An In-Depth Look At The Haptic Smart Knob

June 24, 2022 by Dan Maloney 22 Comments

At Hackaday, we love those times when we get a chance to follow up on a project that we’ve already featured. Generally, it’s because the project has advanced in some significant way, which is always great to see. Sometimes, though, new details on the original project are available, and that’s where we find ourselves with [Scott Bez] and his haptic smart knob project.

Alert readers may recall [Scott]’s announcement of this project back in March. It made quite a splash, with favorable comments and a general “Why didn’t I think of that?” vibe. And with good reason; the build quality is excellent, and the idea is simple yet powerful. By attaching a knob to the shaft of a brushless DC motor and mounting a small circular LCD screen in the middle, [Scott] came up with an input device that could be reprogrammed on the fly. The BLDC can provide virtual detents at any interval while generating haptic feedback for button pushes, and the LCD screen can provide user feedback.

But how is such a thing built? That’s the subject of the current video, which has a ton of neat design details and build insights. The big challenge for [Scott] was supporting the LCD screen in the middle of the knob while still allowing the knob — and the motor — to rotate. Part of the solution was, sadly, a hollow-shaft motor that was out of stock soon after he released this project; hopefully a suitable replacement will be available soon. Another neat feature is the way [Scott] built tiny strain gauges into the PCB itself, which pick up the knob presses that act as an input button. We also found the way button press haptics are provided by a quick jerk of the motor shaft very clever.

This is one of those projects that seems like a solution waiting for a problem, and something that you’d build just for the coolness factor. Hats off to [Scott] for following up a sweet build with equally juicy details.

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OpenMower: Open Source Robotic Lawn Mower With RTK GPS

April 7, 2022 by Dave Rowntree 40 Comments

Robotic mowers are becoming a common sight in some places, enabled by the cost of motors and the needed control electronics being much lower, thanks to the pace of modern engineering. But, in many cases, they still appear to be really rather dumb, little more than a jacked up bump-and-go with a spinning blade. [Clemens Elflein] has taken a cheap, dumb mower and given it a brain transplant based around a Raspberry Pi 4 paired up with a Raspberry Pi Pico for the real time control side of things. [Clemens] is calling this OpenMower, with the motivation to create an open source robot mower controller with support for GPS navigation, using RTK for extra precision.

The donor robot was a YardForce Classic 500, and after inspection of the control PCB, it looks like many other robot mower models are likely to use the same controller and thus be compatible with the openmower platform. A custom mainboard houses the Pi 4 and Pico, an ArduSimple RTK GPS module (giving a reported navigational accuracy of 1 cm,) as well as three BLDC motor drivers for the wheels and rotor. Everything is based on modules, plugging into the mainboard, reducing the complexity of the project significantly. For a cheap mower platform, the Yardforce unit has a good build quality, with connectors everywhere, making OpenMower a plug and play solution. Even the user interface on top of the mower was usable, with a custom PCB below presenting some push buttons at the appropriate positions.

Motor control is courtesy of the xESC project, which provides FOC motor control for low cost, interfacing with the host controller via a serial link. This is worth looking into in its own right! On the software side of things, [Clemens] is using ROS, which implements the low level robot control, path planning (using code taken from Slic3r) as well a kinematics constraints for object avoidance. The video below, shows how simple the machine is to operate — just drive it around the perimeter of lawn with a handheld controller, and show it where obstacles such as trees are, and then set it going. The mower is even capable of mowing multiple lawns, making the journey between them automatically!

Robotic mower projects are not new around here, here’s the mysterious TK with an interesting take, another using RTK GPS for good (or possibly bad) and quite probably the jankiest one we’ve seen in a while, which uses a LoRa base-station to transmit RTK corrections. We’d recommend keeping well away from that last one.

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3D-Printed Parts Let You Assemble Your Own Biggest Fan

March 17, 2022 by Dan Maloney 14 Comments

It’s getting close to the time of year when we need to start carefully vetting projects here at Hackaday. After all, nobody likes to get punked by an early April Fool’s joke. But as silly as this outsized PC fan looks, it sure seems like a legit build, if a bit on the pointless side.

Then again, perhaps pointless is too harsh a word to use. This 500-mm fan is by [Angus] over at Maker’s Muse, and it represents a lot of design work to make it buildable, as well as workable and (mostly) safe. Using both CNC-cut MDF and printed parts, the fan is an embiggened replica of a normal-sized case fan. The fan’s frame had to be printed in four parts, which lock together with clever interlocking joints. Each of the nine blades locks into a central hub with sturdy-looking dovetails.

