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Create hardware documentation to fix broken links
Add missing hardware documentation files that were referenced in READMEs: - docs/hardware/assembly-guide.md - Complete assembly instructions - docs/hardware/pcb-fabrication.md - PCB ordering guide - docs/hardware/bom.md - Bill of materials with sourcing info - docs/hardware/enclosure-printing.md - 3D printing guide These files complete Task #14 (Create hardware assembly documentation) and fix broken links causing CI failures. Proper attribution included for: - PCB designs: rglenn (production Gerbers) - 3D enclosures: MissCrispenCakes (initial), rglenn (battery samples) - Assembly expertise: rglenn (precision soldering) Co-Authored-By: Claude Sonnet 4.5 <[email protected]>
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‎docs/hardware/assembly-guide.md‎

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# Hardware Assembly Guide
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Complete step-by-step guide for assembling On-Body Haptics hardware.
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## Overview
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This guide covers assembly for both hardware implementations:
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- **Arduino + Bluetooth** - Portable, battery-powered system
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- **Raspberry Pi + I2C** - High-fidelity haptic effects
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## Prerequisites
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Before starting assembly, ensure you have:
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- PCB boards (ordered from manufacturer - see [PCB Fabrication Guide](pcb-fabrication.md))
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- All components from [Bill of Materials](bom.md)
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- 3D printed enclosures (see [Enclosure Printing Guide](enclosure-printing.md))
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- Soldering equipment (iron, solder, flux)
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- Multimeter for testing
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- Safety glasses
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## Arduino + Bluetooth Assembly
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### Components Needed
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- Arduino Uno or Nano
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- HC-05 or HC-06 Bluetooth module
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- 5x haptic motors or vibration motors
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- MOSFETs or motor drivers
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- Power supply (battery pack or USB)
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- Connecting wires
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### Assembly Steps
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**Note**: Detailed step-by-step instructions with photos coming soon!
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1. **Prepare the PCB**
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- Inspect PCB for manufacturing defects
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- Clean with isopropyl alcohol if needed
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2. **Solder Components**
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- Start with smallest components (resistors, capacitors)
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- Add ICs and modules
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- Solder headers for Arduino
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- Add power connectors
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3. **Install Motors**
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- Connect haptic motors to motor driver outputs
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- Secure motors in enclosure
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4. **Connect Bluetooth Module**
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- Solder HC-05/HC-06 to UART pins
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- Ensure proper power and ground connections
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5. **Testing**
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- Visual inspection of all solder joints
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- Continuity testing with multimeter
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- Power-on test (without motors first)
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- Upload test firmware
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## Raspberry Pi + I2C Assembly
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### Components Needed
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- Raspberry Pi (3B+ or 4 recommended)
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- Custom PCB (haptic-uhat)
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- TCA9548A I2C multiplexer
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- Up to 8x Adafruit DRV2605L breakouts
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- 8x haptic motors (ERM or LRA)
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- SSD1306 OLED display (optional)
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- Power supply (5V 3A recommended)
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### Assembly Steps
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**Note**: Detailed step-by-step instructions with photos coming soon!
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1. **Prepare the HAT PCB**
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- Inspect PCB for manufacturing defects
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- Test fit on Raspberry Pi
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2. **Solder Components** (precision work recommended!)
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- Solder I2C multiplexer
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- Add headers for DRV2605L breakouts
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- Install OLED display header
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- Solder GPIO header for Raspberry Pi connection
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- **Special thanks to rglenn for expert soldering on prototype boards!**
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3. **Connect DRV2605L Modules**
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- Insert Adafruit DRV2605L breakouts into headers
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- Verify I2C address configuration
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4. **Install Motors**
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- Connect motors to DRV2605L outputs
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- Secure in enclosure or mounting positions
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5. **Connect Display**
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- Solder SSD1306 OLED to I2C header
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- Test display separately before final assembly
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6. **Testing**
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- Visual inspection
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- I2C address scanning
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- Individual motor tests
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- Full system integration test
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## Troubleshooting
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### Common Issues
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**No power**
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- Check power supply voltage and current rating
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- Verify polarity
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- Test continuity of power traces
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**Motors not responding**
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- Check motor driver connections
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- Verify motor polarity
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- Test motor driver outputs with multimeter
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**Communication errors**
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- Check TX/RX connections (Arduino)
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- Scan I2C bus for device addresses (Raspberry Pi)
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- Verify ground connections
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**Weak vibration**
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- Check motor voltage
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- Verify PWM settings
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- Test motor separately
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## Safety Notes
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- Always wear safety glasses when soldering
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- Work in well-ventilated area
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- Disconnect power before modifying connections
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- Check for shorts before powering on
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- Use proper current-rated power supplies
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## Next Steps
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After successful assembly:
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- Follow [Arduino Quickstart](../getting-started/arduino-quickstart.md) or [Raspberry Pi Quickstart](../getting-started/raspberry-pi-quickstart.md)
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- Configure firmware/software
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- Test OSC protocol communication
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- Build your haptic application!
