xl97's Iron Man motorized face plate tutorial

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xl97

Sr Member
In an effort to:

1.) decrease confusion
2.) keep posts organized, in order
3.) hopefully help others spot people making money off what was freely giving for the community here

I am posting my approach (which I'm fairly certain people have taken and made 'products' for sale from) on how to add some electronics to your Iron Man buckets.. to get a motorized face plate and led (blinking) eyes..

The original post is located here:
http://www.therpf.com/showthread.php?t=170853

(I would suggest reading it regardless, and MUCH information has been provided to help trouble shoot other members with their issues)

* Take note of member: "memebr's" post over there as well as it is solid info (with a slight variation on my wiring and code for his wiring and code)

Key notes to take with you on this adventure:

1.) Servos shoud NOT be powered (driven) by your Arduino.. it may be 'ok' to temporarily connect the servo to your Arduino (with no load, nothing attached to the servo).. but generally they need more voltage and more current than the Arduino pin can provide.. and can blow your Arduino

2.) It is best/better to power your servo's separately, and connect the GND wires together for everything,

3.) I suggest using a +7.v Li-Ion pack with some sort of voltage regulation for your servos (and Arduino board if needed)

4.) Not connecting ground wires together may result in odd behavior and/or jitter in your servos.

5.) An Arduino pin is +5v tolerant and can only provide (roughly) 20-40mA... so enough to light up 1 or 2 small accent leds (not high powered ones)

6.) Your key components (eye leds, Arduino, servos) all take different voltage (have different power needs).. keep this in mind while you design, buy your parts.
https://www.youtube.com/watch?feature=player_detailpage&v=GSzVs7_aW-Y

* Arduino usually has vRegulator on-board (depending what variant you have/use) or needs a REGULATED +5v source (not more or you'll blow it)
* Servos (please read data sheet on your particular model).. most I have seen require about +6v (some +4.8-+6).. so you need to ensure you are not giving them more
* Your led eyes is a tricky and can be set up several ways..but most leds (depends on color too) need (roughly) +2.0v (reds) to +3.3v (blues, greens..etc)..
if wired up in parallel, they require more current (in total).. if wired up in series (you require less current, and can get closer to the voltage of the battery source, and not waste as much excess voltage as heat), so depending how it is configured/wired.. you'll need a +3.3v regulator or a maybe a +6v regulator..etc..

Read: http://www.therpf.com/showthread.php?t=170853&p=2729601&viewfull=1#post2729601



Link to the eye pcb's I made:
http://www.therpf.com/showthread.php?t=170853&p=2648856&viewfull=1#post2648856


Link to calculate the resistors needed in your personal set up:
http://www.therpf.com/showthread.php?t=170853&p=2650741&viewfull=1#post2650741


Random Link to sound FX: (if applicable to your project, a bit outside the scope of this tutorial though)
http://www.therpf.com/showthread.php?t=170853&p=2650741&viewfull=1#post2650741
http://www.therpf.com/showthread.php?t=170853&p=2662440&viewfull=1#post2662440


Bring this to the next level:
* You can add audio
* You can use other ways to trigger the faceplate (bluetooh, IR, accelerometer..etc) easily added in the base code below



Example vids:
http://youtu.be/VzPivAzSb5M

My personal (final) video: (servo, lights & sounds)
http://youtu.be/cTXt8l2XH-Q

*using a 'custom' Arduino board I made (it has built-in Waveshield/microSd..etc all on-board).. roughly same size of a Nano
*plays audio (.wav file from SD card)
ref pic: http://dmstudios.net/misc/scab_assembly/flash_board.jpg



First version of code posted: (eye blink code only)

Code:
// IronMan Helmet: eye blink sequence_v1.0
// created by: xl97


// led control pins (need to be PWM enabled pins for fading)
const int leftEye =  6;  // the number of the left eye/pcb LEDs
const int rightEye =  3;  // the number of the right eye/pcb LEDs

