Clever Mechanism Makes A Linear Control From A Rotary Hall Sensor

January 9, 2023 by Dan Maloney 81 Comments

Every once in a while we stumble across something so simple yet so clever that we just have to call it out. This custom linear Hall effect sensor is a perfect example of this.

By way of backstory, [Nixieguy], aka [The Electronic Mercenary], offers up a relatable tale — in the market for suitable hardware to make the game Star Citizen more enjoyable, and finding the current commercial joystick offerings somewhat wanting, he decided to roll his own controllers. This resulted in the need for a linear sensor 100 mm in length, the specs for which — absolute sensing, no brushes or encoders, easily sourced parts — precluded most of the available commercial options, like linear pots. What to do?

The solution [Nixieguy] settled on was to use a Hall effect sensor and a diametrally magnetized neodymium ring magnet. The magnet is rotated through 180 degrees by a twisted aluminum bar, which is supported in a frame by bearings. A low-friction slider with a slot captures the bar; moving the slider along the length of the control rotates the bar, which rotates the magnet, which allows the Hall sensor to measure the angle of the magnetic field. Genius!

The parts for the prototype sensor are all made from 0.8-mm aluminum sheet stock and bent to shape. The video below shows the action better than words can describe it, and judging by the oscilloscope trace, the output of the sensor is pretty smooth. There’s clearly a long way to go to tighten things up, but the basic mechanism looks like a clear win to us.

Hats off to [Nixieguy] for this one, which we’ll surely be following for more developments. In the meantime, if you need to brush up on the Hall effect, [Al Williams] did a nice piece on that a while back.

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Fifteen Flat CRTs And A Bunch Of Magnets Make For Interactive Fun

January 6, 2023 by Dan Maloney 46 Comments

If you were a curious child growing up when TVs were universally equipped with cathode ray tubes, chances are good that you discovered the effect a magnet can have on a beam of electrons. Watching the picture on the family TV warp and twist like a funhouse mirror was good clean fun, or at least it was right up to the point where you permanently damaged a color CRT by warping the shadow mask with a particularly powerful speaker magnet — ask us how we know.

To bring this experience to a generation who may never have seen a CRT display in their lives, [Niklas Roy] developed “Deflektron”, an interactive display for a science museum in Switzerland. The CRTs that [Niklas] chose for the exhibit were the flat-ish monochrome tubes that were used in video doorbell systems in the late 2000s, like the one [Bitluni] used for his CRT Game Boy. After locating fifteen of these things — probably the biggest hack here — they were stripped out of their cases and mounted into custom modules. The modules were then mounted into a console that looks a little like an 80s synthesizer.

In use, each monitor displays video from a camera mounted to the module. Users then get to use a selection of tethered neodymium magnets to warp and distort their faces on the screen. [Niklas] put a lot of thought into both the interactivity of the exhibit, plus the practical realities of a public installation, which will likely take quite a beating. He’s no stranger to such public displays, of course — you might remember his interactive public fountain, or this cyborg baby in a window.

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solenoid wound pickup coil next to a selection of bolts and a steel rod

The Barkhausen Effect: Hearing Magnets Being Born

November 19, 2022 by Dave Rowntree 21 Comments

The Barkhausen effect — named after German Physicist Heinrich Barkhausen — is the term given to the noise output produced by a ferromagnetic material due to the change in size and orientation of its discrete magnetic domains under the influence of an external magnetic field. The domains are small: smaller than the microcrystalline grains that form the magnetic material, but larger than the atomic scale. Barkausen discovered that as a magnetic field was brought close to a ferrous material, the local magnetic field would flip around randomly, as the magnetic domains rearranged themselves into a minimum energy configuration and that this magnetic field noise could be sensed with an appropriately arranged pickup coil and an amplifier. In the short demonstration video below, this Barkhausen noise can be fed into an audio amplifier, producing a very illustrative example of the effect.

One example of practical use for this effect is with non-destructive testing and qualification of magnetic structures which may be subject to damage in use, such as in the nuclear industry. Crystalline discontinuities or impurities within a part under examination result in increased localized mechanical stresses, which could result in unexpected failure. The Barkhausen noise effect can be easily leveraged to detect such discontinuities and give the evaluator a sense of the condition of the part in question. All in all, a useful technique to know about!

If you were thinking that the Barkhausen is a familiar name, you may well be thinking about the Barkhausen stability criterion, which is fundamental to describing some of the conditions necessary for a linear feedback circuit to oscillate. We’ve covered such circuits before, such as this dive into bridge oscillators.

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Faceless Clock Makes You Think Twice About How It Works

November 18, 2022 by Dan Maloney 23 Comments

We love projects that make you do a double-take when you first see them. It’s always fun to think you see one thing, but then slowly realize everything is not quite what you expected. And this faceless analog clock is very much one of those projects.

