Human-Powered Laser Gun Makes Battery-Free Target Practice

April 26, 2020 by Donald Papp 15 Comments

[Dirk] shared a fascinating project of his that consists of several different parts coming together in a satisfying whole. It’s all about wanting to do target practice, indoors, using a simple red laser dot instead of any sort of projectile. While it’s possible to practice by flashing a red laser pointer and watching where it lands on a paper target, it’s much more rewarding (and objective) to record the hits in some way. This is what led [Dirk] to create human-powered, battery-free laser guns with software to track and display hits. In the image above, red laser hits on the target are detected and displayed on the screen by the shooter.

Right under the thumb is the pivot point for the lever, and that’s also where a geared stepper motor (used as a generator) is housed. Operating the action cranks the motor.

There are several parts to this project and, sadly, the details are a bit incomplete and somewhat scattered around, so we’ll go through the elements one at a time. The first is the guns themselves, and the star of the show is his 3D printed cowboy rifle design. The rifle paints the target with a momentary red laser dot when the trigger is pressed, but that’s not all. [Dirk] appears to have embedded a stepper motor into the lever action, so that working the lever cranks the motor as a generator and stores the small amount of power in a capacitor. Upon pulling the trigger, the capacitor is dumped into the laser (and into a piezo buzzer for a bit of an audio cue, apparently) with just enough juice to create a momentary flash. We wish [Dirk] had provided more details about this part of his build. There are a few more images here, but if you’d like to replicate [Dirk]’s work it looks like you’ll be on your own to some extent.

As for the target end of things, blipping a red dot onto a paper target and using one’s own eyeballs can do the job in a bare minimum sort of way, but [Dirk] went one further. He used Python and OpenCV with a camera to watch for the red dot, capture it, then push an image of the target (with a mark where the impact was detected) to a Chromecast-enabled screen near the shooter. This offers much better feedback and allows for easier scoring. The GitHub repository for the shot detector and target caster is here, and while it could be used on its own to detect any old laser pointer, it really sings when combined with the 3D printed cowboy rifle that doesn’t need batteries.

Not using projectiles in target practice does have some benefits: it’s silent, it’s easy to do safely, there is no need for a backstop, there are no consumables or cleaning, and there is no need to change or patch targets once they get too many holes. Watch it all in action in the video embedded below.

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OpenScan 3D Scans All Of The (Small) Things

April 25, 2020 by Donald Papp 22 Comments

The OpenScan project has been updated quite a bit since its inception. OpenScan is an open source, Arduino or Raspberry Pi-based 3D scanner for small objects that uses 3D printed hardware and some common electronic components to create 3D scans using photogrammetry; a process by which a series of still images from different angles are used to create a 3D point cloud of an object, which can then be used to generate a 3D model.

Feature visualization overlays detected features onto the camera preview to help judge quality. Broadly speaking, green is good.

Photogrammetry is a somewhat involved process that relies on consistent conditions, so going through the whole process only to find out the results aren’t up to snuff can be tiresome. Happily, OpenScan offers some interesting new functions such as feature visualization via the web interface, which helps a user judge scan quality and make changes to optimize results without having to blindly cross their fingers quite so much. OpenScan remains a one-person project by [Thomas], who is clearly motivated to improve his design and we’re delighted to see it getting updates.

Embedded below is a video that walks through the installation and web interface. It’s a fairly long and comprehensive, but if you like you can skip directly to [Thomas] demonstrating the interface around the 8:22 mark, or watch it below. Interested in your own unit? [Thomas] has an e-shop for parts and the GitHub repository is right here; the project also has its own subreddit.

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How To Keep Unique Equipment Running When Parts Run Out

April 23, 2020 by Donald Papp 16 Comments

[JGlass] deals with public-facing technology, which he says includes things like theatre equipment, retail displays, and museum displays. Many of these pieces of technology are literally one-of-a-kind devices, even if they were constructed from what was once off-the-shelf, commercially available parts. When these machines need servicing, replacement parts aren’t always available, and reverse engineering comes in handy. He recently began documenting exactly how to approach this process by using the identification and replacement of an obsolete 7-segment industrial display as an example.

The particular part shown is the Lascar EM32-4-LED, which up and died in a unique piece of equipment. The trouble is that the EM32-4-LED is out of production and unobtainable, and the Programmable Logic Controller (PLC) that drives the whole thing is a black box that cannot be modified. It’s very good news that a datasheet exists, but that’s often just a starting point. To create a one-off, drop-in solution requires a combination of research, troubleshooting, and design work.

To do this, [JGlass] starts off by walking through datasheet elements and explains that it’s important to build a high level understanding of function first, then drill down into details, and always be ready to verify, challenge, or throw out one’s assumptions. After establishing a high level understanding comes matching physical evidence to things like block and functional diagrams, then cracking open the faulty component to see if anything else can be learned. Only then are multimeters and probes taken out for more active research. All of this sleuthing must always be done with the end goal firmly in mind: creating a new device that acts like the one being replaced. Without focus, one can easily get lost in details and unknowns.

Reverse Engineering is a process, and the more tools, the better. If you missed our earlier post about a hacker’s guide to JTAG, here’s your chance to check it out and be all the more prepared for the next time you need to do some electron detective work of your own.