/* we always wait a bit between updates of the display */
unsigned long delaytime = 1;
unsigned long fadespeed = 500;
unsigned long blinkspeed = 100;
unsigned long currentPWM = 0;

#define S_IDLE 1
#define S_LEDON 2
#define S_WAITON 3
#define S_LEDOFF 4
#define S_WAITOFF 5
#define S_INITON 6
#define S_INITWAIT 7
#define S_BLINKON 8


//FSM init vars
static int state = S_IDLE; // initial state is 1, the "idle" state.
static unsigned long lastTime;  // To store the "current" time in for delays.


void setup() {
  // Set up serial port
  Serial.begin(9600);  
  Serial.print("INTIT STATE: ");
  Serial.println(state);

  //start it off
  state = S_BLINKON; 
}





void loop() { 
  switch(state)
  {
  case S_IDLE:
    // We don't need to do anything here, waiting for a forced state change...like button press.
    break;

  case S_BLINKON:
    //do blink routine here
    analogWrite(leftEye, 155);
    analogWrite(rightEye, 155);
    delay(blinkspeed);
    analogWrite(leftEye, 0);
    analogWrite(rightEye, 0);
    delay(blinkspeed);
    analogWrite(leftEye, 155);
    analogWrite(rightEye, 155);
    delay(blinkspeed);
    analogWrite(leftEye, 0);
    analogWrite(rightEye, 0);
    delay(10);
    currentPWM = 0;
    
    state = S_LEDON;    
    break;

  case S_LEDON:
    Serial.println("increase........");
    analogWrite(leftEye, currentPWM);
    analogWrite(rightEye, currentPWM);
    lastTime = millis();  // Remember the current time
    state = S_WAITON;  // Move to the next state
    break;

  case S_WAITON:
    // If one second has passed, then move on to the next state.
    if(millis() > lastTime + delaytime)
    {
      if(currentPWM < 255){
        currentPWM++;
        state = S_LEDON;        
      }
      else{
        Serial.println("@255 done........");
        state = S_IDLE;
        //state = S_LEDOFF; //no auto turn off.. set to idle state
      }
    }
    break;

  case S_LEDOFF:
    Serial.println("........decrease"); 
    lastTime = millis();  // Remember the current time
    state = S_WAITOFF;
    break;

  case S_WAITOFF:
    // If one second has passed, then go back to state 2.
    if(millis() > lastTime + delaytime)
    {
      if(currentPWM > 0){
        currentPWM--;
        state = S_LEDOFF;        
      }
      else{
        state = S_LEDON;
      }
    }
    break;

  default:
    state = S_IDLE;
    break;
  } 
}



Second version of code: (eye blink and servo)

*Summary:

1.) 1 x button (digital pin 2) controls both open and close operations
2.) when OPEN.. the servos will close and then trigger the led 'blink & fade in' routine
3.) when CLOSED... the leds will fade out then the servos will 'open'.

should be a very scalable and easy editable sketch so far:
Code:
// IronMan Helmet: eye blink sequence_v1.0
// created by: xl97
// Movie Props, Costumes and Scale Models | the RPF thread: 
// http://www.therpf.com/f24/iron-man-m...ml#post2647126

//import servo lib
#include <Servo.h>

//servo object names
Servo myservo; // create servo object to control a servo
Servo myservo1;

const int buttonPin = 2; // the pin that the pushbutton is attached to
int buttonState = 0; // current state of the button
int lastButtonState = 0; // previous state of the button
int pos = 0; // variable to store the servo positions
int pos1 = 180;

// led control pins (need to be PWM enabled pins for fading)
const int leftEye =  6;  // the number of the left eye/pcb LEDs
const int rightEye =  3;  // the number of the right eye/pcb LEDs

unsigned long delaytime = 1;
unsigned long blinkspeed = 100;
unsigned long currentPWM = 0;
boolean isOpen = true;

