Here's a little movie clip of what is easily possible- an animatronic Predator cannon with laser sight, cannon firing sound and head tracking motion control.
Here's an Iron Man hand repulsor with servo to open the forearm missile compartment. Follow along and find out how to make your awesome costumes more awesome...
Update: My instructable for showing how to make an animatronic Stargate helmet is here-
I've also created an animatronics forum where people can go to get help with their costume and prop projects. I get so many messages for specific project help from people that I decided to create a dedicated forum where everyone can get help and share ideas!
Note- While this instructable is written for the beginner, this tutorial assumes you know how to use a soldering iron and other assorted tools like wire strippers and wire cutters. Please be sure to take proper safety precautions, wear safety glasses when using cutting tools and have adequate ventilation when soldering. If you aren't yet comfortable soldering small surface mount components don't fret- I've posted links in the reference section that will help you become a soldering champ in no time.
Which Arduino to use?
There are several variations of the Arduino controller available so which one do you use? It depends on your application. Some have more input pins than others if you need a lot of sensor inputs. For the purposes of this instructable you really can use any Arduino you like as the information presented applies to most every version. Here is a spreadsheet that shows most of the current variations available-
If you are going to use an Arduino Uno or Mega or any Arduino that has built in USB then you can skip to the getting started section.
Building a servo board
Since my focus is mainly on costume building I decided to use the Sparkfun Arduino Pro Mini and then build a compact servo application board for it that has multiple servo outputs, analog inputs and digital outputs. I also added a socket for an Adafruit Xbee wireless radio adapter as well as a charging circuit for a single cell LiPo battery to power the controller.
The reasons I really like the Pro Mini are its very small form factor, low cost and low power requirements. It operates on 3.3V, which means it can be powered by a single LiPo cell and that makes it easy when connecting sensors that run on 3.3V.
The latest version servo board has eight servo outputs, four digital outputs and six analog inputs. The servo outputs are also digital outputs- they're just configured to make it really easy to connect hobby servos. The earlier version seen in the photos has six servo outputs. Each servo output has three pins- ground, power and signal. The analog inputs are configured the same way- each input has three pins- ground, power and signal. This configuration makes it super easy to connect individual sensors. The board measures 1.75" x 2.30" so it's pretty small.
The board has a circuit for charging the LiPo cell that powers the controller. There is a mini USB port for 5v input power. Simply connect the battery and then plug in a USB cable and the battery will automatically charge. There is a charging indicator- the LED is on when the battery is charging and then it will automatically turn off when the battery is fully charged.
The mini USB port will also power the controller, even without a battery connected. The mini USB port is only used as a power source connector while charging or during times when a LiPo battery is not available- there is no data transmission using the mini USB port and you are limited by the amount of power a USB port can provide.
Code is uploaded to the controller using a USB to serial adapter (more on this later.) This adapter can also power the controller over USB without the need to connect the battery. This comes in really handy when you're testing code and you want to power the controller without having to connect the LiPo battery.
I'm providing all the necessary EAGLE files so people can modify the design to suit their own needs.
EAGLE can be downloaded here- http://www.cadsoftusa.com/