View source for Simple Sound to Servo

The Simple sound to servo is an inexpensive controller based on the Scary Terry sound to servo circuit found here  http://www.scary-terry.com/audioservo/audioservo.htm This circuit takes an audio source such as an MP3 player and outputs a signal to a hobby servo to move the jaw to the sound on talking props. 
 
[[File:SS2S Tplace.jpg]]
[[File:Sound to servo.JPG]]


==Adjustments==
'''Gain:'''
The gain adjustment is used to control the gain of the amplifier to match the controller to your source audio

'''Threshold:'''  The threshold adjustment is used to calibrate the circuit and set the point of sound or no sound

'''Max Adj:'''   
The max adjust is used to set the maximum servo position when sound is present.  You can think of this like a high limit switch

'''Min Adj:'''  
The min adjust is used to set the minimum servo position when sound is not present.  You can think of this like a low limit switch.

'''Capacitor Select:'''  
There are 3 capacitors of different values to chose from.  The higher the value of the capacitor the more smooth the jaw will move.  If you want a more jerky action enable a lower value capacitor or no capacitor at all.  The capacitors are arranged lowest to highest value from left to right.  Capacitors are enabled by placing a shunt on the jumpers JP4,JP5,JP6 directly above the capacitors.

'''LED:'''  
The LED lights up when sound is present and is used to aid in setting the threshold adjustment

'''L/R Select:''' 
If you want the board to "Listen" only to the left or right channel of audio install a shunt on either the left or right jumper.  If you want it to "listen" to both channels install shunts on both jumpers.

==Connections==

'''Audio input: X3'''  
This is where you connect stereo audio to the board.  anything from line level to low level speaker should be OK

'''Power input: X2'''  
4.7-6 VDC is connected here.  The current required will depend largely on the servo you are using.  This circuit draws very little current check the specs your servo for current requirements

'''Servo Header: JP3'''  
This is where your servo will connect to the board.  Pin#1(yellow) goes to the left when connecting the servo


==Setup==

1 Turn on the power and remove all audio source.  This can be done by removing the L/R select shunts

2 Turn the threshold adjustment clockwise until the circuit trips(the LED will light and the servo will move to the open position)

3  Adjust the MAX adjust to your desired full open position.

4  Slowly turn the threshold adjustment counter-clockwise until the circuit resets(LED will turn off and servo will move to the closed position)

5  Adjust the Min adjustment to your desired full closed position. 

6  Add your audio source and adjust the gain as needed to make the circuit trip and reset with the audio

==Description of operation==
 
From the Scary Terry [http://www.scary-terry.com/audioservo/audioservo.htm website]

"As long as there is sound present, the servo will drive to its "max" position. If the sound is short in duration, the servo will not have time to drive to "max" but will drive part way and return to "min" position. While this method of moving a mouth is not perfect, it's pretty good and I'm very happy with the effect. It's important to remember that any sound will drive the servo, voice, music or noise, so if you're trying to make a Bucky mouth move to a voice track, you shouldn't have music in the background of that particular track. There is a way to include music or other sounds and still have the appropriate jaw movement. Jeff Stevens came up with a solution and I include his email at the bottom of this page"

Jeff Stevens solution

"Dear Scary-Terry, I am writing you about a new method for using your audio-servo driver. Here’s how you do it. First, you record your sounds on a two channel cd and player. On one of the channels have the voice and all other audio effects that you want people to hear, such as music or thunder etc. On the other channel, whether it is the left or right it doesn’t matter, you record the sounds that you want to drive the audio-servo driver. You connect this channel to the audio driver. You then use a y-splitter to take the first channel, the one you want people to hear, and connect it to both channels on the amplifier or amplified speakers. You now have the ability to have music without it activating the skull. The effect sounds stereo because it is coming out of two speakers, but both are playing the same thing. That is the only disadvantage. Let me know what you think. -Jeff Stevens"
==Assembly==
'''THE ASSEMBLY INSTRUCTIONS ARE A WORK IN PROGRESS, PLEASE CHECK BACK IN A FEW DAYS WHEN IT IS FINALLY CORRECT'''

The Simple Sound to Servo is a simple device to assemble and test.  It is easiest if you build the units by inserting  the various components from smallest to tallest . 

