Author: Dan Maloney

3211 Articles

A Classroom-Ready Potentiometer From Pencil And 3D Prints

February 19, 2024 by 18 Comments

If you need a potentiometer for a project, chances are pretty good that you’re not going to pick up a pencil and draw one. Then again, if you’re teaching someone how a variable resistor works, that old #2 might be just the thing.

When [HackMakeMod] realized that the graphite in pencil lead is essentially the same thing as the carbon composition material inside most common pots, the idea for a DIY teaching potentiometer was born. The trick was to build something to securely hold the strip while making contact with the ends, as well as providing a way to wipe a third contact across its length. The magic of 3D printing provided the parts for the pot, with a body that holds a thin strip of pencil-smeared paper securely around its inner diameter. A shaft carries the wiper, which is just a small length of stripped hookup wire making contact with the paper strip. A clip holds everything firmly in place. The video below shows the build process and the results of testing, which were actually pretty good.

Of course, the construction used here isn’t meant for anything but demonstration purposes, but in that role, it performs really well. It’s good that [HackMakeMod] left the body open to inspection, so students can see how the position of the wiper correlates to resistance. It also makes it easy to slip new resistance materials in and out, perhaps using different lead grades to get different values.

Hats off to a clever build that should be sure to help STEM teachers engage their students. Next up on the lesson plan: a homebrew variable capacitor.

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Hackaday Links: February 18, 2024

February 18, 2024 by 17 Comments

So it turns out that walking around with $4,000 worth of hardware on your head isn’t quite the peak technology experience that some people thought it would be. We’re talking about the recently released Apple Vision Pro headset, which early adopters are lining up in droves to return. Complaints run the gamut from totally foreseeable episodes of motion sickness to neck pain from supporting the heavy headset. Any eyeglass wearer can certainly attest to even lightweight frames and lenses becoming a burden by the end of the day. We can’t imagine what it would be like to wear a headset like that all day. Ergonomic woes aside, some people are feeling buyer’s remorse thanks to a lack of apps that do anything to justify the hefty price tag. The evidence for a wave of returns is mostly gleaned from social media posts, so it has to be taken with a grain of salt. We wouldn’t expect Apple to be too forthcoming with official return figures, though, so the ultimate proof of uptake will probably be how often you spot one in the wild. Apart from a few cities and only for the next few weeks, we suspect sightings will be few and far between.

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No Inductors Needed For This Simple, Clean Twin-Tee Oscillator

February 18, 2024 by 11 Comments

If there’s one thing that amateur radio operators are passionate about, it’s the search for the perfect sine wave. Oscillators without any harmonics are an important part of spectrum hygiene, and while building a perfect oscillator with no distortion is a practical impossibility, this twin-tee audio frequency oscillator gets pretty close.

As [Alan Wolke (W2AEW)] explains, a twin-tee oscillator is quite simple in concept, and pretty simple to build too. It uses a twin-tee filter, which is just a low-pass RC filter in parallel with a high-pass RC filter. No inductors are required, which helps with low-frequency designs like this, which would call for bulky coils. His component value selections form an impressively sharp 1.6-kHz notch filter about 40 dB deep. He then plugs the notch filter into the feedback loop of an MCP6002 op-amp, which creates a high-impedance path at anything other than the notch filter frequency. The resulting sine wave is a thing of beauty, showing very little distortion on an FFT plot. Even on the total harmonic distortion meter, the oscillator performs, with a THD of only 0.125%.

This video is part of [Alan]’s “Circuit Fun” series, which we’ve really been enjoying. The way he breaks complex topics into simple steps that are easy to understand and then strings them all together has been quite valuable. We’ve covered tons of his stuff, everything from the basics of diodes to time-domain reflectometry.

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Back To Basics With A 555 Deep Dive

February 17, 2024 by 28 Comments

Many of us could sit down at the bench and whip up a 555 circuit from memory. It’s really not that hard, which is a bit strange considering how flexible the ubiquitous chip is, and how many ways it can be wired up. But when was the last time you sat down and really thought about what goes on inside that little fleck of silicon?