And sturdy is important, as the fan is powered by a 1,500 Watt brushless DC motor. With a 4:1 reduction thanks to a printed gear train, the fan spins at around 3,300 RPM, which makes a terrifying noise. There’s a little bit of “speed-wobble” evident, but [Angus] managed to survive testing. The fan, however, did not — the 3D-printed gears self-destructed after a full-speed test, but not before the fan did its best wind tunnel imitation. And the RGB LEDs looked great.

This one reminds up of something we might see [Ivan Miranda] come up with. In fact, his super-sized 3D printer might have been just the thing to shorten [Angus]’ print times.

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Haptic Smart Knob Does Several Jobs

March 13, 2022 by Ryan Flowers 64 Comments

A knob is a knob, a switch is a switch, and that’s that, right? And what about those knobs that have detents, set in stone at the time of manufacturing? Oh, and those knobs that let you jog left to right and then snap back to center — that can’t be modified…right? Well, you likely know where this is going, and in the video below the break, [scottbez1] shows off a new open source haptic input knob that can be all of these things with just some configuration changes!

The list of possibilities is long: virtual snap points, virtual spring loading, virtual detents, virtual end points. It’s a virtual smörgåsbord of configuration options that make this haptic smart knob a one stop shop for all of your knob needs. This is all possible because the knob contains a high resolution magnetic encoder chip that has a single degree resolution. The sensor is coupled, through software, to a brushless DC motor. The round LCD gives visual feedback as well.

As [Myself] on the Hackaday Discord channel noted, having configurable spacing and strength for detents, springs, and stops, is nothing short of incredible. Being able to reconfigure the knob at-will means that it can become context sensitive. It’s wonderfully unique and it’s open source, so you can make your own with the information available at GitHub.

And according to its creator, the only thing the Haptic Smart Knob can’t do is do your taxes or blend your margarita. Well, it’s open source, so perhaps some of our more enterprising readers can submit just the right pull request.

This isn’t Hackaday’s first Motorized Volume Knob feature, but it might be one of the neatest we have seen so far. Thanks to [mattvenn] on the Hackaday Discord server for the great tip!

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Differential Drive Doesn’t Quite Work As Expected

June 6, 2021 by Bryan Cockfield 10 Comments

Placing two motors together in a shared drive is a simple enough task. By using something like a chain or a belt to couple them, or even placing them on the same shaft, the torque can be effectively doubled without too much hassle. But finding a way to keep the torque the same while adding the speeds of the motors, rather than the torques, is a little bit more complicated. [Levi Janssen] takes us through his prototype gearbox that attempts to do just that, although not everything works exactly as he predicts.

The prototype is based on the same principles as a differential, but reverses the direction of power flow. In something like a car, a single input from a driveshaft is sent to two output shafts that can vary in speed. In this differential drive, two input shafts at varying speeds drive a single output shaft that has a speed that is the sum of the two input speeds. Not only would this allow for higher output speeds than either of the two motors but in theory it could allow for arbitrarily fine speed control by spinning the two motors in opposite directions.

The first design uses two BLDC motors coupled to their own cycloidal drives. Each motor is placed in a housing which can rotate, and the housings are coupled to each other with a belt. This allows the secondary motor to spin the housing of the primary motor without impacting the actual speed that the primary motor is spinning. It’s all a lot to take in, but watching the video once (or twice) definitely helps to wrap one’s mind around it.

The tests of the drive didn’t go quite as planned when [Levi] got around to measuring the stall torque. It turns out that torque can’t be summed in the way he was expecting, although the drive is still able to increase the speed higher than either of the two motors. It still has some limited uses though as he notes in the video, but didn’t meet all of his expectations. It’s still an interesting build and great proof-of-concept otherwise though, and if you’re not clear on some of the design choices he made there are some other builds out there that take deep dives into cycloidal gearing or even a teardown of a standard automotive differential.

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Shoot Above The Waves On This E-Foil Made From A Rifle Case

April 7, 2021 by Dan Maloney 16 Comments

So you say you want to fly above the waves on an electric hydrofoil, but you don’t have the means to buy a commercial board. Or, you don’t have the time and skills needed to carve a board and outfit it with the motor and wing that let it glide above the water. Are you out of luck? Not if you follow this hackworthy e-foil build that uses a waterproof rifle case as the… hull? Board? Whatever, the floaty bit.

If you haven’t run across an e-foil before, prepare to suddenly need something you never knew existed. An e-foil is basically a surfboard with a powerful brushless motor mounted on a keel of sorts, fairly far below the waterline. Along with the motor is a hydrofoil to provide lift, enough to raise the board well out of the water as the board gains speed. They look like a lot of fun.