#define S_IDLE 1
#define S_LEDON 2
#define S_WAITON 3
#define S_LEDOFF 4
#define S_WAITOFF 5
#define S_INITON 6
#define S_INITWAIT 7
#define S_BLINKON 8
#define S_SERVOUP 9
#define S_SERVODOWN 0



//FSM init vars
static int state = S_IDLE; // initial state is 1, the "idle" state.
static unsigned long lastTime;  // To store the "current" time in for delays.


void setup() {
  // Set up serial port
  Serial.begin(9600);  
  //start it off
  //state = S_BLINKON; 
  Serial.print("INTIT STATE: ");
  Serial.println(state);

  myservo.attach(9); // attaches the servo on pin 9 to the servo object
  myservo1.attach(10); // attaches the servo on pin 10 to the servo object

  pinMode(buttonPin, INPUT); // initialize the button pin as a input
  digitalWrite(buttonPin, HIGH); //use interal pull up resistors
}

void loop() { 
  switch(state)
  {
  case S_IDLE:
    // We don't need to do anything here, waiting for a forced state change...like button press.
    //check mian button state
    buttonState = digitalRead(buttonPin);

    // compare buttonState to previous state  
    if (buttonState != lastButtonState) {
      //if button pressed/down
      if (buttonState == LOW){
        //ie: pressed   
        if(isOpen == true){
          Serial.print("CLOSING FACE PLATE: ");
          Serial.println(isOpen, DEC); 
          state = S_SERVODOWN;
        }
        else{
          Serial.print("OPENING FACE PLATE: ");
          Serial.println(isOpen, DEC); 
          //state = S_SERVOUP;
          state = S_LEDOFF;
        }
        isOpen = !isOpen;

      }
      else{
        //went from ON/HIGH to LOW/OFF..ie: released
        //Serial.print("RELEASE: ");
        //Serial.println(isOpen, DEC); 
      } 

    }
    // save the current state for next loop
    lastButtonState = buttonState;
    break;

  case S_BLINKON:
    Serial.println("init blink.........");   
    //do blink routine here
    analogWrite(leftEye, 155);
    analogWrite(rightEye, 155);
    delay(blinkspeed);
    analogWrite(leftEye, 0);
    analogWrite(rightEye, 0);
    delay(10);
    /*
    analogWrite(leftEye, 155);
    analogWrite(rightEye, 155);
    delay(blinkspeed);
    analogWrite(leftEye, 0);
    analogWrite(rightEye, 0);
    delay(10);
    */    
    currentPWM = 0;
    state = S_LEDON;    
    break;

  case S_LEDON:
    Serial.println("increase........");    
    lastTime = millis();  // Remember the current time
    analogWrite(leftEye, currentPWM);
    analogWrite(rightEye, currentPWM);
    state = S_WAITON;  // Move to the next state
    break;

  case S_WAITON:
    // If one second has passed, then move on to the next state.
    if(millis() > lastTime + delaytime)
    {
      if(currentPWM < 255){
        currentPWM += 5;
        state = S_LEDON;        
      }
      else{
        Serial.println("@ 255 done........");
        state = S_IDLE;
        //state = S_LEDOFF; //no auto turn off.. set to idle state
      }
    }
    break;

  case S_LEDOFF:
    Serial.println("........decrease");     
    lastTime = millis();  // Remember the current time
    analogWrite(leftEye, currentPWM);
    analogWrite(rightEye, currentPWM);
    state = S_WAITOFF;
    break;

  case S_WAITOFF:
    // If one second has passed, then move on to the next state.
    if(millis() > lastTime + delaytime)
    {
      if(currentPWM > 0){
        currentPWM -= 5;
        state = S_LEDOFF;        
      }
      else{
        Serial.println("@ 0 done........");
        state = S_SERVOUP; //leds off..raise faceplate
      }
    }
    break; 

  case S_SERVOUP:
    myservo.write(100);
    myservo1.write(100);
    //delay(20); //wait to trigger the led flicker.. will remove delay() use in next revision
    state = S_IDLE;
    Serial.println("servo up.........");   
    break;

  case S_SERVODOWN:
    myservo.write(0);
    myservo1.write(0);
    delay(20); //wait to trigger the led flicker.. will remove delay() use in next revision
    state = S_BLINKON;
    Serial.println("servo down.........");   
    break;

  default:
    state = S_IDLE;
    break;
  } 
}

3rd version of code:

