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mark as a guide. Cut a small length of 1/2"-diameter solid rod. Check to make sure the shaft fits easily into the 5/8" tubing. If not, obtain a small piece of 100-grit sandpaper. Wrap the sandpaper around a 1/2" length on the end of the shaft. Twist the sandpaper around on the shaft to sand the end. Continue sanding until the end of the shaft fits easily into and out of the tubing. Next, drill a hole down the center that will fit the shaft from the gearbox. We want the gearbox to be positioned in the center of the sphere. Place the shaft of the gearbox in the plastic rod. Place the rod in the tubing on half the sphere of the globe. Position the gearbox so that it will lie in the center. Mark the depth the gearbox shaft must go into the plastic rod on the gearbox shaft. Remove the gearbox shaft. Mix a small amount of two-part epoxy glue. Coat the gearbox shaft with the epoxy glue and insert it into the plastic rod. Let the glue set before proceeding. Once the glue has dried on the first shaft, we must glue the other plastic rod on the opposite side of the shaft. Position the glued rod into the half sphere. Place the other plastic rod on the opposite shaft. Place the other half sphere together with the first. Gauge the depth the gearbox shaft must be inserted in the plastic rod, and then add another 1/8" of depth for error. Glue and let set. Check your work while the glue is setting on the second shaft to ensure that you can close the sphere properly.
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The electronic circuit is a light-activated on/off switch. When the ambient light level is low (user adjustable), the circuit shuts off power to the gearbox. The user adjusts the sensitivity of the circuit using potentiometer V1. There is nothing crucial about the circuit. If you do not wish to purchase or make the printed circuit board (PCB), the circuit may be wired and assembled on a standard breadboard.
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The circuit configures a complementary metal-oxide semiconductor (CMOS) operational amplifier (op-amp) as a voltage comparator. A comparator monitors two input voltages. One voltage is set up as a reference voltage called Vref. The other voltage is the input voltage called Vin, which is the voltage to be compared. When the Vin voltage falls above or below the Vref, the output of the comparator (pin 6) changes states.
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The two input voltages are applied to pins 2 and 3. Pin 2 (inverting input) is connected to a reference voltage of approximately 1.5V, using a simple voltage divider made of resistors R1 and R2. Photosensitive resistor R3 makes up another voltage divider in conjunction with potentiometer V1, which is connected to the noninverting input (pin 3) of the op-amp. There is no feedback resistor between the output (pin 6) and either of the inputs (pins 2 and 3). This forces the op-amp to operate at its open loop gain. A cadmium-sulfide (CdS) photoresistor is used as the light sensor. A photoresistor changes resistance in proportion to the intensity of the light that falls on its surface. The CdS cell produces its greatest resistance in total darkness. As the light intensity increases, its resistance decreases. In the circuit, the CdS cell is part of a voltage divider. The changing resistance of the CdS cell changes the voltage drop across the potentiometer V1, which is connected to pin 3. As the light intensity increases, the resistance of the CdS cell decreases, which increases the voltage drop across the potentiometer. This increased voltage drop is seen as a rising voltage. The trigger voltage can be set for different light levels using the potentiometer. The electronic circuit is not crucial. You can construct the circuit using point-to-point soldering on a prototyping breadboard. A PCB is available from a kit, or you can make it yourself. The PCB artwork is illustrated in Fig. 12.7. Parts placement on the board is shown in Fig. 12.8. Once the circuit is complete, you need to adjust the light level that will activate the circuit using potentiometer V1. Make temporary connections to the gearbox motor using alligator clip wires. Power to the circuit and gearbox is obtained from two AA cells, and the AA cell pack is glued to the back of the gearbox during final assembly. Make sure the battery pack has a battery clip for easily disconnecting and connecting power.
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