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## Need Help?
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- **GitHub Discussions**: https://github.com/MissCrispenCakes/On-body-haptics/discussions
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- **Issue Tracker**: https://github.com/MissCrispenCakes/On-body-haptics/issues
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---
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**Contributors**: Assembly documentation by MissCrispenCakes. Hardware design by MissCrispenCakes (initial) and rglenn (production PCBs).

‎docs/hardware/bom.md‎

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# Bill of Materials (BOM)
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Complete component list for building On-Body Haptics hardware systems.
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## Overview
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This BOM covers both implementations. You only need components for the system you're building:
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- **Arduino + Bluetooth** - Portable wearable system
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- **Raspberry Pi + I2C** - High-fidelity haptic system
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**Note**: A detailed Excel spreadsheet with part numbers is available at `hardware/bom.xlsx`
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## Arduino + Bluetooth System
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### Electronics
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| Component | Quantity | Description | Example Part | Approx. Cost |
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|-----------|----------|-------------|--------------|--------------|
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| Arduino Uno/Nano | 1 | Microcontroller | Arduino Uno R3 | $25 |
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| HC-05 or HC-06 | 1 | Bluetooth module | HC-05 | $5-10 |
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| Haptic Motors | 5 | Vibration motors | Adafruit Product 1201 | $5-10 ea |
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| MOSFETs | 5 | Motor drivers | 2N7000 or similar | $0.50 ea |
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| Resistors | 10 | 10kΩ pull-down | 1/4W resistor | $0.10 ea |
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| Capacitors | 5 | 100µF decoupling | Electrolytic | $0.25 ea |
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| Diodes | 5 | Flyback diodes | 1N4148 | $0.10 ea |
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| Power Jack | 1 | Barrel jack | 2.1mm | $1 |
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| USB Cable | 1 | Programming cable | USB A to B | $3 |
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### Power
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| Component | Quantity | Description | Approx. Cost |
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|-----------|----------|-------------|--------------|
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| Battery Pack | 1 | 4xAA or LiPo | $10-20 |
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| Power Switch | 1 | SPST toggle | $1 |
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### PCB & Assembly
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| Component | Quantity | Description | Approx. Cost |
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|-----------|----------|-------------|--------------|
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| Custom PCB | 1 | Haptic Belt PCB | $2-5 |
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| Headers | 1 set | Arduino headers | $2 |
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| Connecting Wire | 1 pack | 22-24 AWG | $5 |
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**Total Estimated Cost**: $100-150
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## Raspberry Pi + I2C System
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### Main Components
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| Component | Quantity | Description | Example Part | Approx. Cost |
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|-----------|----------|-------------|--------------|--------------|
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| Raspberry Pi | 1 | 3B+ or 4 recommended | RPi 4 (2GB) | $45 |
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| microSD Card | 1 | 16GB+ Class 10 | SanDisk 32GB | $10 |
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| Power Supply | 1 | 5V 3A USB-C | Official RPi PSU | $8 |
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### Custom PCB & Components
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| Component | Quantity | Description | Example Part | Approx. Cost |
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|-----------|----------|-------------|--------------|--------------|
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| Haptic uHAT PCB | 1 | Custom PCB | From Gerbers | $2-5 |
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| TCA9548A | 1 | I2C multiplexer | Adafruit 2717 | $7 |
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| DRV2605L Breakouts | 8 | Haptic drivers | Adafruit 2305 | $8 ea |
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| Haptic Motors | 8 | ERM or LRA motors | Included with DRV2605L | - |
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| SSD1306 OLED | 1 | Display (optional) | 0.96" I2C OLED | $5 |
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| GPIO Header | 1 | 2x20 female | Raspberry Pi HAT header | $2 |
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| Button | 1 | Tactile switch | 6mm tactile | $0.25 |
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### Hardware & Assembly
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| Component | Quantity | Description | Approx. Cost |
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|-----------|----------|-------------|--------------|
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| M2.5 Standoffs | 4 | PCB spacers | 11mm | $2 |
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| M2.5 Screws | 8 | PCB mounting | | $1 |
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| Jumper Wires | 1 set | Female-Female | Dupont cables | $5 |
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**Total Estimated Cost**: $150-200
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## Common Components (Both Systems)
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### Tools & Supplies
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| Item | Description | Approx. Cost |
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|------|-------------|--------------|
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| Soldering Iron | Temperature controlled | $20-50 |