* here is an updated version...

where you can easily control the 'wait' between when you call/start the eye flicker/fade in, after the face plate servo starts to bring it down.. (easy to time your own servo/wait...etc)

Code:
// IronMan Helmet: eye blink sequence_v1.0
// created by: xl97


//import servo lib
#include <Servo.h>

//servo object names
Servo myservo; // create servo object to control a servo
Servo myservo1;

const int buttonPin = 2; // the pin that the pushbutton is attached to
int buttonState = 0; // current state of the button
int lastButtonState = 0; // previous state of the button


// led control pins (need to be PWM enabled pins for fading)
const int leftEye =  6;  // the number of the left eye/pcb LEDs
const int rightEye =  3;  // the number of the right eye/pcb LEDs

unsigned long fadeDelay = .5; //speed of the eye 'fade'
unsigned long callDelay = 700; //length to wait to start eye flicker after face plate comes down
unsigned long blinkSpeed = 100; //delay between init blink on/off
unsigned long currentPWM = 0;
boolean isOpen = true;

#define S_IDLE 1
#define S_LEDON 2
#define S_WAITON 3
#define S_LEDOFF 4
#define S_WAITOFF 5
#define S_INITON 6
#define S_INITWAIT 7
#define S_BLINKON 8
#define S_SERVOUP 9
#define S_SERVODOWN 0
#define S_SERVOWAIT 10



//FSM init vars
static int state = S_IDLE; // initial state is 1, the "idle" state.
static unsigned long lastTime;  // To store the "current" time in for delays.


void setup() {
  // Set up serial port
  Serial.begin(9600);  
  //start it off
  //state = S_BLINKON; 
  Serial.print("INTIT STATE: ");
  Serial.println(state);

  myservo.attach(9); // attaches the servo on pin 9 to the servo object
  myservo1.attach(10); // attaches the servo on pin 10 to the servo object

  pinMode(buttonPin, INPUT); // initialize the button pin as a input
  digitalWrite(buttonPin, HIGH); //use interal pull up resistors
}

void loop() { 
  switch(state)
  {
  case S_IDLE:
    // We don't need to do anything here, waiting for a forced state change...like button press.
    //check mian button state
    buttonState = digitalRead(buttonPin);

    // compare buttonState to previous state  
    if (buttonState != lastButtonState) {
      //if button pressed/down
      if (buttonState == LOW){
        //ie: pressed   
        if(isOpen == true){
          Serial.print("CLOSING FACE PLATE: ");
          Serial.println(isOpen, DEC); 
          state = S_SERVODOWN;
        }
        else{
          Serial.print("OPENING FACE PLATE: ");
          Serial.println(isOpen, DEC); 
          //state = S_SERVOUP;
          state = S_LEDOFF;
        }
        isOpen = !isOpen;
      } 
      else{
        //went from ON/HIGH to LOW/OFF..ie: released
        //Serial.print("RELEASE: ");
        //Serial.println(isOpen, DEC); 
      } 
    }
    // save the current state for next loop
    lastButtonState = buttonState;
    break;

  case S_BLINKON:
    Serial.println("init blink.........");   
    //do blink routine here
    //one blink
    analogWrite(leftEye, 155);
    analogWrite(rightEye, 155);
    delay(blinkSpeed);
    analogWrite(leftEye, 0);
    analogWrite(rightEye, 0);
    delay(10);
    //two blinks
    /*
    analogWrite(leftEye, 155);
     analogWrite(rightEye, 155);
     delay(blinkSpeed);
     analogWrite(leftEye, 0);
     analogWrite(rightEye, 0);
     delay(10);
     */
    state = S_LEDON;    
    break;

