In the previous blog I showed you my research that I did in order to build my own version of the famous sorting hat.
Here's what have I been up to:
- Did the sketch on the mechanics for the mouth
- Did the sketch on the Servo motor mount for the eyebrow
- Did the sketch for the Servo motor mount for the moving hat top
- Completed the prototype
- 3d printed the mechanics
- Did some testing with servo motors and the mouth mechanism
- Did a second iteration on the code, now implementing two cores on the ESP32
- Designed and ordered a PCB
So that's actually a lot :-) You can say I was busy. Let me show you.
Designing the Mechanical Parts
First I designed the mechanical mount and it included a base plate that can be used to mount a PCB.
I used the tutorial by Kevin McAleer from Kevin Robots. Link is in the first blog.
Basically, I up scaled it, making it bigger and I changed the base plate to my liking. I recommend his video and tutorial if you want to learn the basics of Fusion 360.
It helped me a lot and after designing the mouth section, I was able to create 2 more mechanical parts to be used for the other two servos.
First let me show you the mouth parts:
As soon as the video is released, all work files and step files will be available for download.
I also made a server mount for the eyebrow and the tip of the hat. The tip of the hat will be moveable in a way that I haven't figured out just yet..
So after completing the sketches for the mechanics, I used a online print service to 3d print all the parts. It's affordable and fast and the quality of the prints is good enough for this design.
So, after receiving the parts, It's assembly time:
So far so good! I do have to change or shorten some of the bolts but other then that..All is good.
On the left you can see the mount bracket for the eyebrow servo and on the right is the mount for the hat top.
So the mechanical prototype is kind of finished, except maybe the position of the PCB is in need of changing......Turns out that there is no room to place the ESP32 on a socket. Now I need to make a choice between not using header and socket to mount the ESP32 or soldering it directly onto the mainboard or making some sort of bracket.
Left: Without socket it fits
Right: With socket the servo is in the way....
Designing the electronics
As you already might have guessed from the picture above, I designed a PCB for this project.
I intended to keep it small so I can save money on the PCB and the mechanical 3d printed parts.
First, Let me show you the schematic.
Each block in the schematic shows you it's purpose. It is straight forward and I have not much to add.
The PCB is not complex it's nearly a well arranged placement of components on a plate. Take a Look:
As you can see, the ESP32 board is sticking out over the mainboard. This was to save on the production costs of the main pcb and the base of the 3d printed mechanical mounth.
First results
https://www.instagram.com/p/CrWR7-oosID/
https://www.instagram.com/p/Ct7RmkoA3xu/
What's next?
- Building the actual Hat using paper glue and leather
- Recording funny sounds using some of my funny voices ( well...if you must ask...the kids call it funny, who am I to judge)