LeLamp Assembly Guide

Complete mechanical and electrical assembly instructions for building your LeLamp robot

LeLamp Assembly Guide

⏱️ Estimated time: 1–2 hours
🔧 Required tools: Soldering iron, screwdrivers, heat insert tool
📦 Required components: Raspberry Pi, ReSpeaker Hat, speaker, LED Matrix, SD card, servo driver

This guide covers the complete assembly of your LeLamp, from individual component preparation to final integration and testing.

Assembly Overview

LeLamp consists of three main sections that work together to create an expressive robotic lamp:

LeLamp Head

Audio & Visual Components

• 4Ω/3W Speaker for audio output
• WS2812B LED Matrix for expressions
• Camera for computer vision

LeLamp Base

Control Electronics

• Raspberry Pi with ReSpeaker Hat
• Motor Driver for servo control
• Power management systems

LeLamp Body

Mechanical Systems

• 5 STS3215 servo motors
• 3D printed structural components
• Precision mechanical assemblies

All connections between the Head and Base are made through a stripped Ethernet cable, which carries power and data signals. Connections from the Base to motors use the default wires provided with each motor.

Pre-Assembly Preparation

Safety First: Review all safety warnings before beginning assembly. Ensure adequate ventilation, proper lighting, and have safety equipment ready.

Required Materials Checklist

Electronic Components

• Raspberry Pi 4 (4GB+ recommended)
• ReSpeaker 2-Mics Pi HAT
• Servo driver board
• 4Ω/3W speaker
• WS2812B LED matrix
• Camera module (Pi Camera or USB webcam)
• MicroSD card (32GB+ recommended)

Mechanical Components

• 5× STS3215 servos (configured with IDs 1-5)
• All 3D printed parts (supports removed, surfaces cleaned)
• Heat inserts (M2 and M3 sizes)
• Screws and fasteners per BOM
• Servo horns and mounting hardware

Cables and Connectors

• Ethernet cable (for stripping into individual wires)
• USB Type-C cable (Pi to servo driver)
• Female header connectors
• JST 2.0 male connectors
• Heat shrink tubing
• Wire (22-26 AWG, various colors)

Section 1: LeLamp Head Assembly

The head assembly contains the audio and visual components that give LeLamp its expressive capabilities.

1. Prepare the Ethernet Cable

   Strip the outer insulation from approximately 50cm of Ethernet cable to expose the 8 individual wires inside.

   Wire Color Assignments

   Orange/White: LED Data Signal
   Orange: LED Ground
   Green/White: LED 5V Power
   Blue: Speaker Positive
   Blue/White: Speaker Negative
   Green: Reserved/Unused
   Brown: Reserved/Unused
   Brown/White: Reserved/Unused
   

   You may use individual wires instead of Ethernet cable, but ensure each wire is at least 50cm long to reach from head to base.

2. Solder LED Matrix Connections

   Connect the LED matrix following WS2812B wiring standards:

   Connection Diagram

   LED Matrix Pad	Wire Color	Function
   VCC/5V	Green/White	Power supply
   GND	Orange	Ground reference
   DIN/Data	Orange/White	Data signal

   Soldering Tips

   • Use flux for clean, reliable joints
   • Keep iron temperature at 350°C
   • Tin both wire and pad before joining
   • Use heat shrink to insulate connections
   • Test continuity with multimeter

   LED matrices are sensitive to static discharge. Use anti-static precautions and avoid touching the LED chips directly.

   
3. Connect Speaker Wiring

   Solder the speaker connections:

   1. Identify speaker polarity (usually marked + and -)
   2. Solder Blue wire to positive terminal
   3. Solder Blue/White wire to negative terminal
   4. Add JST 2.0 male connector to the other end of speaker wires

   The JST connector will plug directly into the ReSpeaker Hat’s speaker port, making assembly and disassembly easier.

4. Install Components in Head Structure

   Mount the components in the 3D printed head assembly:

   1. Position LED matrix according to orientation markings
   2. Mount speaker with cone facing outward
   3. Route cables through designated cable management channels
   4. Secure components with appropriate screws
   5. Test fit head assembly before final tightening

   

Section 2: LeLamp Base Assembly

The base contains all control electronics and power management systems.

