Mostly Printed CNC Gets A Few Upgrades

May 7, 2024 by Dan Maloney 9 Comments

The Mostly Printed CNC is famous for two things. First, being made mostly from 3D printed parts and commonly available steel tubing. Second, because of the materials used, its rigidity isn’t fantastic. But any CNC router is better than no CNC router, and [Alan Reiner]’s “Mostly Mostly Printed CNC” upgrades the base MPCNC into a much more capable unit.

MPCNC purists may want to look away, as the video below shows [Alan] committing the heresy of adding linear rails to his machine. The rails were sourced from VEVOR and at less than $100 for 10 meters, it must have been hard to resist. The rigidity wasn’t amazing — witness the horrific chatter at around the 5:15 mark — but [Alan] sorted that out with some aluminum extrusion and printed adapters.

Those upgrades alone were enough to let [Alan] dive into some aluminum cutting, but he also wanted to address another gripe with his base build: the Z-axis backlash. The fix there was to add another lead screw nut on an adjustable carrier. By tweaking the relative angles of the two opposed nuts, almost all of the backlash was taken up. [Alan] also replaced the motor coupling on the Z axis with a Lovejoy-style coupler, to remove as much axial compliance as possible.

Along with the motion control mods, [Alan] improved work holding and added an enclosure to tame the chip beast, along with some upgrades to the control electronics. The results are pretty good and appear well worth the modest added expense. Maybe a wireless controller can be next on the upgrade list?

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RepTrap Keeps Watch Over Our Cold-Blooded Friends

May 7, 2024 by Dan Maloney 1 Comment

Wait a second, read that title again. This isn’t a throwback 3D printing project at all. That’s “RepTrap” as in reptile trap, and it’s a pretty clever way to study our cold-blooded friends in their natural habitat.

Now, game cameras — or trail cameras, if you’re less interested in eating what you see — are pretty much reduced to practice. For not that much money you can pick up one of these battery-powered devices, strap it to a tree, and have it automatically snap high-quality pictures of whatever wildlife happens to wander past. But nearly all of the commercially available game cameras have pyroelectric infrared sensors, which trigger on the temperature difference between a warm-blooded animal and the ambient temperature of the background. But what to do when you’re more interested in cold-blooded critters?

Enter [Mirko], who stumbled upon this problem while working with a conservation group in Peru. The group wanted to study snakes, insects, and other ectothermic animals, which are traditionally studied by trapping with pitfalls and other invasive techniques. Unable to rely on PIR, [Mirko] rigged up what amounts to a battery-powered light curtain using a VL53L4CD laser time-of-flight sensor. Mounted above the likely path of an animal, the sensor monitors the height of everything in its field of view. When an animal comes along, cold-blooded or otherwise, RepTrap triggers a remote camera and snaps a picture. Based on the brief video below, it’s pretty sensitive, too.

[Mirko] started out this project using an RP2040 but switched to an ESP32 to take advantage of Bluetooth camera triggering. The need for weatherproofing was also a big driver for the build; [Mirko] is shooting for an IP68 rating, which led to his interesting use of a Hall sensor and external magnet as a power switch.

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Retrotechtacular: How Not To Use Hand Tools

May 6, 2024 by Dan Maloney 48 Comments

Whatever you’re doing with your hand tools, by the US Army’s lights, you’re probably doing it wrong. That seems to be the “Green Machine’s” attitude on pliers and screwdrivers, at least, the main stars of this 1943 War Department training film on the horrors of tool abuse.

As kitschy as the film might be, they weren’t wrong. That’s especially true about the dreaded slip-joint pliers, which seem to find their way onto everyone’s list of unloved tools and are shown being used for their true purpose — turning nuts and bolt heads from hexagons into circles. Once that gore is wrapped up, we’re treated to the proper uses of pliers, including the fascinating Bernard-style parallel jaw pliers. We can recall these beauties kicking around the bottom of Dad’s tool kit and being entranced by the mechanism used to keep the jaws parallel and amplify the force applied. Sadly, those pliers are long gone now; Tubalcain did a great review of these pliers a few years back if you need a refresher.

A selection of screwdrivers gets the same treatment, complete with dire warnings against using them as prybars and chisels. Also against the Army Way is using the wrong size screwdriver for the job, lest you strip the head of the screw or break the tool itself. It has to be said that the Plomb Tool Company of Los Angeles, which produced the film, made some fantastic-looking screwdrivers back in the day. The square shanks on some of those straight screwdrivers are enormous, and the wooden handles look so much more comfortable than the greebled-up plastic nonsense manufacturers seem to favor these days. Also interesting is the reference to the new-fangled Phillips screw, not to mention the appearance of a Yankee-style spiral ratcheting screwdriver, another of Dad’s prized acquisitions that thankfully is still around to this day.

What strikes us about these military training films is how many of them were produced. No subject seemed too mundane to get a training film made about it, and so many were made that one is left wondering how there was any time left for soldiering after watching all these films. But really, it’s not much different today, when we routinely pull up a random YouTube video to get a quick visual demo of how to do something we’ve never tried before. The medium may have changed, but visual learning is still a thing.

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The Computers Of Voyager

May 6, 2024 by Dan Maloney 70 Comments

After more than four decades in space and having traveled a combined 44 billion kilometers, it’s no secret that the Voyager spacecraft are closing in on the end of their extended interstellar mission. Battered and worn, the twin spacecraft are speeding along through the void, far outside the Sun’s influence now, their radioactive fuel decaying, their signals becoming ever fainter as the time needed to cross the chasm of space gets longer by the day.

