B.E.A.M.
BEAM is an acronym standing for :
Biology, Electronics, Aesthetics and Mechanics
Andy's Light-seeking Robots
DIY Robot : Solar-Bug

last updated : Mar 27, 2007

Parts list :

2 Transistors 2N3904

2 pager motors, high-efficient motors

1 solar panel, 3 volts

2 Transistors 2N3906

2 pager motor holders

1 capacitor, 2200uF, 16 volts

2 blinking LEDs (green or red)

2 resistors 2.2k Ohms, 1/4 watt, 5%

copper wires & heat-shrink tube

It's only 10 items, you can handle it for sure !

How to freeform it (without PCB) :  the regular FLED solar-engine.

1: 2N3904, bend the base lead (middle lead) toward you.
The labelled flat-side facing you and the leads are pointing downward.

2: 2N3906, bend the collector lead (the third lead) away.
The labelled flat-side facing you and the leads are pointing downward.

3: solder them together face to face and clip off the excess leads

4: bends the leads as shown
2N3904 :the collector upward
2N3906 : the base upward

5: solder on the 2.2K resistor, clip off the excess leads

6: bends the leads like that, it's the bug's left brain

E3904 goes to -ve lead of the caps

E3906 goes to +ve lead. Also make a loop for motor lead (E3906 loop)

7: bends the leads like that, it's the bug's right brain

The leads of left brain bend one way, and the leads of right brain bend the other way.

E3904 goes to -ve lead of the caps
E3906 goes to +ve lead. Also make a loop for motor lead.

8: prepare the motors and mount

9: attach the copper-wires to the motors and capacitor : looping the +ve lead of the caps

10: strip the coating of the capacitor, it's more cyber-look this way

11:
left motor blue wire go to
E3906 loop of the left brain
left motor red wire go to
C3904 loop of left brain

right motor blue wire go to C3904 loop of the right brain
right motor red wire go to
E3906 loop of right brain

12: solder the left brain, then the right brain

13: solder the left-eye (FLED), then the right-eye
For the left eye (fled)
solder the anode (round-sided with longer lead) of the fled to the junction between 2N3906B (base of 2N3906) and 2.2K resistor, 
solder the cathode (flat-sided with shorter lead) to the -ve (shorter) lead of the 2200uF caps.
Do the same to the right-eye as well.

14: finally the solar panel

solder the leads and 
glue (or epoxy) the leads onto the panel
handle with care (don't pull the leads to test their strength) before the glue (epoxy) set in

15:  bend the + ve lead down as the front support

put on the shoes (heat-shrink tubing) and you're done !! 
handle the bug by its tail (main caps) or it eye (fled bulb, not the leads)

See, it's not that hard !!

Solar-panel soldering

 I use " low temp" method to solder the wires on. 

 1. Heat up the soldering iron first until it can melt down the solder
 2. Unplug it and cool for 20 sec 
 3. lay the wires on top of pads( I use C-clamp to fix the position) 
 4. solder the wires onto the pads 
 5. check to see if wires can conduct electricity 
 6. if so, crazy-glue the wires onto the back of solar-panel 
 7. if not, clean the pads and re-solder it again (step 1 to 6) 
 8. don't pull the wires to test the soldering strength, a definitely " no-no " 
 9. after the glue set (5 min-overnight), remove the C-clamp 

Tutorial for making Ben Hitchcock's Fred

Tutorial for making Light Tracking Bicore Head

Tutorial for making Lee's Solar-Pockmark

Tutorial for making Math's Lighthead2



 
 
 
 

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