1. Prepare ReSpeaker Hat

   Solder header pins to the ReSpeaker Hat:

   1. Insert 40-pin header into GPIO holes
   2. Ensure proper alignment with Pi GPIO layout
   3. Solder all connections with clean, consistent joints
   4. Test fit on Raspberry Pi before proceeding

   

   All GPIO pins should be straight, properly aligned, and securely soldered.

2. Mount Electronics in Base

   Install the control electronics in the base structure:

   Component Placement

   • Raspberry Pi: Mount in designated area with access to ports
   • Motor Driver: Position for easy USB connection to Pi
   • Power connections: Ensure adequate clearance for cables
   • Ventilation: Don’t block any ventilation holes

   Mounting Hardware

   • Use M2.5 screws for Raspberry Pi mounting
   • Secure motor driver with appropriate fasteners
   • Ensure no components can shift during operation
   • Verify all connections are accessible

   
3. Connect USB Communication

   Connect the motor driver to Raspberry Pi:

   Pi USB Port → USB Type-C Cable → Motor Driver
   

   Use a high-quality USB cable to ensure reliable communication. Poor cables can cause intermittent servo control issues.

4. Install ReSpeaker Hat

   Mount the ReSpeaker Hat on the Raspberry Pi:

   1. Align GPIO headers carefully
   2. Press down evenly to ensure full connection
   3. Secure with standoffs if provided
   4. Verify no bent pins or poor connections

   
5. Connect Head Wiring to Base

   Connect the Ethernet cable from the head to the ReSpeaker Hat:

   1. Prepare female header connectors on Ethernet wires
   2. Match wire colors to ReSpeaker Hat pin assignments
   3. Connect JST speaker connector to speaker port
   4. Verify all connections against schematic

   Wire Function	ReSpeaker Pin	Connection
   LED 5V	5V	Female header to 5V pin
   LED Ground	GND	Female header to GND pin
   LED Data	GPIO18	Female header to GPIO18
   Speaker	Speaker Port	JST connector

   Double-check all connections before powering on. Incorrect wiring can damage components permanently.

Section 3: LeLamp Body Assembly

The body assembly provides the mechanical structure and servo mounting for LeLamp’s expressive movement.

Reference the OnShape 3D Assembly for detailed component positioning and orientation.

Servo Preparation

1. Attach Servo Horns

   Each STS3215 servo comes with two horns - prepare them correctly:

   Geared Horn (Output Side)

   • Location: Side with copper gear visible
   • Attachment: Secure firmly with provided screws
   • Torque: Tighten to manufacturer specification
   • Function: Transmits power to mechanical linkages

   Alignment Horn (Input Side)

   • Location: Opposite side from copper gear
   • Attachment: Place without screwing (alignment only)
   • Function: Provides axis alignment and support
   • Note: Not needed for yaw and roll servos

   
2. Verify Servo Orientation

   Correct servo orientation is critical for proper operation:

   Motor body asymmetry: The STS3215 servo body is not symmetrical. Incorrect orientation will cause binding and potential damage.

   Orientation Guidelines:

   • View LeLamp from top-down with wire slit facing right
   • Pitch servo horns (geared) should face outward (away from you)
   • Yaw and roll servos don’t require alignment horns

   

Mechanical Assembly

1. Install Heat Inserts

   Install threaded heat inserts in all 3D printed parts:

   M2 Heat Inserts

   • Temperature: 200-220°C
   • Depth: Flush with surface
   • Alignment: Perpendicular to surface
   • Cooling: Allow to cool completely before use

   M3 Heat Inserts

   • Temperature: 220-240°C
   • Depth: Slightly below surface
   • Pressure: Steady, even pressure during insertion
   • Verification: Test thread engagement with screw

   Heat inserts reach dangerous temperatures. Use proper tools, ventilation, and safety equipment.