But still, they soldier on, humanity’s furthest-flung outposts and testaments to the power of good engineering. And no small measure of good luck, too, given the number of nearly mission-ending events which have accumulated in almost half a century of travel. The number of “glitches” and “anomalies” suffered by both Voyagers seems to be on the uptick, too, contributing to the sense that someday, soon perhaps, we’ll hear no more from them.

That day has thankfully not come yet, in no small part due to the computers that the Voyager spacecraft were, in a way, designed around. Voyager was to be a mission unlike any ever undertaken, a Grand Tour of the outer planets that offered a once-in-a-lifetime chance to push science far out into the solar system. Getting the computers right was absolutely essential to delivering on that promise, a task made all the more challenging by the conditions under which they’d be required to operate, the complexity of the spacecraft they’d be running, and the torrent of data streaming through them. Forty-six years later, it’s safe to say that the designers nailed it, and it’s worth taking a look at how they pulled it off.

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Hackaday Links: May 5, 2024

May 5, 2024 by Dan Maloney 16 Comments

It may be hard to believe, but BASIC turned 60 this week. Opinions about the computer language vary, of course, but one thing everyone can agree on is that Professors Kemeny and Kurtz really stretched things with the acronym: “Beginner’s All-Purpose Symbolic Instruction Code” is pretty tortured, after all. BASIC seems to be the one language it’s universally cool to hate, at least in its current incarnations like Visual Basic and VBA. But back in 1964, the idea that you could plunk someone down in front of a terminal, or more likely a teletype, and have them bang out a working “Hello, world!” program with just a few minutes of instruction was pretty revolutionary. Yeah, line numbers and GOTO statements encouraged spaghetti code and engrained bad programming habits, but at least it got people coding. And perhaps most importantly, it served as a “gateway drug” into the culture for a lot of us. Many of us would have chosen other paths in life had it not been for those dopamine hits provided by getting that first BASIC program working. So happy birthday BASIC!

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This Robot Picks Locks, If You’re Very Patient

May 5, 2024 by Dan Maloney 17 Comments

We all know the Hollywood trope of picking a lock with a paperclip, and while it certainly is doable, most reputable locks require slightly more sophisticated tools to pick effectively. That’s not to say that wire is off the table for locksports, though, as this cool lock-picking robot demonstrates.

The basics behind [Sparks and Code]’s design are pretty simple. Locks are picked by pushing pins up inside the cylinder until they line up with the shear plane, allowing the cylinder to turn. Normally this is done a pin at a time with a specialized tool and with a slight bit of torque on the cylinder. Here, tough, thin, stiff wires passing through tiny holes in a blade shaped to fit the keyway are used to push all the pins up at once, eliminating the need to keep tension on the cylinder to hold pins in place.

Sounds simple, but in practice, this looks like it was a nightmare. Getting five wires to fit into the keyway and guiding them to each pin wasn’t easy, nor was powering the linear actuators that slide the wires in and out. Applying torque to the lock was a chore too; even though tension isn’t needed to retain picked pins, the cylinder still needs to rotate, which means moving the whole picking assembly. But the biggest problem by far seems to be the fragility of the blade that goes into the keyway. SLA might not be the best choice here; perhaps the blade could be made from two thin pieces of aluminum with channels milled on their faces and then assembled face-to-face.

The robot works, albeit very slowly. This isn’t [Sparks and Code]’s first foray into robot lock picking. His previous version attempted to mimic how a human would pick a lock, so this is really thinking outside the box.

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Put More Korry In Your Flight Sim Switches

May 3, 2024 by Dan Maloney 20 Comments

Never underestimate how far some flight simulator aficionados will go with their builds. No detail is too small, and every aspect of the look and feel has to accurately reflect the real cockpit. As a case in point, check out these very realistic Korry buttons that [Santi Luib III] built for an Airbus A320 simulator.

Now, you might never have heard of a “Korry button” before, but chances are you’ve seen them, at least in photos of commercial or military aircraft cockpits. Korry is a manufacturer of switches and annunciators for the avionics industry, and the name has become shorthand for similar switches. They’ve got a very particular look and feel and are built to extremely high standards, as one hopes that anything going into a plane would be. That makes the real switches very expensive, far more so than even the most dedicated homebrew sim builder would be comfortable with.

That’s where [Santi] comes in. His replica Korry buttons are built from off-the-shelf parts like LEDs and switches mounted to custom PCBs. The PCB was designed for either momentary or latching switches, and can support multiple LEDs in different colors. The assembled PCBs snap into 3D printed enclosures with dividers to keep light from bleeding through from one legend to the other.

The lenses are laser-cut translucent acrylic painted with urethane paint before the legends are engraved with a laser. The attention to detail on the labels is impressive. [Santi]’s process, which includes multiple coats of sealers, gets them looking just right. Even the LEDs are carefully selected: blue LEDs are too bright and aren’t quite the proper shade, so [Santi] uses white LEDs that are dimmed down with a bigger resistor and a light blue photographic gel to get the tint just right.

These buttons are just beautiful, and seeing a panel full of them with the proper back-lighting must be pretty thrilling. If civil aviation isn’t your thing, check out this A-10 “Warthog” cockpit sim, and the cool switches needed to make it just right.

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