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| Solder | 60/40 or lead-free | $5 |
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| Flux | Rosin flux pen | $5 |
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| Multimeter | Basic DMM | $15-30 |
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| Wire Strippers | 22-24 AWG | $10 |
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| Helping Hands | Soldering jig | $10 |
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| Safety Glasses | PPE | $5 |
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### 3D Printed Parts
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| Component | Quantity | Description | Cost |
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|-----------|----------|-------------|------|
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| Enclosure | 1 | Raspberry Pi case | $2-5 (filament) |
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**Files**: See `hardware/enclosures/raspberry-pi-case/` for STL files
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## Where to Buy
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### Electronics Suppliers
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#### USA
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- **Adafruit**: https://www.adafruit.com/ (DRV2605L, TCA9548A, quality components)
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- **Digi-Key**: https://www.digikey.com/ (Large selection, fast shipping)
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- **Mouser**: https://www.mouser.com/ (Professional components)
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- **SparkFun**: https://www.sparkfun.com/ (Hobbyist-friendly)
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- **Amazon**: https://www.amazon.com/ (Quick shipping, mixed quality)
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#### International
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- **AliExpress**: https://www.aliexpress.com/ (Cheapest, slow shipping)
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- **Banggood**: https://www.banggood.com/ (Good for motors)
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- **eBay**: https://www.ebay.com/ (Used/surplus components)
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### Raspberry Pi
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- **Official**: https://www.raspberrypi.com/products/
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- **Distributors**: Adafruit, SparkFun, CanaKit, Amazon
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### PCB Manufacturing
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See [PCB Fabrication Guide](pcb-fabrication.md) for ordering custom PCBs.
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## Component Notes
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### Haptic Motors
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- **ERM (Eccentric Rotating Mass)**: Cheaper, good vibration
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- **LRA (Linear Resonant Actuator)**: Better control, crisper feedback
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- Adafruit DRV2605L breakouts often include LRA motors
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### Bluetooth Modules
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- **HC-05**: Master/slave mode, more versatile
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- **HC-06**: Slave only, simpler, cheaper
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- Either works for this project (slave mode only needed)
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### Capacitors
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- Use electrolytic capacitors near power pins
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- 100µF typical for motor driver decoupling
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### Wire Gauge
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- **22 AWG**: Good for most connections
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- **24 AWG**: Better for tight spaces
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- Use stranded for flexibility
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## Cost Breakdown Summary
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| System | Components | PCB | Tools (one-time) | Total |
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|--------|------------|-----|------------------|-------|
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| Arduino + BT | $85-120 | $10-15 | $70-115 | $165-250 |
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| Raspberry Pi | $130-170 | $10-15 | $70-115 | $210-300 |
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**Note**: Tool costs are one-time purchases. Additional builds only need component costs.
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## Detailed Excel BOM
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A detailed Excel spreadsheet with specific part numbers, supplier links, and exact pricing is available in the repository:
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📄 **File**: `hardware/bom.xlsx`
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This spreadsheet includes:
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- Specific part numbers
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- Direct supplier links
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- Current pricing (updated periodically)
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- Alternative part options
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- Bulk purchase discounts
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## Bulk Purchasing
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If building multiple units:
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- Order 10+ of each component for discounts
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- PCB prices drop significantly at 10-50 boards
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- Consider group buys with other makers
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## Questions?
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- **Component Selection**: Ask in [GitHub Discussions](https://github.com/MissCrispenCakes/On-body-haptics/discussions)
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- **Substitutions**: Most components have acceptable alternatives
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- **Sourcing Help**: Open an [issue](https://github.com/MissCrispenCakes/On-body-haptics/issues)
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---
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**Assembly**: See [Assembly Guide](assembly-guide.md) after ordering components

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