2. Mount Servos in Structure

   Install servos in their designated positions:

   1. Base Yaw Servo (ID: 1): Bottom of base assembly
   2. Base Pitch Servo (ID: 2): Primary articulation joint
   3. Elbow Pitch Servo (ID: 3): Mid-body joint
   4. Wrist Roll Servo (ID: 4): Head rotation mechanism
   5. Wrist Pitch Servo (ID: 5): Head tilt mechanism

   Servo Mounting Guidelines

   • Use appropriate screw length to avoid binding
   • Ensure servo cables can move freely
   • Verify full range of motion before final tightening
   • Check for interference with adjacent components

   Cable Management

   • Route cables through designated channels
   • Avoid sharp bends or pinch points
   • Secure cables to prevent snagging
   • Leave service loops for maintenance access

   
3. Connect Servo Daisy Chain

   Wire the servos in sequence for communication:

   Motor Driver → Base Yaw → Base Pitch → Elbow Pitch → Wrist Roll → Wrist Pitch
   

   Connection Order

   1. Start at motor driver output connector
   2. Connect to Base Yaw servo input
   3. Chain through each servo in sequence
   4. End at Wrist Pitch servo (no output connection needed)

   Wire Management

   • Use provided servo extension cables if needed
   • Secure connections with heat shrink tubing
   • Test each connection before proceeding
   • Document wire routing for future service

   If servo wires are too short, extend them by splicing additional wire using proper techniques.

Power System Setup

LeLamp requires two separate power supplies for optimal operation:

1. Servo Power Supply

   5V 2A DC Power Supply with DC Plug

   • Function: Powers all servo motors
   • Connection: DC plug to motor driver power input
   • Verification: Check voltage with multimeter before connection

   Servo power supply provides stable 5V under load conditions.

2. Raspberry Pi Power Supply

   5V 2A USB Type-C Charger

   • Function: Powers Raspberry Pi and ReSpeaker Hat
   • Connection: USB-C to Pi power port
   • Quality: Use official Pi power supply or high-quality equivalent

   While it’s possible to power the Pi from the motor driver, this is not recommended due to risk of voltage fluctuations damaging the Pi.

Assembly Verification and Testing

1. Visual Inspection

   Perform thorough visual inspection:

   • All screws properly tightened
   • No loose wires or connections
   • Servo cables properly routed
   • No interference between moving parts
   • Heat inserts properly seated
   • All components securely mounted
2. Mechanical Function Test

   Test mechanical operation before powering electronics:

   • All joints move freely by hand
   • No binding or excessive resistance
   • Full range of motion available
   • No unusual noises during movement
   • Servo horns properly aligned
3. Electrical Continuity

   Verify electrical connections:

   • Power supply voltages correct
   • All ground connections secure
   • Signal wires properly connected
   • No short circuits detected
   • USB communication cable functional

Final Assembly Integration

1. Connect All Subsystems

   Integrate head, base, and body assemblies:

   1. Route head cable through body structure
   2. Connect to base electronics per wiring diagram
   3. Secure all cable connections
   4. Verify mechanical clearances
   5. Test basic functionality
2. Initial Power-On Test

   Perform first power-up with safety precautions:

   Be prepared to disconnect power immediately if any problems occur during initial testing.

   1. Connect servo power supply (servos should initialize)
   2. Connect Pi power supply (Pi should boot normally)
   3. Observe LED indicators on all boards
   4. Listen for unusual sounds or heating
   5. Verify basic communication via SSH

Assembly Completion Checklist

Mechanical Assembly

• All 3D printed parts properly assembled
• Heat inserts correctly installed and threaded
• Servos mounted in correct positions and orientations
• Full range of motion verified for all joints
• No mechanical interference or binding
• Cable routing clean and secure

Electrical Assembly

• All electronic components properly mounted
• ReSpeaker Hat correctly installed on Pi
• Head components wired and connected to base
• Servo daisy chain properly configured
• Power supplies connected and tested
• No short circuits or wiring errors

System Integration

• Head, base, and body properly integrated
• All cable connections secure and accessible
• Power-on test completed successfully
• Basic communication verified
• Ready for software configuration and testing

What You Should Have

At this stage, you should have a complete, mechanically assembled LeLamp with:

• Functional mechanical structure with smooth servo operation
• Integrated electronics with proper power and communication
• Connected head assembly with audio and visual components
• Proper cable management throughout the system

Assembly Complete! Your LeLamp hardware is now ready for software configuration and calibration.

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Take photos of your completed assembly for troubleshooting reference and to share with the community on Discord!