Author: Bryan Cockfield

1760 Articles

Custom Fume Hood For Safe Electroless Plating

October 22, 2023 by 10 Comments

There are plenty of chemical processes that happen commonly around the house that, if we’re really following safety protocols to the letter, should be done in a fume hood. Most of us will have had that experience with soldering various electronics, especially if we’re not exactly sure where the solder came from or how old it is. For [John]’s electroless plating process, though, he definitely can’t straddle that line and went about building a fume hood to vent some of the more harmful gasses out of a window.

This fume hood is pretty straightforward and doesn’t have a few of the bells and whistles found in commercial offerings, but this process doesn’t really require things like scrubbing or filtering the exhaust air so he opted to omit these pricier and more elaborate options. What it does have, though, is an adjustable-height sash, a small form factor that allows it to easily move around his shop, and a waterproof, spill-collecting area in the bottom. The enclosure is built with plywood, allowing for openings for an air inlet, the exhaust ducting, and a cable pass-through, and then finished with a heavy-duty paint. He also included built-in lighting and when complete, looks indistinguishable from something we might buy from a lab equipment supplier.

While [John] does admit that the exhaust fan isn’t anything special and might need to be replaced more often than if he had gone with one that was corrosion-resistant, he’s decided that the cost of this maintenance doesn’t outweigh the cost of a specialized fan. He also notes it’s not fire- or bomb-proof, but nothing he’s doing is prone to thermal anomalies of that sort. For fume hoods of all sorts, we might also recommend adding some automation to them so they are used any time they’re needed.

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Humble Arduino As PLC

October 19, 2023 by 35 Comments

On the surface, a programmable logic controller (PLC) might seem like nothing more than a generic microcontroller, perhaps outfitted to operate in industrial settings with things like high temperatures or harsh vibrations. While this is true to some extent, PLCs also have an international standard for their architecture and programming languages. This standard is maintained by the International Electrotechnical Commission, making it so that any device built under these specifications will be recognizable to control engineers and maintenance personnel worldwide. And, if you use this standard when working with certain Arduinos, this common platform can become a standard-compliant PLC as well.

The IDE itself supports programming ladder diagrams, functional block diagrams, and other programming systems covered under the IEC 61131-3 standard. Not only that, it allows the combination of these types of PLC programming with Arduino sketches. The system offers many of the perks of PLC programming alongside the familiar Arduino platform, and supports a number of protocols as well including CANOpen, Modbus RTU, and Modbus TCP. It can also be used for monitoring a PLC system, essentially adding IoT capabilities to existing systems, enabling continuous monitoring, debugging, and program updates.

While not every Arduino is a great platform to build a PLC around, there are a few available for those looking for a system a little less proprietary and a little more user-friendly than typical PLC systems tend to be. There’s a reason that PLCs are built around an international standard and generally have certain hardware in mind to run it, though, and this comparison of a Raspberry Pi with an off-the-shelf PLC goes into detail about why certain components aren’t good choices for PLCs.

Variable-Nozzle Ducted Fan Provides Fluid Dynamics Lessons

October 19, 2023 by 15 Comments

Any student new to the principles of fluid dynamics will be familiar with Bernoulli’s principle and the Venturi effect, where the speed of a liquid or gas increases when the size of the conduit it flows through decreases. When applying this principle to real-world applications, though, it can get a bit more complex than a student may learn about at first, mostly due to the shortcomings of tangible objects when compared to their textbook ideals. [Mech Ninja] discovered this while developing a ducted fan based around an RC motor.

The ducted fan is meant to be a stand-in for a model jet engine, based around a high-powered motor generally designed for drone racing. Most of the build is 3D printed including duct system, but in order to improve the efficiency and thrust beyond simple ducting, [Mech Ninja] designed and built a variable nozzle to more finely control the “exhaust” of his engine. This system is also 3D printed and can restrict or open up the outflow of the ducted fan, much like a real jet engine would. It uses two servos connected to collars on the outside of the engine. When the servos move the collars, a set of flaps linked to the collars can choke or expand the opening at the rear of the engine.

This is where some of the complexity of real-life designs comes into play, though. After testing the system with a load cell under a few different scenarios, the efficiency and thrust weren’t always better than the original design without the variable nozzle. [Mech Ninja] suspects that this is due to the gaps between the flaps, allowing air to escape and disrupting the efficient laminar flow of the air leaving the fan, and plans to build an improved version in the future. Fluid dynamics can be a fairly complex arena to design within, sometimes going in surprising directions like this ducted fan that turned out better than the theory would have predicted, at least until they accounted for all the variables in the design.

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STM32 Offers Performance Gains For DIY Oscilloscope

October 18, 2023 by 23 Comments

There’s no shortage of cheap digital oscilloscopes available today from the usual online retailers, but that doesn’t mean the appeal of building your own has gone away — especially when we have access to powerful microcontrollers that make it easier than ever to spin up custom gear. [mircemk] is using one of those microcontrollers to build an improved, pocket-sized oscilloscope.

