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To fabricate the two servo horn spring-loading mechanisms, take a piece of the 1/2-inch aluminum stock and cut two pieces to a length of 2 inches each Cut and drill the pieces, as shown in Figure 441 The finished pieces should resemble the one shown in Figure 442 Modify two servo horns so that they resemble the one shown in Figure 442 This is accomplished by cutting two of the cross pieces off with a pair of side cutters, and then lining up the middle hole of the servo horn with the middle hole in piece W or X When the middle holes are lined up, mark the area where the 5/32-inch holes line up Use a 5/32-inch bit to drill on the markings so that the finished horn looks like the one in Figure 442 Attach one of the modified servo horns to piece W with two 6/32inch 1/2-inch machine screws and locking nuts Attach the second servo horn to piece X, also using two 6/32-inch 1/2-inch machine screws and locking nuts Insert two 6/32-inch 3/4inch machine screws through the two outer holes of piece W, and secure in place with two lock washers and nuts Do the same for piece X One of the finished spring-loading mechanisms is shown in Figure 443, and can be used as a guide

Take the two completed spring-loading mechanisms and attach each one to a servo that has been modified for continuous rotation Use the servo screw that came with the servo horn to secure the mechanism in place on the servo shaft, as shown in Figure 444 Take one of the servos with the spring-loading mechanism attached and secure it to a servo mount, using four 6/32-inch 1/2-inch machine screws, lock washers, and nuts Attach the second servo to the second servo mount, also using four 6/32-inch 1/2-inch machine screws, lock washers, and nuts, but note that the servo is attached so that it mirrors the first one, as shown in Figure 445 Attach the servo mounts to the frog s body using four 6/32-inch 1/2-inch machine screws, lock washers, and nuts The servo

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mounts should be positioned with the servo shaft closest to the frog s head Figure 446 illustrates the proper orientation of the servo mounts on the frog s body

Howard University (BArch) School of Architecture and Design 2366 Sixth St NW Washington, DC 20059 howardedu/ceacs/

Cut two front leg pieces to a length of 4 inches, using the 1/2-inch aluminum Use Figure 447 as a guide to cut, drill, and bend the aluminum Attach the finished legs to the robot s body, using two 6/32-inch 1/2-inch machine screws, lock washers, and nuts, as shown in Figure 448

The leg position sensors are limit switches that will determine when the legs are set to their jumping position, at which point the spring mechanism is fully loaded This information will be used by the microcontroller to coordinate the legs for jumping To attach the limit switches, manually rotate each servo by hand so that the spring is fully loaded toward the top of the spring-loading mechanism s travel, as shown in Figure 449 While maintaining this position, use hot glue to fix the limit switch to part E so that the switch is triggered, as shown in Figure 449 Do the same for the other leg, attaching the second limit switch to part F

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Cut a piece of 2-strand connector wire to a length of 6 inches and solder the wire to connect the two limit switches, as shown in Figure 450 Cut another piece of the 2-strand connector wire to a length of 3-1/2 inches Solder one end of each wire to a 2-post female header connector, and the opposite ends to the left leg limit

switch, as shown in Figure 450 The header will be plugged into the 5 VDC and the GND connector on the main controller circuit board later in the chapter Next, cut two single-strand connector wires to a length of 5-1/2 inches Solder one end of each wire to a single-post female header connector, and the other end of each wire to the left and right limit switches, as shown in Figure 450 The limit switch connectors will eventually be attached to microcontroller inputs Figure 451 shows the connectors wired to the limit switches Fabricate a 6-volt battery pack holder using 1/16-inch thick aluminum by following the cutting, drilling, and bending guide shown in Figure 452 When the battery pack holder is finished, attach it to the robot s body using a 6/32-inch 1/2-inch machine screw, lock washer, and nut Figure 453 shows the completed battery pack holder fastened to the robot s body At this point, the robot s mechanical construction is complete The next section of 4 will focus on the electronics