Mechanized One-Man Sawmill

The title of ‘maker’ is conventionally applied to the young-adult age group. In the case of 84 year-old Ralph Affleck, a lifelong sawmiller, ‘maker’ perhaps undersells the accomplishment of building a fully functioning sawmill that can be operated by a single individual.

Starting in the trade at the age of 16 under his father’s tutelage, fifty years of working in sawmills saw him still loving what he did as retirement loomed. So, with pen, paper, and a simple school ruler he designed the entire shop from scratch. Decades of expertise working with wood allowed him to design the machines to account for warping and abnormalities in the timber resulting in incredibly accurate cuts.

With no other examples to guide his design — aside from perhaps old style steam-powered sawmills, and newer portable ones that he feels are inadequate for the job — much of the shop is built from scratch with scavenged parts. And, that list is impressive: four hydraulic cylinders from a Canberra bomber, levers from an old locomotive, differentials and gearboxes from a MAC and 1912 Republic trucks, a Leyland engine that operated for 13 years without the need for maintenance, and an assortment of old military and air force vehicle parts. This is complimented by his log skidder — also custom — that would look at home in a post-apocalyptic wasteland. Built from two tractors, it combines three gearboxes for 12 forward and 8 reverse gears(what!?), and can hit 42mph in reverse!

Continue reading “Mechanized One-Man Sawmill”

How to Measure the Extremely Small: Atomic Mass

How does one go about measuring the mass of an object? Mass is defined as the amount of matter an object contains. This is very different from weight, of course, as the mass of our object would remain the same despite the presence or size of a gravitational field. It is safe to say, however,  that most laboratory measurement systems are here on Earth, and we can use the Earth’s gravity to aid in our mass measurement. One way is to use a balance and a known amount of mass. Simply place our object on one side of the balance, and keep adding known amounts of mass to the other side until the balance is balanced.

But what if our object is very small…too small to see and too light to measure with gravity? How does one measure the mass of single atom? Furthermore, how does one determine how much of an object consists of a particular type of atom? There are two commonly used tools just for this purpose. Chances are you’ve heard of one of these but not the other. These tools used to measure substances on the atomic level is the focus of today’s article.

Continue reading “How to Measure the Extremely Small: Atomic Mass”

Parallel Compressors for Sandblasting without Crashing Your Grid

[Hannah] is restoring a 1962 Volkswagen Bug. The goal is to get the car on the road in time for her driver’s test. This is no easy task, as the lower 3 inches of all the body work is rusted out, and the engine is…. well, missing. Basically, the car needs a frame off restoration. This means that [Hannah] will have a lot of metal bodywork to clean up. One of the easiest ways to do that is sandblasting.

Large scale sandblasting is a bit different from most air-powered operations. Sandblasting needs only a modest air pressure, but a high air flow. [Hannah] need 25 Sustained Cubic Feet Per Minute (SCFM) at 80 PSI for sandblasting. Most compressors can easily supply that pressure, but 25 SCFM is asking quite a lot. She could go with an expensive 3 phase unit, or rent a diesel screw compressor. However, [Hannah] decided to connect 4 compressors in parallel to give her the flow she needed.

Connecting the air outputs in parallel is easy. The problem is the electricity. Each compressor is rated for 9 amps while running. They draw quite a bit more while starting up. The compressors have to be wired to individual 15 amp circuits to avoid blowing fuses. They also need to be started in sequence so they don’t pull down the AC for the entire house while starting.

Hannah could have used any sort of delay for this, but she chose an Arduino. The Arduino’s wall wart is wired up to the master compressor. Turning on the master powers up the Arduino which immediately starts a 2 second delay. When the delay times out, the Arduino fires up the second compressor. After several delay loops, all 4 compressors are running together.

hannah-schThe Arduino’s GPIO pins can’t handle 9 amp AC loads, so [Hannah] wired them to TIP120 transistors. The TIP120s drive low power relays, which in turn drive high current air conditioning relays. The system works quite well, as can be seen in the video below the break.

If you’re interested in air compressor projects, check out this setup made from an old refrigerator compressor. For more background on the TIP120, check out this article about these useful transistors.

Continue reading “Parallel Compressors for Sandblasting without Crashing Your Grid”

Ask Hackaday: How Hard Is It To Make A Bad Solder Joint?

When you learn to solder, you are warned about the pitfalls of creating a solder joint. Too much solder, too little solder, cold joints, dry joints, failing to “wet” the joint properly, a plethora of terms are explained  if you read one of the many online guides to soldering.

Unsurprisingly it can all seem rather daunting to a novice, especially if they are not used to the dexterity required to manipulate a tool on a very small-scale at a distance. And since the soldering iron likely to be in the hands of a beginner will not be one of the more accomplished models with fine temperature control and a good tip, it’s likely that they will experience most of those pitfalls early on in their soldering career.