The microcontroller he’s chosen is the STM32F103C8T6, part of the 32-bit STM family which has tremendous performance compared to common 8-bit microcontrollers for only a marginally increased cost. Paired with a small 3-inch TFT color display, it has enough functions to cover plenty of use cases, capable of measuring both AC and DC signals, freezing a signal for analysis, and operating at an impressive 500 kHz at a cost of only around $15. The display also outputs a fairly comprehensive analysis of the incoming signal as well, with the small scope capable of measuring up to 6.6 V on its input.

This isn’t [mircemk]’s first oscilloscope, either. His previous versions have used Arduinos, generally only running around 50 kHz. With the STM32 microcontroller the sampling frequency is an order of magnitude higher at 500 kHz. While that’s not going to beat the latest four-channel scope from Tektronix or Rigol, it’s not bad for the form factor and cost and would be an effective scope in plenty of applications. If all you have on hand is an 8-bit microcontroller, though, we have seen some interesting scopes built with them in the past.

Full Self-Driving, On A Budget

October 17, 2023 by 35 Comments

Self-driving is currently the Holy Grail in the automotive world, with a number of companies racing to build general-purpose autonomous vehicles that can get from point A to point B with no user input. While no one has brought one to market yet, at least one has promised this feature and had customers pay for it, but continually moved the goalposts for delivery due to how challenging this problem turns out to be. But it doesn’t need to be that hard or expensive to solve, at least in some situations.

The situation in question is driving on a single stretch of highway, and only focuses on steering, so it doesn’t handle the accelerator or brake pedal input. The highway is driven normally, using a webcam to take images of the route and an Arduino to capture data about the steering angle. The idea here is that with enough training the Arduino could eventually steer the car. But first some math needs to happen on the training data since the steering wheel is almost always not turning the car, so the Arduino knows that actual steering events aren’t just statistical anomalies. After the training, the system does a surprisingly good job at “driving” based on this data, and does it on a budget not much larger than laptop, microcontroller, and webcam.

Admittedly, this project was a proof-of-concept to investigate machine learning, neural networks, and other statistical algorithms used in these sorts of systems, and doesn’t actually drive any cars on any roadways. Even the creator says he wouldn’t trust it himself, but that he was pleasantly surprised by the results of such a simple system. It could also be expanded out to handle brake and accelerator pedals with separate neural networks as well. It’s not our first budget-friendly self-driving system, either. This one makes it happen with the enormous computing resources of a single Android smartphone.

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Low-Cost Electret Microphone Preamplifiers

October 16, 2023 by 8 Comments

Before the invention of microelectromechanical system (MEMS) microphones, almost all microphones in cell phones and other electronics were a type of condenser microphone called the electret microphone. The fact that this type of microphone is cheap and easy enough to place into consumer electronics doesn’t mean they’re all low quality, though. Electret microphones can have a number of qualities that make them desirable for use recording speech or music, so if you have a struggling artist friend like [fvfilippetti] has who needs an inexpensive way to bring one to life, take a look at this electret microphone pre-amp.

The main goal of the project is to enhance the performance of these microphones specifically in high sound pressure level (SPL) scenarios. In these situations issues of saturation and distortion often occur. The preampl design incorporates feedback loops and an AD797 opamp to reduce distortion, increase gain, and maintain low noise levels. It also includes an output voltage limiter using diodes to protect against input overload and can adjust gain. The circuit’s topology is designed to minimize distortion, particularly in these high SPL situations.

Real-world testing of the preamp confirms its ability to handle high SPL and deliver low distortion, making it a cost-effective solution for improving the performance of electret microphones like these. If you want to go even deeper into the weeds of designing and building electret microphones and their supporting circuitry, take a look at this build which discusses some other design considerations for these types of devices.

Re-imagining The Water Supply

October 15, 2023 by 48 Comments

Getting freshwater supplied across cities and towns in a reliable and safe way is no simple task. Not only is a natural freshwater reservoir or other supply needed, but making sure the water is safe to drink and then shipping it out over a dense network of pumps and pipes can cost a surprising amount of time and money. It also hinges on a reliable power grid, which is something Texas resident [Suburban Biology] doesn’t have. But since fresh water literally falls out of the sky for free, he decided to take this matter into his own hands.

The main strategy with a system like this is to keep the rainwater as clean as possible before storage so that expensive treatment systems are less necessary. That means no asphalt shingles, a way to divert the first bit of rain that washes dust and other contaminants off the roof away, and a safe tank. This install uses a 30,000 gallon tank placed above ground for storage, but that’s not the only thing that goes into a big rainwater catchment system like this. A system of PVC pipes are needed both for sending rainwater from the roofs of the buildings into the tank and for pumping it into the home for use. With all of that in place it’s both a hedge against climate change, unstable electric grids, and even separates the user from the local aquifer which may or may not have its own major issues depending on where you live.

While Texas legally protects the rights of citizens to collect and store rainwater, the same isn’t true for all areas. For example, Colorado only just passed a law allowing the collection and storage of a meager 110 gallons of rainwater and forbade it entirely beforehand. There are some other considerations for a project like this too, largely that above-ground systems generally won’t work in cold climates. On the other hand, large systems like these are really only needed where rainfall is infrequent; in more tropical areas like south Florida a much smaller storage system can be used

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