If it’s been a while, then [DiodeGoneWild]’s back-to-basics exploration of the 555 is worth a look. At first glance, this is just a quick blinkenlights build, which is completely the point of the exercise. By focusing on the simplest 555 circuits, [Diode] can show just what each pin on the chip does, using an outsized schematic that reflects exactly what’s going on with the breadboarded circuit. Most of the demos use the timer chip in free-running mode, but circuits using bistable and monostable modes sneak in at the end too.

Yes, this is basic stuff, but there’s a lot of value in looking at things like this with a fresh set of eyes. We’re impressed by [DiodeGoneWild]’s presentation; while most 555 tutorials focus on component selection and which pins to connect to what, this one takes the time to tell you why each component makes sense, and how the values affect the final result.

Curious about how the 555 came about? We’ve got the inside scoop on that.

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Salvaged Meter Movements Really Pop In This DIY VU Meter Bridge

February 17, 2024 by 3 Comments

If you’re going to build a nice VU meter bridge for the recording studio, the first thing you need is a nice pair of VU meters. But lest you think it’s as easy as putting some meters into a nice box and calling it a day, think again.

This project comes to us from [Frank Olson], whose projects usually incorporate wood as part of the mechanism, as with his famous wooden ribbon microphone. This build does indeed use wood, and to excellent effect, but only in the project’s final enclosure. Before that, [Frank] had salvaged a pair of good-looking moving coil meters from an old tape recorder. He muddled through some ideas before settling on a design. A NE5532 dual-channel audio buffer module is used as a preamp, with each channel feeding into a bridge rectifier before heading to the meter. Wisely, [Frank] chose to illuminate the meters with their existing incandescent bulbs, so a small DC-DC supply was added to provide the necessary 8 volts.

As for the enclosure, that’s where [Frank]’s experience working with veneers paid off. He chose mahogany, carefully cut all the pieces to shape with a knife, and glued it all up with CA glue — at least we assume it was CA; based on previous efforts, he uses a lot of the stuff. The tung oil finish looks fantastic, and the completed build aesthetic looks great! The video below shows it all.

If you need some backstory on the VU meter, we can help with that.

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Compact Cycloidal Drive Lives Inside This Custom Brushless Motor

February 16, 2024 by 7 Comments

With the popularity of robot dogs, many people have gotten on the bandwagon and tried building DIY versions. Most of them end up attaching a gearbox to an off-the-shelf brushless motor and call it a day. Not everyone goes that way, though, which is why this internal cycloidal drive actuator caught our eye.

Taking design cues from the MIT Mini Cheetah, [Aaed Musa] approached his actuator from the inside out, literally. His 3D printed cycloidal gearbox is designed to fit inside the stator of a BLDC motor. And not just any BLDC motor, but one built mostly from scratch using a hand-wound — and unwound, and wound again — stator along with a rotor that started as a printed part but was eventually machined from steel. Apart from its fixed ring, the cycloidal drive was mostly 3D printed, with everything fitting nicely inside the stator.

The video below shows the design and assembly process as well as testing of the finished drive. It seems to do really well with speed and positional accuracy, and it delivers a substantial amount of torque. Maybe a little too much, though; testing it with a heavy weight on the end of an arm got the stator coils hot enough to warp the printed parts within. But no matter; this was only a prototype after all. [Aaed] says improvements are in the works, including replacing all the plastic parts with metal ones.

Need a little background on cycloidal drives? They’re pretty cool.

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Retrotechtacular: Some Days You Just Can’t Get Rid Of A Nuclear Bomb

February 15, 2024 by 19 Comments

It may seem a bit obvious to say so, but when a munition of just about any kind is designed, little thought is typically given to how to dispose of it. After all, if you build something that’s supposed to blow up, that pretty much takes care of the disposal process, right?

But what if you design something that’s supposed to blow up only if things go really, really wrong? Like nuclear weapons, for instance? In that case, you’ll want to disassemble them with the utmost care. This 1993 film, produced by the US Department of Energy, gives a high-level overview of nuclear weapons decommissioning at the Pantex plant in Texas. Fair warning: this film was originally on a VHS tape, one that looks like it sat in a hot attic for quite a few years before being transferred to DVD and thence to YouTube. So the picture quality is lousy, in some points nearly unwatchably so. Then again, given the subject matter that may be a feature rather than a bug.

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