As your soldering skills increase, you get the knack of making a good joint. Applying just the right amount of heat and supplying just enough solder becomes second nature, and though you still mess up from time to time you learn to spot your errors and how to rework and fix them. Your progression through the art becomes a series of plateaux, as you achieve each new task whose tiny size or complexity you previously thought rendered it impossible. Did you too recoil in horror before your first 0.1″ DIP IC, only to find it had been surprisingly easy once you’d completed it?

A few weeks ago we posted a Hackaday Fail of the Week, revolving around a soldering iron failure and confirmation bias leading to a lengthy reworking session when the real culprit was a missing set of jumpers. Mildly embarrassing and something over which a veil is best drawn, but its comments raised some interesting questions about bad solder joints. In the FoTW case I was worried I’d overheated the joints causing them to go bad, evaporating the flux and oxidising the solder. This was disputed by some commenters, but left me with some curiosity over bad solder joints. We all know roughly how solder joints go wrong, but how much of what we know is heresay? Perhaps it is time for a thorough investigation of what makes a good solder joint, and the best way to understand that would surely be to look at what makes a bad one.

Continue reading “Ask Hackaday: How Hard Is It To Make A Bad Solder Joint?”

A Very Tidy Circular Saw Bench

If your parents had a workshop as you grew up, the chances are it harbored some tools you came to know and love as you used them for your formative projects. Our reader [Joerg]’s father for instance has a circular saw bench that [Joerg] sorely misses, now living over 500km away. Our subject today is his response to this problem, now needing to cut aluminium he set about creating a  saw bench of his own, and the result is a rather nice build.

table-sawHe put together a variety of CAD models to formulate his ideas, and arrived at a structure in 18mm waterproof plywood with moving table linear bearings. The saw blade itself was mounted on a 5mm aluminum plate, though he doesn’t tell us what motor it uses. All the wooden parts came from a single sheet of plywood, and the result is a very tidy creation indeed.

Power saws are among the more hazardous tools in your workshop arsenal, whatever their type. If this was a commercial saw it would probably have a guard over the top of its blade, but even without that its sturdy construction and relatively low profile blade make this one stand above some of the more basic home-made saws we’ve seen. Building a power saw is something you have to take seriously.

We’ve featured quite a few home-made saws over the years. At least one other large table saw, a rather powerful but surprisingly tiny saw bench, this scroll saw using a sewing machine mechanism, or how about this simple jigsaw table?

Tools of the Trade – Inspection

In the last episode, we put our circuit boards through the reflow process. Unfortunately, it’s not 100% accurate, and there are often problems that can occur that need to be detected and fixed. That’s what the inspection step is for. One could insert an inspection step after paste, after placement, and after reflow, but the first two are icing on the cake — the phase where most mistakes can be caught is after reflow.

There are a number of problems typical with a surface mount reflow process: Continue reading “Tools of the Trade – Inspection”

Reverse Engineering The OWON SDS7102 Oscilloscope

It is something of a rite of passage for an electronics enthusiast, the acquisition of a first oscilloscope. In decades past that usually meant a relatively modest instrument, maybe a 20MHz bandwidth and dual trace if you were lucky. Higher spec devices were eye-wateringly expensive monsters, not for the Common People.

We are fortunate that like most other areas of technology the world of test equipment has benefited in the last few years both from developments in digital technology and from the growth in Chinese manufacturing. If your first ‘scope is that second-hand 20MHz CRT you will probably secure it for pennies, and the first ‘scope you buy new will probably have a spec closer to those unattainable super-scopes of yesteryear. Gone is the CRT and timebase generator, in its place a TFT, system-on-chip, and super-fast A to D converter.

[Christer Weinigel] has just such an entry-level modern digital ‘scope, an OWON SDS7102. He comments that it’s got an impressive spec for its price, though the input is noisier than you’d expect on a more expensive device, and the software has one or two annoying bugs. Having owned it for a while, he’s now subjected it to a lengthy teardown and reverse engineer, and he’s posted his findings in a succession of blog posts.

[Christer]’s interest lay mainly in the OWON’s digital section, it seems there is already a substantial community paying attention to its analog front end. He’s deduced how its internals are connected, ported Linux to its Samsung SoC in the scope, succeeded in getting its peripherals working, and set to work programming the Xilinx FPGA that’s responsible for signal processing.

The series of posts is a fascinating read as a run through the process of reverse engineering , but he points out that it’s quite a lot of information. If you are just interested in how a cheap modern oscilloscope works, he says, he suggests reading his post in which he recaps on all its different components.

He also makes a plea for help, he’s no slouch on the ‘scope’s software but admits he’s a bit out of his depth on some aspects of the FPGA. If you’re an FPGA wizard with an interest in ‘scopes, he’d like to hear from you.

This isn’t the first time we’ve featured ‘scope reverse engineering here at Hackaday, though it may be more in-depth than others. In the past we’ve seen a Uni-T screen grab protocol laid bare, and an investigation of a Rigol 1054Z.