#Begin by inspecting the PCBs to look for any defects such as cracks or breaks. The holes on the board should be open on both sides. Then inspect and sort out the various parts for the board.
#Install the resistors:
##	220K OHM Resistor	R9	The resistor is not polarized, so it can go either way.
##	1K OHM Resistor		R1	The resistor is not polarized, so it can go either way.	
##	47K OHM Resistor	R2,R4	The resistor is not polarized, so it can go either way.	
##	10K OHM Resistor	R5,R12,R15,R20	The resistor is not polarized, so it can go either way.
##	2.2K OHM Resistor	R14	The resistor is not polarized, so it can go either way.
##	470 OHM Resistor	R8	The resistor is not polarized, so it can go either way.
##	4.7K OHM Resistor	R4,R11	The resistor is not polarized, so it can go either way.
#Install adjustment trimpots:
##	5K OHM Trimpot Resistor R3	The trimpot only fits one way, with the two legs towards the top of the board.	
##	1K OHM Trimpot Resistor R6	The trimpot only fits one way, with the two legs towards the top of the board.	
##	50K OHM Trimpot Resistor R10,R22	The trimpot only fits one way, with the two legs towards the top of the board.
#Install 1N914 Diode 	D1	The diode is polarized and it can only go one way.
#Install IC Sockets:
##	14 pin IC Socket IC2	The notch on the socket should face the left side of the board.
##	8 pin IC Socket Ic1, IC3	The notch on the socket should face the left side of the board.
#Install 2N3904 Transistor	Q1	The flat side of the transistor should face the left side of the board.
#Install Capacitors:	
##	2.2uF Electrolytic Capacitor 5x11mm	C5	The capacitor is polarized.  The side of the capacitor will have a stripe on the negative side.  The long lead is the positive side, and it goes in the hole towards the top side of the board.
##	4.7uF Electrolytic Capacitor 5x11mm	C2	The capacitor is polarized.  The side of the capacitor will have a stripe on the negative side.  The long lead is the positive side, and it goes in the hole towards the top side of the board.
##	10uF Electrolytic Capacitor 5x11mm	C7	The capacitor is polarized.  The side of the capacitor will have a stripe on the negative side.  The long lead is the positive side, and it goes in the hole towards the top side of the board.
##	100nF (0.1uF) Mylar Film Capacitor	C1,C3,C6,C11	The capacitor is not polarized, so it can go either way.
##	10nF (0.01uF) Mylar Film Capacitors	C4		The capacitor is not polarized, so it can go either way.
#Install LED 3mm Red	D2	The LED is polarized.  There is a flat side (cathode) has a short lead and it faces towards the left side of the board.
#Install jumpers:
##	40 Pin 2.54 mm Single Row Pin Header Strip	JP1,JP2,JP3,JP4,JP5,JP6	  The short side of the jumper strip goes into the board.
#Install Screw connectors:
##	Screw Terminal Block 3 Positions  X3 	The side where the wires enter under the screw should face the bottom of the board.
##	Screw Terminal Block 2 Positions  X2	The side where the wires enter under the screw should face the bottom of the board.
#Install ICs:
##	LM1458N IC1	The notch on the IC should face the left side of the board.
##	CD4066 IC2	The notch on the IC should face the left side of the board.
##	NE555 IC3	The notch on the IC should face the left side of the board.

Congratulations, you have just fnished building the Simple Sound to Servo.

==Schematic==

Here is a schematic diagram in pdf format [[File:Simple Sound to Servo sch.pdf]]

==Board==

Currently this is a home etch only circuit board.  You can download the needed files to etch your own circuit board from the [http://doityourselfchristmas.com/forums/dynamics/showentry.php?e=169&catid=8 File Library]

==BOM==

All parts were sourced from [http://www.taydaelectronics.com Tayda Electronics] 1 BOM will populate 2 Simple Sound to Servo Boards. The BOM is a double order because just one does not meet the $5 minimum order.  You will also have a few left over resistors due to the fact that Tayda requires minimum of 10 each value. The only part that I have not tested is the 3.5mm audio Jack. This jack was an after though and is meant to be mounted as a pass thru connector on your enclosure that way you don't need to open the enclosure to plug your audio cable in.


