Flexures Keep This Printed Displacement Sensor In Line

May 18, 2024 by Dan Maloney 5 Comments

When the job at hand is measuring something with micron-range precision, thoughts generally turn to a tool with a Mitutoyo or Starrett nameplate. But with a clever design and a little electronics know-how, it turns out you can 3D print a displacement sensor for measuring in the micron range for only about $10.

While the tool that [BubsBuilds] came up with isn’t as compact as a dial indicator and probably won’t win any industrial design awards, that doesn’t detract from its usefulness. And unlike a dial indicator — at least the analog type — this sensor outputs an easily digitized signal. That comes courtesy of a simple opto-interrupter sensor, which measures the position of a fine blade within its field of view. The blade is attached to a flexure that constrains its movement to a single plane; the other end of the flexure has a steel ball acting as a stylus. In use, any displacement of the stylus results in more or less light being received by the phototransistor in the opto-interrupter; the greater the deflection, the less light and the lower the current through the transistor. In addition to the sensor itself, [Bub] printed a calibration jig that allows precision gauge blocks or simple feeler gauges to be inserted in front of the stylus. The voltage across the emitter resistor for these known displacements is then used to create a calibration curve.

[Bub] says he’s getting 5-micron repeatability with careful calibration and multiple measurements of each gauge block, which seems pretty impressive to us. If you don’t need the digital output, this compliant mechanism dial indicator might be helpful too. Continue reading “Flexures Keep This Printed Displacement Sensor In Line” →

Put A Little Pigeon In Your Next Clock Project

May 17, 2024 by Dan Maloney 11 Comments

If you’re anything like us, you’ve probably wondered why gear teeth are shaped the way they’re shaped. But we’ll go out on a limb and say you’ve never wondered why gear teeth aren’t shaped like pigeons, and what a clock that’s not quite a clock based around them would look like.

If this sounds like it has [Uri Tuchman] written all over it, give yourself a cookie. [Uri] has a thing for pigeons, and they make an appearance in nearly all his whimsical builds, from his ink-dipping machine to his intricately engraved metal mouse. For this build, pigeons are transformed into the teeth of a large, ornate wheel, cut from brass using an impressive Friedrich Deckel pantograph engraver. To put the pigeon wheel to work, [Uri] built an escapement and a somewhat crooked pendulum, plus a drive weight and dial. It’s almost a clock, but not quite, since it doesn’t measure time in any familiar units, and the dial has a leg rather than hands — classic [Uri].

It may not be [Clickspring]-level stuff, but it’s still a lovely piece of work, and instructive to boot. The way [Uri] figured out the profile for the meshing teeth by looking at the negative space swept out by the pigeon profiles was pretty sweet. Plus, pigeons.

Continue reading “Put A Little Pigeon In Your Next Clock Project” →

Betta Aims To Bring Wire EDM To The Desktop

May 17, 2024 by Dan Maloney 35 Comments

Just as practical nuclear fusion has been “only 20 years away” for the last 80 years or so, the promise of electrical discharge machining (EDM) in the home shop seems to always be just around the corner. It’s hard to understand why this is so — EDM is electrically and mechanically more complicated than traditional subtractive manufacturing techniques, so a plug-and-play EDM setup seems always just out of reach.

Or perhaps not, if this 3D printed 4-axis wire EDM machine catches on. It comes to us from [John] at Rack Robotics and is built around the Powercore EDM power supply that we’ve previously featured. Since wire EDM is a process that requires the workpiece to be completely immersed in a dielectric solution, the machine, dubbed “Betta,” is designed to fit inside a 10-gallon aquarium — get it?

A lot of thought went into keeping costs down. for example, rather than use expensive sealed motors, [John] engineered the double CoreXY platform to keep the motors out of the water bath using long drive shafts and sealed bearings. The wire handling mechanism is also quite simple, at least compared to commercial WEDM machines, and uses standard brass EDM wire. The video below shows the machine going to town of everything from aluminum to steel, with fantastic results on thin or thick stock.

While Rack Robotics is going to be offering complete kits, they’re also planning on open-sourcing all the build files. We’re eager to see where this leads, and if people will latch onto EDM with the same gusto they did with 3D printing.

Continue reading “Betta Aims To Bring Wire EDM To The Desktop” →

Broken Lens Provides Deep Dive Into Camera Repair

May 13, 2024 by Dan Maloney 18 Comments

While most of us are probably willing to pick up the tools and void the warranty on just about anything, often just to see what’s inside, many of us draw the line at camera gear. The tiny screws, the complex mechanisms, and the easily destroyed optical elements are all enough to scare off the average hacker. Not so for [Anthony Kouttron], who tore into a broken eBay Sigma lens and got it working again.

Now, to be fair, modern lenses tend to have a lot more in them that’s amenable to repair than back in the old days. And it seemed from the get-go that [Anthony]’s repair was going to be more electronic than optical or mechanical. The 45-mm lens was in fantastic shape physically, but wouldn’t respond to any controls when mounted to a camera body. Removing the lens bayonet mount exposed the main controller PCB, which is tightly packed with SMD components and connectors for the flex cables that burrow further into the lens to its many sensors and actuators. By probing traces with his multimeter, [Anthony] found a DC-DC converter on the main PCB with an unknown component nearby. This turned out to be an SMD fuse, and as luck would have it, it was open. Replacing the fuse got the lens working again, and while there’s always the nagging suspicion that whatever blew the fuse the first time could happen again, the repair seems to have worked.

