Automate Your Pin Header Chopping Chores Away

July 29, 2023 by Dan Maloney 7 Comments

In most cases, cutting pin headers is a pretty simple job to tackle with a pair of cutters or even your bare fingers. But if you’re doing a lot of it, like for kitting up lots of projects for customers, then you might want to look at something like this automatic pin header cutter.

Even if you don’t need to follow [Mr. Innovative]’s lead on this, it’s worth taking a look at the video below, which has a couple of cool ideas that are probably applicable to other automation projects, especially those where lots of small parts are handled. Processing begins with a hopper that holds a stack of header strips over what we’d call a “reverse guillotine,” consisting of a spring-loaded plunger riding on a cam. A header strip is pushed out of the hopper to expose the specified number of terminals, the cam rotates and raises the plunger, and the correct length header is snapped off.

For our money, the neatest part of this build is the feed mechanism for the hopper. Rather than anything complicated like a rack-and-pinion, [Mr. Innovative] opted for a pusher made from a stiff yet flexible strip of plastic, which is forced along the bottom of the hopper by a pair of stepper-driven drive rollers. The plastic pusher is stored rolled up in a spiral fixture so it doesn’t take up much room.

Overall, it’s a simple and largely effective design. [Mr. Innovative] does express a little dissatisfaction with some aspects of the build, though; it looks like the stack of header strips needs a little weight on top of it to keep them feeding properly, and we notice a couple of iterations of the cutting mechanism in the video. The cut headers do seem to either fly off into the stratosphere or stay attached to each other, which could lead to jamming problems.

But still, it’s a solid design and reminds us of some other projects by [Mr. Innovative], like this SMD tape slicer or a CNC gear cutter.

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Adding Two Axes Makes CNC Router More Than The Sum Of Its Parts

July 26, 2023 by Dan Maloney 20 Comments

The problem with building automated systems is that it’s hard to look at any problem and not see it in terms of possible automation solutions. Come to think of it, that’s probably less of a bug and more of a feature, but it’s easy to go overboard and automate all the things, which quickly becomes counterproductive in terms of time and money.

If you’re clever, though, a tactical automation solution can increase your process efficiency without breaking the budget. That’s where [Christopher Helmke] seems to have landed with this two-axis add-on fixture for his CNC router. The rig is designed to solve the problem of the manual modification needed to turn off-the-shelf plastic crates into enclosures for his line of modular automation components, aspects of which we’ve featured before. The crates need holes drilled in them and cutouts created in their sides for displays and controls. It’s a job [Christopher] tackled before with a drill and a jigsaw, with predictable results.

To automate the job without going overboard, [Christopher] came up with a tilting turntable that fits under the bed of the CNC router and sticks through a hole in the spoil board. The turntable is a large, 3D printed herringbone gear driven by a stepper and pinion gear. A cheap bearing keeps costs down, while a quartet of planetary gears constrain the otherwise wobbly platform. The turntable also swivels 90 degrees on a herringbone sector gear; together, the setup adds pitch and roll axes to the machine that allow the spindle access to all five sides of the crates.

Was it worth the effort? Judging by the results in the video below, we’d say so, especially given the number of workpieces that [Christopher] has to process. Add in the budget-conscious construction that doesn’t sacrifice precision too much, and this one seems like a real automation win.

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A Lightweight Smart Home Server

June 6, 2023 by Bryan Cockfield 29 Comments

Working towards automating a few things in a home often seems simple on the surface, but it’s easy for these projects to snowball into dozens of sensors and various servos, switches, and cameras strewn about one’s living space. The same sort of feature creep sneaks into some of the more popular self-hosted home server platforms as well, with things like openHAB requiring so much computing power that they barely function on something like a Raspberry Pi. [Paulo] thought there should be a more lightweight way of tackling a project like this, and set about building his own smart home server with help from some interesting software.

The project is based around the Dirigera hub from Ikea, partially because [Paulo] is planning to use other smart home devices from Ikea as he can easily find them where he is, and also because these devices tend to use Zigbee, a non-proprietary communications standard. This means that if he ever wants to swap out the hub for another one in the future, it won’t be difficult to do. From here the major hurdle is that using the default software from these devices is fairly limiting, so [Paulo] reached for a Raspbee 2 Zigbee gateway for use with a Raspberry Pi and an extremely lightweight and customizable web server called Mako to make this happen. Using Lua as the high-level language to tie everything together he was able to easily deploy the server to control the Ikea hub and devices and automate them in any way he sees fit.

While it is true that software like openHAB and others already exists to do virtually any home automation task that could be imagined, if you’re looking to do something with a bare minimum of computing power something like [Paulo]’s solution is likely going to be the fastest and most reliable method of getting a few things automated around the home. If you’re looking for something completely open source and built from the ground up, though, we have seen a few alternative smart home solutions like this one which don’t rely on any proprietary hardware or software, but do take a little bit more effort on the user’s part.

