Author: Bryan Cockfield

1850 Articles

APRS Implemented At Low Cost And Small Size

June 15, 2021 by 17 Comments

Before smartphones and Internet of Things devices were widely distributed, the Automatic Packet Reporting System (APRS) was the way to send digital information out wirelessly from remote locations. In use since the 80s, it now has an almost hipster “wireless data before it was cool” vibe, complete with plenty of people who use it because it’s interesting, and plenty of others who still need the unique functionality it offers even when compared to more modern wireless data transmission methods. One of those is [Tyler] who shows us how to build an APRS system for a minimum of cost and size.

[Tyler]’s build is called Arrow and operates on the popular 2 metre ham radio band. It’s a Terminal Node Controller (TNC), a sort of ham radio modem, built around an ESP32. The ESP32 handles both the signal processing for the data and also uses its Bluetooth capability to pair to an Android app called APRSDroid. The entire module is only slightly larger than the 18650 battery that powers it, and it can be paired with a computer to send and receive any digital data that you wish using this module as a plug-and-play transceiver.

While the build is still has a few limitations that [Tyler] notes, he hopes that the project will be a way to modernize the APRS protocol using methods for radio transmission that have been improved upon since APRS was first implemented. It should be able to interface easily into any existing ham radio setup, although even small balloon-lofted radio stations can make excellent use of APRS without any extra equipment. Don’t forget that you need a license to operate these in most places, though!

A 3D Printer With An Electromagnetic Tool Changer

June 12, 2021 by 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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Hi-Fi Combines Best Of 60s And 90s Technology

June 7, 2021 by 55 Comments

The 90s were a dark time for audio equipment, literally and figuratively. Essentially the only redeeming quality from the decade of nondescript black plastic boxes was the low cost. Compared to the audio equipment of the 60s, largely produced in high-end enclosures with highly desirable tube amplifiers, the 90s did not offer much when it came to hi-fi stereo sound. However, those cheap black boxes from the 90s turn out to be surprisingly perfect for project enclosures for other amplifier builds, such as this 60s-era tube amp recreation.

This mesh of the best of two distinct decades comes from [Alvenh] and begins by preparing the old enclosure for its new purpose. This means a lot of work fabricating a custom metal face plate for the new amplifier and significantly modifying the remaining case. After the box is complete, the amplifier build began. It uses a tube-based preamp and a solid-state power amplifier since [Alvenh]’s experience suggested that the warm tube sound was generated mostly in the preamp. This means that his design is a hybrid but still preserves the essential qualities of a full tube build.

The build also includes a radio module that has the ability to cover the 2m and 70cm bands popular in ham radio. This module also has been found to have much better audio quality than the standard AM/FM receiver typically used in projects like this. With the radio module added to the custom enclosure, as well as a phono amp and a power supply, [Alvenh] has an excellent audio amplifier in an inexpensive case which preserves the tube sound from the true hi-fi eras of decades past.

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Differential Drive Doesn’t Quite Work As Expected

June 6, 2021 by 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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Radio Build Goes Outside The Box

June 3, 2021 by 4 Comments

It’s easy to get caught up in a build and forget that the final version usually needs some sort of enclosure, especially things with sensitive electronics in them. The [Director of Legal Evil] at the LVL1 Louisville Hackerspace notes as much in his recent radio build. It seems as though the case was indeed an afterthought, but rather than throwing it in a nondescript black project enclosure it was decided to turn the idea of a project enclosure itself inside-out.

The radio build is based on an SI4732 radio receiver which is a fairly common radio module and is easily adaptable. It needs a microcontroller to run though, so a Maple STM32 platform was chosen to do all of the heavy lifting. The build includes a screen, some custom analog controls, and a small class D audio amplifier, but this is the point it begins to earn its name: the Chaos Radio. While playing around with the project design in CAD, a normal design seemed too bland so one was chosen which makes the radio look like the parts are exploding outward from what would have been a more traditional-style enclosure.

While the project includes a functioning radio receiver, we have to complement the creator for the interesting display style for this particular set of hardware. It can get boring designing the same project enclosures time after time, so anything to shake things up is often welcomed especially when it puts all of the radio components on display like this. In fact, it’s reminiscent of some of [Dmitry]’s projects, an artist known for deconstructing various common household appliances like this CD Player.

Thanks to [Jose] for the tip!

Full Size 3D-Printed Wind Turbine

June 2, 2021 by 29 Comments

Wind energy isn’t quite as common of an alternative energy source as solar, at least for small installations. It’s usually much easier just to throw a few panels and a battery together than it is to have a working turbine with many moving parts that need to be maintained when only a small amount of power is needed. However, if you find yourself where the wind blows but the sun don’t shine, there are a few new tools available to help create the most efficient wind turbine possible, provided you have a 3D printer.

[Jan] created this turbine with the help of QBlade, a piece of software that helps design turbine blades. It doesn’t have any support for 3D printing though, such as separating the blades into segments, infill, and attachment points, so [Jan] built YBlade to help take care of all of this and made the software available on the project’s GitHub page. The blades are only part of this story, though. [Jan] goes on to build a complete full-scale wind turbine that can generate nearly a kilowatt of power at peak production, although it does not currently have a generator attached and all of the energy gets converted to heat.

While we hope that future versions include a generator and perhaps even pitched blades to control rotor speed, [Jan] plans to focus his efforts into improving the blade design via the 3D printer. He is using an SLA printer for these builds, but presumably any type of printer would be up to the task of building a turbine like this. If you need inspiration for building a generator, take a look at this build which attempted to adapt a ceiling fan motor into a wind turbine generator.

 

Adding In-Game Reset To Classic Playstations

June 1, 2021 by 6 Comments

The first Playstation is quickly approaching three decades since its release, and while this might make some of us who were around for that event feel a little aged, the hardware inside these machines isn’t getting any younger either. Plenty of people are replacing the optical drive in the original hardware with an optical drive emulator as they begin to fail, and with that comes the option for several other modifications to the hardware like this in-game reset mod.

In-game reset is a function that allows a console to be reset via a controller button combination rather than pressing the console’s reset button directly. Especially for devices modified with either the XStation or PSIO drive emulators, this can be a handy feature to have as this method can more easily take the user back to the emulator menu as well as physically reset the device. The modification is a small PCB which attaches to the controller port and, unlike previous versions, only requires a single pin to be soldered to the Playstation’s control board.

If you’re someone who enjoys playing games on original hardware rather than a patchwork of emulators, this could be an excellent addition to your PS1 that still allows most of the original feel and experience the PS1 offered. The drive emulator can greatly expand the range of the hardware as well, much like this NES cartridge which similarly expands the capabilities of that much older system.