===Tayda Electronics===
<table border="1">
<tr><td>Part</td><td>Location</td><td>Qty</td><td>Part #</td><td>Link</td></tr>
<tr><td>220K OHM 1/4W 5% Carbon Film Resistor</td><td>R9</td><td>10</td><td>A-2110</td><td>[http://www.taydaelectronics.com/10-x-resistor-220k-ohm-1-4w-5-carbon-film-pkg-of-10.html Link]</td></tr>
<tr><td>100nF 0.1uF 100V 5% Mylar Film Capacitor</td><td>C1,C3,C6,C11</td><td>8</td><td>A-4110</td><td>[http://www.taydaelectronics.com/0-1uf-100v-5-mylar-film-capacitors.html Link]</td></tr>
<tr><td>1K OHM 1/4W 5% Carbon Film Resistor</td><td>R1</td><td>10</td><td>A-2123</td><td>[http://www.taydaelectronics.com/10-x-resistor-1k-ohm-1-4w-5-carbon-film-pkg-of-10.html Link]</td></tr>
<tr><td>47K OHM 1/4W 5% Carbon Film Resistor</td><td>R2,R4</td><td>10</td><td>A-2066</td><td>[http://www.taydaelectronics.com/10-x-resistor-47k-ohm-1-4w-5-carbon-film-pkg-of-10.html Link]</td></tr>
<tr><td>5K OHM Trimpot Variable Resistor 6mm</td><td>R3</td><td>2</td><td>A-2513</td><td>[http://www.taydaelectronics.com/5k-ohm-trimpot-variable-resistor-6mm.html Link]</td></tr>
<tr><td>1K OHM Trimpot Variable Resistor 6mm</td><td>R6</td><td>2</td><td>A-2509</td><td>[http://www.taydaelectronics.com/1k-ohm-trimpot-variable-resistor-6mm.html Link]</td></tr>
<tr><td>10K OHM 1/4W 5% Carbon Film Resistor</td><td>R5,R12,R15,R20</td><td>20</td><td>A-2115</td><td>[http://www.taydaelectronics.com/10-x-resistor-10k-ohm-1-4w-5-carbon-film-pkg-of-10.html Link]</td></tr>
<tr><td>1N914 Small Signal Diode 200mA 100V</td><td>D1</td><td>2</td><td>A-615</td><td>[http://www.taydaelectronics.com/1n914-small-signal-diode-200ma-100v.html Link]</td></tr>
<tr><td>LM1458N LM1458 1458 IC DUAL OPERATIONAL AMPLIFIER</td><td>IC1</td><td>2</td><td>A-286</td><td>[http://www.taydaelectronics.com/lm1458n-lm1458-1458-ic-dual-operational-amplifier.html Link]</td></tr>
<tr><td>10uF 25V105C Radial Electrolytic Capacitor 5x11mm</td><td>C7</td><td>2</td><td>A-4534</td><td>[http://www.taydaelectronics.com/10uf-25v-105c-radial-electrolytic-capacitor-5x11mm.html Link]</td></tr>
<tr><td>2.2K OHM 1/4W 5% Carbon Film Resistor</td><td>R14</td><td>10</td><td>A-2087</td><td>[http://www.taydaelectronics.com/10-x-resistor-2-2k-ohm-1-4w-5-carbon-film-pkg-of-10.html Link]</td></tr>
<tr><td>CD4066 4066 IC CMOS QUAD BILATERAL SWITCH</td><td>IC2</td><td>2</td><td>A-555</td><td>[http://www.taydaelectronics.com/cd4066-4066-ic-cmos-quad-bilateral-switch.html Link]</td></tr>
<tr><td>470 OHM 1/4W 5% Carbon Film Resistor</td><td>R8</td><td>10</td><td>A-2049</td><td>[http://www.taydaelectronics.com/10-x-resistor-470-ohm-1-4w-5-carbon-film-pkg-of-10.html Link]</td></tr>
<tr><td>4.7K 4K7 OHM 1/4W 5% Carbon Film Resistor</td><td>R4,R11</td><td>10</td><td>A-2027</td><td>[http://www.taydaelectronics.com/10-x-resistor-4-7k-4k7-ohm-1-4w-5-carbon-film-pkg-of-10.html Link]</td></tr>
<tr><td>50K OHM Trimpot Variable Resistor 6mm</td><td>R10,R22</td><td>4</td><td>A-2500</td><td>[http://www.taydaelectronics.com/50k-ohm-trimpot-variable-resistor-6mm.html Link]</td></tr>