When we first saw [Shinsaku Hiura]’s “Hollow Clock 4,” we assumed the trick to making it look like the hands were floating in space would rely on the judicious use of clear acrylic. But no, this clock is truly faceless — you could easily stick a finger from front to back. The illusion is achieved by connecting the minute hand to the rim of the clock, and rotating the whole outer circumference through a compact 3D printed gear train. It’s a very clever mechanism, and it’s clear that it took a lot of work to optimize everything so that the whole look of the clock is sleek and modern.

But what about the hour hand? That’s just connected to the end of the minute hand at the center of the clock’s virtual face, so how does that work? As it is with most things that appear to be magical, the answer is magnets. The outer rim of the clock actually has another ring, this one containing a pair of neodymium magnets. They attract another magnet located in the very end of the hour hand, dragging it along as the hour ring rotates. The video below shows off the secrets, and it gives you some idea of how much work went into this clock.

We’re used to seeing unique and fun timepieces and other gadgets from [Shinsaku Hiura] — this up-flipping clock comes to mind, as does this custom RPN calculator — but this project is clearly a step beyond.

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One Stepper Plus A Whole Bunch Of Magnets Equals A Unique Seven-Segment Display

March 5, 2022 by Dan Maloney 23 Comments

Sometimes the cost of simplicity is extra complexity. It seems counterintuitive, but it seems to be true. And this single-motor mechanical seven-segment display seems to be a perfect example of this paradox.

On second thought, [aeropic]’s mechanism isn’t really all that mechanically complicated, but there sure was a lot of planning and ingenuity that went into it. The front has a 3D-printed bezel with the familiar segment cutouts, each of which is fitted with a pivoting segment, black on one side and white on the other.

Behind the bezel is a vertical shaft with three wheels, one behind each horizontal segment, and a pair of horizontal shafts, each with two wheels behind each vertical segment. The three shafts are geared to turn together by a single stepper in the base. Each wheel has ten magnets embedded in the outer circumference, with the polarity oriented to flip the segment in front of it to the right orientation for the current digit. It’s probably something that’s most easily understood by watching the video below.

We’ve seen quite a few of these mechanical seven-segment displays lately — this cam-and-servo mechanism comes to mind. We love them all, of course, but the great thing about [aeropic]’s display is how quiet it is — the stepper is mostly silent, and the segments make only a gentle clunk when they flip. It’s very satisfying.

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Magnetic Experiments Shows Gradients

October 11, 2021 by Al Williams 3 Comments

You’ve probably heard the term magnetic gradient before, but have you ever seen one? Now you can in [supermagnetman’s] video, below. The key is to use very fine (2 micron) iron filings and special silicone oil. The video is a good mix of whiteboard lectures and practical hands-on experimenting. Just watching him spin the iron filings in the bottle was entertaining. There’s sources in the video description for the oil and the filings if you want to replicate the demonstrations for a classroom or just for your own enjoyment.

It’s one thing to know the math behind magnetic fields. It’s another to be able to use them in practical applications. But a good understanding of the physical manifestation of the magnetic field coupled can help clarify the math and vice versa. There’s a lot of common sense explanations too. For example, the way the filings accelerate as they get closer to the magnet explains why the patterns form the way they do. Iron filings are a traditional way to “see” magnetic fields. Ask anyone who ever had a Wooly Willy.

Iron filings can be fun to play with, although we don’t think we’ve ever had any this fine. If you prefer your magnetic field visualizations to be higher-tech, we have the answer.

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A 3D Printer With An Electromagnetic Tool Changer

June 12, 2021 by Bryan Cockfield 19 Comments

The versatility of 3D printers is simply amazing. Capable of producing a wide variety of prototypes, miscellaneous parts, artwork, and even other 3D printers, it’s an excellent addition to any shop or makerspace. The smaller, more inexpensive printers might do one type of printing well with a single tool, but if you really want to take a 3D printer’s versatility up to the next level you may want to try one with an automatic tool changing system like this one which uses magnets.

This 3D printer from [Will Hardy] uses an electromagnet to attach the tool to the printer. The arm is able to move to the tool storage area and quickly deposit and attach various tools as it runs through the prints. A failsafe mechanism keeps the tool from falling off of the head of the printer in case of a power outage, and several other design features were included to allow others to tweak this design to their own particular needs, such as enclosing the printer and increasing or decreasing the working area of the Core-XY printer as needed.

While the project looks like it works exceptionally well, [Will] notes that it is still in the prototyping phase and needs work on the software in order to refine its operation and make it suitable for more general-purpose uses. It’s an excellent design though and shows promise. It also reminds us of this other tool-changing system we featured a few months ago, albeit with a less electromagnetic twist.

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