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The shell is the first component for consideration. It must be transparent and large enough to hold the gearbox and electronics. The shell used in my prototype has a diameter of 51/2". Snap-together transparent spheres are available in many hobby and craft stores. Hobbyists use them to enclose holiday ornaments, If you cannot find a suitable shell locally, you can purchase one from Images SI (see the parts list at the end of this chapter). The plastic shell is fragile. Do not have your robot try to climb or fall down stairs; it is sure to crack and break. Separate the two halves of the shell. The first job is to locate the center of each half sphere.This is where the shafts of the gearbox will be connected. Locating the center at first appears much easier than it actually is. To find the center, I was forced to trace the diameter of the shell on white paper, then draw a box around the drawn circle that touched the circle on four sides (see Fig. 12.4). Drawing

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the diagonal lines from the corners of the box, I was able to locate the circle center. The half sphere is then positioned over the drawn circle. If you hold your head directly over the half sphere, you may be able to eyeball the center and mark it on the sphere with a magic marker. I tried this once or twice with less than ideal results. Finally, I taped the paper on a 1/2" piece of wood and drilled a small hole at dead center. Then I placed a small dowel, about 2.5" long, in the hole, making sure it was perpendicular to the wood. Place the half sphere over the fixture, lining up its diameter with the drawn circle; the dowel locates the center of the sphere fairly accurately. Mark the center of one half sphere, and then the other. The next step is to make a drive-locking fixture in the sphere that prevents the gearbox shaft from rotating freely inside. With the shaft locked, it forces the gearbox itself to rotate inside the sphere, changing the center of gravity and moving the robot along. The drive fixture must at the same time allow the sphere to be assembled or unassembled at will. The system I devised is illustrated in Figs. 12.5 and 12.6. Although I built all the drive components out of transparent plastic on the prototype, you can fabricate the parts out of other materials like brass and wood.

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The first component is a small length of tubing 5/8" outside diameter (OD), 1/2" inside diameter (ID), and about 3/8" long. This tubing is glued to the center of the half sphere, using the marks as a guide. Inside the tubing, glue a 1/2"-diameter half round about 3/8" long. This piece may be glued inside the tubing before the tubing itself is glued into the sphere. Next, cut a small length of 1/2"-diameter solid rod. On one end of the rod, remove a 3/8" half section. This is accomplished using a hacksaw or coping saw. First make a cut directly down the center of the rod about 3/8" deep. Then make a horizontal cut to remove the half section. Check to make sure this shaft fits easily into the 3 /8" tube and half round assembly inside the half sphere. If not, file the cut end until it does. At the opposite end of this rod, drill a hole down the center that will fit the shaft from the gearbox. Note: On the prototype robot, I made the second shaft a drive connection also. Only when the robot was finished did I realize that this was unnecessary. A single drive connection works just as well as a double. The second half sphere is easier to make. Glue a small length of 5 /8"-OD, 1/2"-ID tubing to the center of the half sphere, using the

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