Open up the bag the Servo came in. There will
be three screws. Two pointy wood screws with large
heads, and one small machine screw. Place the
single machine screw to the side, we won't be using
it now.
Pick up the large round wooden piece without an
arrow on it. The Servo is mounted on the bottom of
the piece.
Line the servo up with the screw holes, and then
carefully use the two Servo screws to secure it in
place. Once in place give it a little tug to make sure
it's secure. Find the second wooden Servo mount.
We'll be doing the same thing here with our second
Servo. Mount it on the "back" of the mount with the
two screws it came with.
Grab the very base plate, the four legs, and the
large round piece that now has a Servo attached to it.
You'll also need 8 of the 6-32 Screws and 8 nuts.
First attach the four legs to the round servo
holder. The Servo needs to be inside all the legs,
between the the base plate and the round servo
holder. Don't tighten the screws all the way, leave
them a bit loose.
Now fit the four legs into the base plate. Make
sure that when you do this the servo wire is
positioned so that it's coming out towards the back
where all our electronics will be.
Once all our legs are screwed into the base plate
go back and tighten the four screws that attach the
legs to the round servo holder.
Lastly, put the four rubber feet on the bottom of
the base plate so that the screw heads don't scratch
up your work surface.
At this time you can also put together the LED
display holder. The LED display just fits between
the two wooden holders and is secured by two
screws and nuts.
Grab the large solar array face. It's the one that
says "Solar Cell Here" on it. We'll also need the two
triangle wings, the small rounded corner square
piece, and the two small sensor divider pieces. To
connect it all we'll need six 6-32 Screws and nuts.
Put the face plate on the table in front of you so
that you can read the words. Attach the triangle wing
piece with the servo arm on the right side, and the
other triangle wing piece onto the left side. We want
the plastic servo arm to be facing the inside.
Use four screws and nuts to hold that together.
Now use the three remaining pieces to build the
sensor divider. Rounded square first, then the tall
skinny piece, and finally the longer piece with the
two screw T slots. Once it's all together use two
screws and nuts to secure it.
Servos move in 180 degrees. The Servo knows
where "zero" degree is and where "180" degree is.
Since we don't want or need full 180 degree range
on our servos we want to set our "zero" degree to
some very specific locations.
Start with the Base plate Servo. Without using
the little screws push the Servo Arm that’s attached
to the Center into the servo. This may take a little
effort, so you may wish to brace the
servo with your other hand. Once together,
slowly rotate the Center counter clockwise until
there servo stops. This is "zero" degrees on the
Servo.
The relationship between battery voltage and
capacity is shown in Figure 1.
Figure 1: Voltage vs. Discharge capacity.
2.4 Assemble of Sensors
Take Connectors. Snip off the ends of the wires and
then strip the wires.
Grab four Light Sensitive Resistors. The legs are
way too long. Remove 2/3rds of their legs.Push one
Light Sensitive Resistor into each of the four
Connectors. The should go in easily.Thread one
Female JST Connector through each of the four
holes around the Sensor Divider.
Now have 8 wires handing down through the
Top around the Sensor Divider.
A diagram of the full circuit with the battery
indicators is shown in Figure 2.