Despite the simplicity of the fix, [Anthony] continued the teardown and shared a lot of tips and tricks for lens repairs, including where he would have looked next if the fuse had been good. One tip we loved was the use of double-sided tape to organize parts as they’re removed; this is particularly important with camera gear where screws or different lengths can make for a really bad day on reassembly.

Feeling the need to dive deeper into lens repair? This step-by-step repair should keep you satisfied.

The Art Of Hackaday Hack Chat

May 13, 2024 by Dan Maloney 15 Comments

Join us on Wednesday, May 15 at noon Pacific for the The Art of Hackaday Hack Chat with Joe Kim!

Here at Hackaday, we writers strive to bring you the freshest hacks and the best news from the world of engineering and science. When we miss the mark and make technical errors or stake out a controversial position on something, our readers will certainly let us know in the comments section. It’s a love-hate thing.

While we don’t always see eye to eye, there’s one thing that everyone seems to agree on: Hackaday’s art is amazing! Our unique look comes down to one man: art director Joe Kim. Joe’s creations have graced Hackaday’s pages for years, and his ability to come up with just the right art to illustrate subject matter that’s often complicated and abstract never ceases to amaze.

A lot of you have asked about Hackaday’s art over the years, so we asked Joe to come on the Hack Chat to talk about the process of creating these mini masterpieces. If you’ve ever wondered about the art of Hackaday, or just wanted to say thanks for the visual feast, here’s your chance.

Our Hack Chats are live community events in the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Wednesday, May 15 at 12:00 PM Pacific time. If time zones have you tied up, we have a handy time zone converter.

Hackaday Links: May 12, 2024

May 12, 2024 by Dan Maloney 9 Comments

Don’t pack your bags for the trip to exoplanet K2-18b quite yet — it turns out that the James Webb Space Telescope may not have detected signs of life there after all. Last year, astronomers reported the possible presence of dimethyl sulfide there, a gas that (at least on Earth) is generally associated with phytoplankton in the ocean. Webb used its infrared spectrometer instruments to look at the light from the planet’s star, a red dwarf about 111 light-years away, as it passed through the hydrogen-rich atmosphere. The finding was sort of incidental to the discovery of much stronger signals for methane and carbon dioxide, but it turns out that the DMS signal might have just been overlap from the methane signal. It’s too bad, because K2-18b seems to be somewhat Earth-like, if you can get over the lack of oxygen and the average temperature just below freezing. So, maybe not a great place to visit, but it would be nice to see if life, uh, found a way anywhere else in the universe.

Attention Fortran fans: your favorite language isn’t quite dead yet. In fact, it cracked the top ten on one recent survey, perhaps on the strength of its numerical and scientific applications. The “Programming Community Index” is perhaps a bit subjective, since it’s based on things like Google searches for references to particular languages. It’s no surprise then that Python tops such a list, but it’s still interesting that there’s enough interest in a 67-year-old programming language to make it onto the list. We’d probably not advise building a career around Fortran, but you never know.

Continue reading “Hackaday Links: May 12, 2024” →

Software Bug Results In Insulin Pump Injuries, Spurs Recall

May 11, 2024 by Dan Maloney 24 Comments

Managing Type 1 diabetes is a high-stakes balancing act — too much or too little insulin is a bad thing, resulting in blood glucose levels that deviate from a narrow range with potentially dire consequences on either side. Many diabetics choose to use an insulin pump to make managing all this easier, but as a recent recall of insulin pump software by the US Food and Drug Administration shows, technology isn’t foolproof.

Thankfully, the recall is very narrow in scope. It’s targeted at users of the Tandem t:slim X2 insulin pump, and specifically the companion application running on iOS devices. The mobile app is intended to run on the user’s phone to monitor and control the pump. The pump itself is a small, rechargeable device that users often keep on their belt or tucked into a pocket that delivers a slow, steady infusion of insulin during the day, plus larger bolus doses to compensate for meals.

But version 2.7 of the t:connect mobile app can crash unexpectedly, and on iOS devices, that can lead to the OS continually relaunching it. Each time it does this, the app tries to reconnect with the pump via Bluetooth, which eventually runs down the battery in the pump. Once the battery is dead, no more insulin can be delivered, potentially leading to a condition called hyperglycemia (“hyper” meaning an excess, “gly” referring to sugar, and “emia” meaning presence in blood — excess sugar in the blood.)

Untreated hyperglycemia can progress to a much more serious state called diabetic ketoacidosis, which can lead to coma and death. Thankfully, nobody has suffered that fate from this bug, but the FDA has received over 200 reports of injuries, hence the recall. Tandem sent out a notice to all affected customers back in March to update their apps, but it’s still possible that some users didn’t get the message.

Apart from the human cost of this bug, there’s a lesson here about software design and unintended consequences. While it intuitively seems like a great idea to automatically relaunch a crashed app, especially one with a critical life-safety function, in hindsight, the better course might have been to just go into a safe mode and alert the user with an alarm. That’s a lesson we’ve learned by exploring space, and it seems to apply here as well.

Images: AdobeStock, Tandem Diabetes