<tr><td>10nF 0.01uF 100V 5% Mylar Film Capacitors</td><td>C4</td><td>2</td><td>A-4106</td><td>[http://www.taydaelectronics.com/10nf-0-01uf-100v-5-mylar-film-capacitors.html Link]</td></tr>
<tr><td>NE555 IC 555 Timer DIP-8</td><td>IC3</td><td>2</td><td>A-249</td><td>[http://www.taydaelectronics.com/ne555-ic-555-timer-dip-8.html Link]</td></tr>
<tr><td>2.2uF 50V 105C Radial Electrolytic Capacitor 5x11mm</td><td>C5</td><td>2</td><td>A-4532</td><td>[http://www.taydaelectronics.com/2-2uf-50v-105c-radial-electrolytic-capacitor-5x11mm.html Link]</td></tr>
<tr><td>4.7uF 16V 105C Radial Electrolytic Capacitor 5x11mm</td><td>C2</td><td>2</td><td>A-4529</td><td>[http://www.taydaelectronics.com/4-7uf-16v-105c-radial-electrolytic-capacitor-5x11mm.html Link]</td></tr>
<tr><td>2N3904 NPN General Propose Transistor</td><td>Q1</td><td>2</td><td>A-111</td><td>[http://www.taydaelectronics.com/2n3904-npn-general-propose-transistor.html Link]</td></tr>
<tr><td>LED 3mm Red</td><td>D2,</td><td>2</td><td>A-261</td><td>[http://www.taydaelectronics.com/led-3mm-red.html Link]</td></tr>
<tr><td>40 Pin 2.54 mm Single Row Pin Header Strip</td><td>JP1,JP2,JP3,JP4,JP5,JP6</td><td>1</td><td>A-197</td><td>[http://www.taydaelectronics.com/40-pin-2-54-mm-single-row-pin-header-strip.html Link]</td></tr>
<tr><td>DG301 Screw Terminal Block 3 Positions 5mm</td><td>X3</td><td>2</td><td>A-669</td><td>[http://www.taydaelectronics.com/dg301-screw-terminal-block-3-positions-5mm.html Link]</td></tr>
<tr><td>DG301 Screw Terminal Block 2 Positions 5mm</td><td>X2</td><td>2</td><td>A-668</td><td>[http://www.taydaelectronics.com/dg301-screw-terminal-block-2-positions-5mm.html Link]</td></tr>
<tr><td>14 pin DIP IC Socket Adaptor Solder Type</td><td></td><td>2</td><td>	A-004</td><td>[http://www.taydaelectronics.com/14-pin-dip-ic-socket-adaptor-solder-type.html Link]</td></tr>
<tr><td>8 pin DIP IC Socket Adaptor Solder Type</td><td></td><td>4</td><td>A-001</td><td>[http://www.taydaelectronics.com/8-pin-dip-ic-socket-adaptor-solder-type.html Link]</td></tr>
<tr><td>3.5mm Stereo Enclosed Socket</td><td></td><td>2</td><td>A-865</td><td>[http://www.taydaelectronics.com/3-5mm-stereo-enclosed-socket.html Link]</td></tr>
</table><br/>

Total cost for 2 BOMs	$5.01

You will also need a few shunts. Tayda does not carry them or at least I could not find them. I just grab them out of old disc drives and motherboards.

===Housing===
The Simple Sound to Servo was designed to fit in the [http://www.aflglobal.com/cmspages/bluekey/getfile.aspx?aliaspath=/productlist/Product-Lines/Optical-Connectivity---Apparatus/Terminal-Access-TA-200-205-Terminal-Enclosure/doc/TA-200-Terminal-Enclosure TA-200 Demarcation Enclosure] available from numerous vendors including [http://wlcventures.com/zencart/index.php?main_page=index&cPath=1| www.wlcventures.com]<br/>
[[File:TA-200.jpg|100px]]<br/>