoid the temptation to directly solder wires between boards. This makes it much harder to work with your robot, including testing variations of your designs with different subsystems. Instead, use connectors whenever possible, as shown in Fig. 6.3. In this approach you connect the various subsystems of your robot together using short lengths of wire. You terminate each wire with a connector of some type or another. The connectors attach to mating pins on each circuit board. You don t need fancy cables and cable connectors for your robots. In fact, these can add significant weight to your bot. Instead, use ordinary 20- to 26-gauge wire, terminated with single- or double-row plastic connectors. You can use ribbon cable for the wire or
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70 ELECTRONIC CONSTRUCTION TECHNIQUES
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FIGURE 6.3 Using connectors makes for more manageable robots. Use connectors on all subsystems of your robot.
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individual insulated strips of wire. Use plastic ties to bundle the wires together. The plastic connectors are made to mate with single- and double-row headers soldered directly on the circuit board. You can buy connectors and headers that have different numbers of pins or you can salvage them from old parts (the typical VCR is chock full of them!). When making interconnecting cables, cut the wires to length so there is a modest amount of slack between subsystems, but not too much. You don t want, or need, gobs and gobs of excess wire. Nor do you want the wire lengths so short that the components are put under stress when you connect them together.
Eliminating Static Electricity
The ancient Egyptians discovered static electricity when they rubbed animal fur against the smooth surface of amber. Once the materials were rubbed together, they tended to cling to one another. Similarly, two pieces of fur that were rubbed against the amber tended to separate when they were drawn together. While the Egyptians didn t understand this mysterious unseen force better known now as static electricity they knew it existed. Today, you can encounter static electricity by doing nothing more than walking across a carpeted floor. As you walk, your feet rub against the carpet, and your body takes on a static charge. Touch a metal object, like a doorknob or a metal sink, and that static is quickly discharged from your body. You feel the discharge as a shock. Carpet shock has never been known to kill anyone. The amount of voltage and current is far too low to cause great bodily harm. But the same isn t true of electronic circuits. Considering how your body can develop a 10,000- to 50,000-volt charge when you walk
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