Battery Bot Makes Sure Cordless Tool Packs Are Always Topped Up

May 24, 2023 by Dan Maloney 19 Comments

There was a time not that long ago when every tool was cordless. But now, cordless power tools have proliferated to the point where the mere thought of using a plain old wrist-twisting screwdriver is enough to trigger a bout of sympathetic repetitive injury. And the only thing worse than that is to discover that the batteries for your tools are all dead.

As [Lance] from the “Sparks and Code” channel freely admits, the fact that his impressive collection of batteries is always dead is entirely his fault, and that’s what inspired his automatic battery charging robot. The design is pretty clever; depleted batteries go into a hopper, under which is a 3D-printed sled. Batteries drop down into the sled, which runs the battery out from under the hopper to the charging station, which is just the guts of an old manual charger attached to a lead screw to adjust the height of the charging terminals for different size batteries. When the battery is charged, the sled pushes it a little further into an outfeed hopper before going back to get another battery from the infeed side.

Of course, that all vastly understates the amount of work [Lance] had to put into this. He suffered through a lot of “integration hell” problems, like getting the charger properly connected to the Arduino running the automation. But with a lot of tweaking, he can now just dump in a bunch of depleted packs and let the battery bot handle everything. The video after the break shows all the gory details.

Of course, there’s another completely different and much simpler solution to the dead battery problem.

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Robotic Coffee Comes To Brooklyn, But Will It Stay?

May 21, 2023 by Donald Papp 25 Comments

Robots are cool. Everyone knows it, and [Eater NY] highlights a coffee shop with a robotic server opening in Brooklyn. While robots able to prepare and serve drinks or food is not new, it isn’t every day a brick-and-mortar café with a robot behind the counter opens up. But expensive automation isn’t the only puzzle piece needed to make a location work.

A robotic coffee shop (like a robotic burger joint) certainly offers novelty, but can it sustain itself beyond that?

As one example, the linked article above points out that the city of New York prohibits entirely cashless businesses. Establishments must accept cash payments, and it’s unclear how the touchscreen-driven system would comply with that requirement.

There are also many tasks involved in running even a modest establishment — loading, cleaning, and maintaining for example — that can’t be realistically taken care of by an immobile robot barista. It’s unclear to what extent the robotic coffee shop will employ human staff, but it’s clear that human involvement is something that isn’t going be eliminated any time soon.

Some of you may remember the robotic burger joint that our own Brian Benchoff managed to check out, and many of his same observations come to mind. The robot burger was perhaps ahead of its time (its single location is listed as closed on Google maps with no recent activity) but maybe the robot coffee place can make it work. Still, expensive automation is only one piece of a system, and the ability to crank out a drink per minute 24/7 might not actually be the missing link.

Tiny Microcontroller Uses Real-Time Operating System

May 10, 2023 by Bryan Cockfield 51 Comments

Most of the computers we interact with on a day-to-day basis use an operating system designed for flexibility. While these are great tools for getting work done or scrolling your favorite sites, they have a weakness when it comes to interacting quickly with a real-world environment. For these kinds of low-latency, high-reliability systems you may want to turn to something like freeRTOS which is optimized for this kind of application and which [Parikshit Pagare] has used to build his home automation system.

This build is based around an ESP32 for which freeRTOS, designed specifically for embedded systems, is uniquely suited. There are several channels built in capable of monitoring temperature, functioning as a smoke alarm, and sensing whether someone is at the front door. All of these are reported to a small OLED screen but are also updated on an Android app as well, which happens nearly instantaneously thanks to the real-time operating system. There are a number of user-controllable switches as well that are capable of turning lights or fans on and off.

For a home automation system, it’s one of the most low-cost and fully-featured we’ve seen and if you’re still having trouble coming across a Raspberry Pi as they sort out supply issues, something like this might make an excellent substitute at a fraction of the price. If you’re looking to expand even beyond this build, one of the gold standards for ESP32-based automation design is this build from [Marcus] which not only demonstrates how to build a system like this but goes into great detail on the ESPHome environment.

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Pi Pico Calculates Water Usage

February 25, 2023 by Bryan Cockfield 18 Comments

Modern WiFi-enabled microcontrollers have made it affordable and easy to monitor everything from local weather information to electricity usage with typically no more than a few dollars worth of hardware and a little bit of programming knowledge. Monitoring one’s own utility data can be a little bit more difficult without interfering with the metering equipment, but we have seen some clever ways of doing this over the years. The latest is this water meter monitoring device based on a Raspberry Pi Pico.

The clever thing here isn’t so much that it’s based on the tiniest of Raspberry Pis, but how it keeps track of the somewhat obscured water flow information coming from the meter. Using a magnetometer placed close to the meter, the device can sense the magnetic field created as water flows through the meter’s internal sensors. The magnetic field changes in a non-obvious way as water flows through it, so the program has to watch for specific peaks in the magnetic field. Each of these specific waveforms the magnetometer detects counts to 0.0657 liters of water, which is accurate for most purposes.

For interfacing with a utility meter, this is one of the more efficient and elegant hacks we’ve seen in a while. There have, of course, been other attempts to literally read the meter using web cams and computer vision software, but the configuration for these builds is much more complex than something like this. You can interface with plenty of utility meters other than water meters, too, regardless of age.