  case S_LEDON:
    Serial.println("increase........");    
    lastTime = millis();  // Remember the current time
    analogWrite(leftEye, currentPWM);
    analogWrite(rightEye, currentPWM);
    state = S_WAITON;  // Move to the next state
    break;

  case S_WAITON:
    // If one second has passed, then move on to the next state.
    if(millis() > (lastTime + fadeDelay)){
      if(currentPWM < 255){
        currentPWM += 5;
        state = S_LEDON;        
      }
      else{
        Serial.println("@ 255 done........");
        state = S_IDLE;
        //state = S_LEDOFF; //no auto turn off.. set to idle state
      }
    }
    break;

  case S_LEDOFF:
    Serial.println("........decrease");     
    lastTime = millis();  // Remember the current time
    analogWrite(leftEye, currentPWM);
    analogWrite(rightEye, currentPWM);
    state = S_WAITOFF;
    break;

  case S_WAITOFF:
    // If one second has passed, then move on to the next state.
    if(millis() > (lastTime + fadeDelay)){
      if(currentPWM > 0){  //change 0 to higher number to init face 'up' function sooner.
        currentPWM -= 5;
        state = S_LEDOFF;        
      }
      else{
        Serial.println("@ 0 done........");
        state = S_SERVOUP; //leds off..raise faceplate
      }
    }
    break; 

  case S_SERVOUP:
    Serial.println("servo up........."); 
    myservo.write(100);
    myservo1.write(100);
    state = S_IDLE;    
    break;

  case S_SERVODOWN:
    lastTime = millis();  // Remember the current time
    Serial.println("servo down.........");   
    myservo.write(0);
    myservo1.write(0);
    state = S_SERVOWAIT;    
    break;

  case S_SERVOWAIT:
    // If enough time has passed, call the eye flicker routine
    if(millis() > (lastTime + callDelay)){   
      Serial.println("start eye flicker routine");
      state = S_BLINKON;        
    }
    else{
      Serial.println("waiting........");
    }
    break;

  default:
    state = S_IDLE;
    break;
  } 
}

Wiring:




Hopefully this will clear up confusion, and offer people a FREE alternative to other justtaking the free work posted and making a profit from it.


Any questions, just ask. (I also suggest reading through the whole other thread for completensss and understanding) :)
 

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IronMeg

Active Member
Thank you so much for condensing this! I've always really wanted to do this, but I found the other thread to be VERY confusing. This, I might be able to give it a shot.
 

xl97

Sr Member
post back if you need help.

As long as you follow the diagram posted here, the code should work as well..

(slight difference in wiring between my code and memebers code there.. and the wiring matches those changes)

I would say first get the servo portion up & running.. then work in the leds and whatever else you want to add. :)
 

IronMeg

Active Member
post back if you need help.

As long as you follow the diagram posted here, the code should work as well..

(slight difference in wiring between my code and memebers code there.. and the wiring matches those changes)

I would say first get the servo portion up & running.. then work in the leds and whatever else you want to add. :)
Thanks! It'll be a while before I can actually work on it but it is very much something I've always wanted to do.
 

Ikras

Active Member
I'm aiming to start work on this shortly and it's a great help having it summarised in this way. I've got most of the bits I need but was looking to check some details about the capacitors with the voltage regulator. I saw in the other thread that those are smooth out any variations from the battery but what determines the values you've chosen?

I've got a large of pack with a range of values (but not the particular ones you've got in the diagram) and I'm just trying to work out the origin of those numbers.
 

xl97

Sr Member
the capacitors used on the voltage regulator will be determined by the specific voltage regulator used.

whatever one you use, check out the data sheet, it should tell you what values to use.
 