Roll Your Own Automation With ESPHome

April 20, 2020 by Donald Papp 17 Comments

There are several different paths to a smart home, and [Marcus] eventually settled on using ESPHome and ESP8266/ESP32 based devices to create a complete DIY smart home solution which covers his garage door, sprinklers, LED strips, light bulbs, and outlets. There’s even an experimental (and very economical) ESP32-CAM based camera, shown here.

In fact, [Marcus]’s write-up could double as a sort of reference design. If you’re curious about ESPHome, be sure to read what he has to say because he explains exactly how he configured each device and any challenges he encountered in the process.

Beyond the software guidance, the post is also a great resource on how to flash a new firmware onto several different smart devices. [Marcus] provides nicely labeled images of the boards that show where you need to connect your programmer, which just might save you some trouble down the line. Though he did manage to set fire to one of the bulbs, so keep an eye out for that.

Tasmota is another open source option for controlling ESP8266-based devices, and if you’d like to explore that direction don’t forget that flashing Sonoff devices with Tasmota firmware recently got much, much easier.

Gain An Understanding Of Injection Molding’s Design Gotchas

April 19, 2020 by Donald Papp 11 Comments

When it comes to manufacturing, sheet metal and injection molding make the world go ’round. As a manufacturing method, injection molding has its own range of unique design issues and gotchas that are better to be aware of than not. To help with this awareness, [studiored] has a series of blog posts describing injection molding design issues, presented from the perspective of how to avoid and address them.

Design of screw bosses demonstrating conflict between molder’s guidelines and vendor’s recommendations. Compromising between both is a science and an art.

Because injection molding involves heat, warp is one issue to be aware of and its principles will probably be familiar to anyone with nitty-gritty experience in 3D printing. Sink marks are also an issue that comes down to differential cooling causing problems, and can ruin a smooth and glossy finish. Both of these play a role in how best to design bosses.

Minimizing and simplifying undercuts (similar to overhangs in 3D printer parlance) is a bit more in-depth, because even a single undercut means much more complex tooling for the mold. Finally, because injection molding depends on reliably molding, cooling, and ejecting parts, designing parts with draft (a slight angle to aid part removal) can be a fact of life.

[studiored] seems to have been working overtime on sharing tips for product design and manufacture on their blog, so it’s worth keeping an eye on it for more additions. We mentioned earlier that much of the manufacturing world revolves around injection molding and sheet metal, so to round out your knowledge we published a primer on everything you need to know about the art and science of bending sheet metal. With a working knowledge of the kinds of design issues that affect these two common manufacturing methods, you’ll have a solid foundation for any forays into either world.

DIY Magsafe Charger Feeds Off 12 V Solar Battery

April 19, 2020 by Donald Papp 18 Comments

[Steve Chamberlin] has a spiffy solar-charged 12 V battery that he was eager to use to power his laptop, but ran into a glitch. His MacBook Pro uses Apple’s MagSafe 2 connector for power, but plugging the AC adapter into the battery via a 110 VAC inverter seemed awfully inefficient. It would be much better to plug it into the battery directly, but that also was a problem. While Apple has a number of DC power adapters intended for automotive use, none exist for the MagSafe 2 connector [Steve]’s mid-2014 MacBook Pro uses. His solution was to roll his own MagSafe charger with 12 VDC input.

Since MagSafe connectors are proprietary, his first duty was to salvage one from a broken wall charger. After cleaning up the wires and repairing any frayed bits, it was time to choose a DC-DC converter to go between the MagSafe connector and the battery. The battery is nominally 12 volts, so the input of the DC-DC converter was easy to choose, but the output was a bit uncertain. Figuring out what the MagSafe connector expects took a little educated guesswork.

The original AC adapter attached to the charger claimed an output of 20 volts, another Apple adapter claimed a 14.85 V output, and a third-party adapter said 16.5 volts. [Steve] figured that the MagSafe connectors seemed fine with anything in the 15 to 20 V range, so it would be acceptable to use a 12 V to 19 V DC-DC boost converter which he had available. The result worked just fine, and [Steve] took measurements to verify that it is in fact much more efficient than had he took the easy way out with the inverter.

MagSafe has been displaced by USB-C nowadays, but there are plenty of MagSafe devices still kicking around. In a pinch, keep in mind that a little bit of filing or grinding is all that’s needed to turn MagSafe 1 into MagSafe 2.

Automatic Timelapses, Made Educational And Easy

April 16, 2020 by Donald Papp 2 Comments

Timelapse fragment from an infrared sky camera watching cloud patterns.

There are plenty of ways to create timelapse videos, but [Andy] has an efficient method for ensuring up-to-date ones exist for his infrared sky camera, and he has it running thanks to some well-documented shell scripts on a spare Raspberry Pi. The resulting timelapse video is always available from the web, and always up-to-date for the current day.

The idea is to automatically fetch images from a remote source (in his case, an infrared sky camera) and turn them into a cumulative video that is regularly updated for the day in question. The resulting video file is either served from the same machine, or sent elsewhere. All that’s needed besides a source for the stills are two shell scripts and some common Linux utilities.

Since [Andy] is mainly interested in tracking clouds his system only runs during daylight hours, but it can be easily changed. In fact, [Andy]’s two shell scripts are great project resources, not only because they are easily modified and well documented, but because he doesn’t make assumptions about how well one might know the command line. He also provides tips from experience; for example he has found that a 120 second interval makes for the best timelapses.

[Andy] runs his scripts on an Raspberry Pi 4, but any Linux system will do. For those who might prefer a more embedded approach, the ESP32-CAM can make a great time lapse camera with remarkably little effort.