Most e-foils are built around what amounts to a surfboard, with compartments to house the battery, motor controller, and other electronics. [Frank] and [Julian] worked around the difficult surfboard build by just buying a waterproof rifle case. It may not be very hydrodynamic, but it’s about the right form factor, it already floats, and it has plenty of space for electronics. The link above has a lot of details on the build, which started with reinforcing the case with an aluminum endoskeleton, but at the end of the day, they only spent about 2,000€ on mostly off-the-shelf parts. The video below shows the rifle case’s maiden voyage; we were astonished to see how far and how quickly the power used by the motor drops when the rifle case leaves the water.

Compared to some e-foil builds we’ve seen, this one looks like a snap. Hats off to [Frank] and [Julian] for finding a way to make this yet another hobby we could afford but never find time for.

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Custom Controller Makes Turbomolecular Pump Suck

January 6, 2021 by Anool Mahidharia 16 Comments

[Mark Aren] purchased a pair of Turbomolecular pumps (TMP) sans controllers, and then built an FPGA based BLDC controller for the Turbomolecular pumps. A TMP is similar to a jet turbine, consisting of several stages of alternating moving turbine blades and stationary stator blades, and having turbine rotation speeds ranging from 10,000 rpm to 90,000 rpm. TMP’s cannot exhaust directly to atmosphere, and must be combined with a backing (or roughing) pump to create a lower grade vacuum first. They find use in lots of applications such as electron microscopy, analytical sciences, semiconductors and lamp manufacturing. With the lamp industry rapidly embracing LEDs, many of the traditional lamp making lines are getting decommissioned, and if you are lucky, you can snag a TMP at a low cost – but it still will not be cheap by any means.

The two BOC-Edwards EXT255H Compound Molecular Pumps (PDF), that [Mark] bought did not have their accompanying EXC100E Turbomolecular Pump Controllers (PDF), and given pandemic related restrictions, he decided to build a controller of his own, using components and modules from his parts bin. The pump and controller user manuals offered only sketchy details about the sensored BLDC motor used in the pump. The low phase-to-phase resistance implied low drive voltage, and [Mark] decided to try running it at 24 V to start with. He already had experience using the Mitsubishi PS21245-E IGBT inverter bridge, and even though it was rated for much higher voltages, he knew that it would work just fine at 24 V too.

After figuring out a state machine for motor commutation that utilized PWM based adjustable current control, he implemented it on a 128 element FPGA board. Considering how expensive the TMP was, he wisely decided to first try out his driver on a smaller “expendable” BLDC motor. This whole process was non-trivial, since his available IGBT module was untested and undocumented, and required several tweaks before he could run it at the required 12 kHz PWM signals. His test motor was also undocumented, failing to run correctly when first hooked up. Fixing that issue meant having to disassemble the motor to check its internal wiring. Eventually, his efforts paid off, and he was able to safely run the TMP motor to confirm that his design worked.

With FPGA code, IGBT wiring and power supply issues sorted, the next step was to add a supervisory micro-controller, using an Arduino Nano. Its functions included interfacing with a touch screen LCD as a user interface, communicating with the FPGA module, and controlling several relays to switch power to the motor power supply, the roughing pump, TMP cooling fan, and a solenoid for the vacuum vent. Spindle current is calculated by measuring voltage drop across shunt resistors on the low side of the IGBT. Motor speed is measured using one of the motor hall sensors, and a thermistor provides motor temperature sensing. [Mark]’s PCB fabrication technique seems a bit different too. Using an Excellon drill file, he drills holes in a piece of plastic using a laser cutter to create a bare board, and then solders copper tracks by hand.

His initial tests at atmospheric pressure (although not recommended unless you monitor pump temperature), resulted in 7300 rpm while consuming about 7 Amps before he had to shut it down. In further tests, after adding a roughing pump to the test setup, he was able to spin the TMP to 20,000 rpm while it consumed 0.6 A. Obviously, the pump is rated to operate at a higher voltage, possibly 48 V based on the values mentioned in the TMP controller manual. The project is still “work in progress” as [Mark] hopes to eventually drive the pump up to its specified 60,000 rpm operating speed. What is not clear is what he eventually intends to do with this piece of exotic machinery. All he mentions is that “he has recently taken an interest in high-vacuum systems and is interested in exploring the high-vacuum world of electron guns.”

Maybe [Mark] can compare notes with the Open Source Turbomolecular Pump Controller that we featured some time back. And if you’d like to be a little bit more adventurous and build you own TMP, we got you covered with this DIY Everyman’s Turbomolecular Pump.