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jediknight

New Member
hey guys, im a total noob, could you write out a shoping list of everything i will need, im from the uk and will probably be buying from ebay.co.uk :) im looking to have the servo and eyes, many thanks!!!!
 

xl97

Sr Member
I dont see why not. :)


Just make sure credit goes to where it needs to go.

Both myself and member "memebr" have contributed a lot of time and info to these two threads/posts... (while others may think they know or did it themselves, or are even profiting from the free work shared here... in reality, no one else contributed anything or truly understood what was going on)

please post links or pm? to the other sites shared on.

thanks
-xl
 

Murdoch

Sr Member
RPF PREMIUM MEMBER
I dont see why not. :)


Just make sure credit goes to where it needs to go.

Both myself and member "memebr" have contributed a lot of time and info to these two threads/posts... (while others may think they know or did it themselves, or are even profiting from the free work shared here... in reality, no one else contributed anything or truly understood what was going on)

please post links or pm? to the other sites shared on.

thanks
-xl
Proper credit is proper all around.
Thanks guys for this...GM
 

xl97

Sr Member
not quite sure what the first line means?


but if your truly saying thanks!.. then no problem!

glad to have helped someone bring their prop to the next level!! :)

(just irks me a bit that some have taken the diagrams, code..etc and tried to profit from it)
 

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Dio

Jr Member
Hi xl97,
I'm new here and recently want to start the Iron Man helmet project. Right Now I'm working on the Electric part and following your instruction. I want to try virtual simulation before I actually hands on these electric parts. I used the website called 123D to do the simulation. Below is what I did.
Test.jpg
Hope the graph doesn't look too messy. After I load the code, nothing happening. The code I used is your "IronMan Helmet: eye blink sequence_v1.0" code.

I'm not sure if I connect everything correctly, since I have no background in electric at all.

One more thing, I couldn't find the vregulator LM7805 under the add components section on 123d's website. So I used pmos instead.

Could you give me a hand on this?

Thanks

Dio
 

xl97

Sr Member
Hi-

Not familiar with the 123D site.. (might have to check it out)

what is a PMOS? the LM7805 is a voltage regulator.. that also required some capacitors to run properly.. (which I think you have in your schematic?)

hard to tell but it looks mostly correct.. what I dont see (which may very well be there.. but not visible with that diagram) is the lines/pins out to the transistors that switch on/off the eye leds?

might be easier to just get a breadboard and prototype things up instead of the simulator..
 

Dio

Jr Member
HI

Thanks for the quick reply.

PMOS is showing as "pMOS Transistor (MOSFET)" on the 123D website (https://123d.circuits.io).

I did add two capacitors just like your instruction. The problem is in your instruction I see the power source is linked at the top left comer as below (I circled blue) :

IronMan_circuitLayout_xl97.jpg

However, on the 123D website they don't have this option. So I linked positive to 5v and negative on the GND both on tthe POWER section showing on the UNO R3 board.

The reason why I use 123D is they have the start simulation function so after I link all the parts together and upload the code, it can virtually show how the result looks like.

I tried to find some other virtual simulation software but they are not free such as VBB. I also tried Fritzing but it is for schematic only, no simulation.

If you know any other good simulation software, could you let me know?

I redid another screenshot. hoe this looks better:

Test 1.jpg

I connect both led to the 0.1 uf Capacitor.

I don't know if you have a schematic with the breadboard? I saw your comments saying that the Jump Wire can be used for temporary test due to their voltage limitation is not suggested for a long run.

I have order the package on amazon but since it come from china the ETA showing as begin or middle of March. So I thought I may play around with the virtual simulation to be prepared. Just want to make sure I don't burn any of the actual parts. If I do, it will take another 1 and half month for the new one arrive:cry

Really hope I can get it work.

Thanks

Dio
 

xl97

Sr Member
I have never worked with EL wire or sheets before...

so I am not sure about the PWM..etc of them.. (or how it works with the inverter)


in theory though... if you need to trigger/power something the Arduino cant.. but need the Arduino to 'control' that triggering.. this is the same approach.
 
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