Upgrade A 3D Printed CNC Milling Machine By Using It

August 4, 2021 by 22 Comments

One of the original ideas behind the RepRap project was for the machines to create their own upgrades. That philosophy is shining brightly in [Ivan Miranda] CNC milling machine project, which has been used to upgrade its aluminum and 3D printed frame components to steel.

For precision machining on hard metal, machine rigidity is of utmost importance. [Ivan]’s original CNC mill made extensive use of lightweight aluminum extrusions with 3D printed fittings. The machine worked, but the lack of rigidity was visible in the surface quality of the machine parts. The latest upgrade included a completely new frame from welded steel tubing and heavy aluminum mounting plates. The original machine was used to slowly machine slots in the steel tubes to retain the adjustability of the Z-axis. Some of the 3D printed motor mounts remained, so in the second video after the break [Ivan] used the newly upgraded machine to mill some aluminum replacements.

While this machine might not be perfect, we have to respect [Ivan]’s willingness to toss himself in at the deep end and show all failures and lessons learned the hard way. This project was clearly used as an opportunity to improve his welding and machining skills. His fabrication skills have come a long way from mainly 3D printed projects like the giant tracked tank and screw tank.

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Working LEGO Space Computers Are A Chip Off The Old Block

August 4, 2021 by No comments

We all have our favorite classic LEGO bricks, and wouldn’t be surprised if one or more of the various space computers showed up on pretty much everyone’s list. [dyoramic] loves them so much that they built two different working versions that do different things.

The first one is about six times the size of the original brick. Inside the 3D printed case is an ESP32 and a 1.5″ OLED display. [dyoramic] wired up the top six buttons as inputs and the rest are just for looks. The screen defaults to the classic white cross on green that just sits there looking legit. But start pushing buttons and you’ll find other modes — the cross becomes a radar screen in one, the computer spits out space facts in another, there’s a falling bricks game, and finally, a time and date screen.

The second LEGO space computer build is even bigger — both were designed around the size of their screens. It has a Raspi 4 and shows a dashboard with the weather, time, date, latest xkcd, and a few cryptocurrency prices. [dyoramic] has an even bigger version in the works that will use a 720 x 720 screen and a handful of brown key switches as inputs. We can’t wait to see that one! For now, check out the build and demo of the first two after the break.

What can’t you do with LEGO? It feels like we’ve seen it all, from cameras to microscopes to continuously variable transmissions. Wouldn’t you love to drive one of those around the block?

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Cablecam Is An Exercise In System Integration

August 4, 2021 by 14 Comments

Drones have become the standard for moving aerial camera platforms, but another option that sees use in the professional world are cable cameras. As an exercise in integrating mechanics, electronics, and software, [maxipalay] created his own Cablecam.

Cablecam is build around a pair of machined wood plates, with some pulleys and motor reduction gearing between them. A brushless hobby motor moves the platform along the rope/cable, driven a drone ESC. Since the ESC doesn’t have a reverse function, [maxipalay] used four relays controlled by an Arduino to swap around the connections of two of the motor wires to reverse direction. The main onboard controller is a Raspberry Pi, connected to a camera module mounted on a two-axis gimbal for stabilization. A GPS module was also added for positioning information on long cables.

The base station is built around an Nvidia Jetson Nano connected to a 7″ screen mounted in a plastic case. Video, telemetry and control signals are communicated using the open-source Wifibroadcast protocol. This uses off-the-shelf WiFi hardware in connectionless mode to broadcast UDP packets, and avoids the lengthy WiFi reconnection process every time a connection drops out. The motion of Cablecam can be controlled manually using a potentiometer on the control station, or use the machine vision capabilities of the Jetson to automatically track and follow people.

We’ve seen several cable robots over the years, including a solar-powered sensor platform that resembles a sloth.

New Part Day: An ESP With ZigBee

August 4, 2021 by 26 Comments

It seems that the folks at Espressif are doing their best to produce chips to fit every possible niche in the microcontroller-with-radio market, because here comes news of their latest chip bearing the ESP32 name: a single-core 96MHz RISC-V part with built-in IEEE 802.15.4 to support ZigBee 3.x and Thread 1.x. The ESP32-H2 is not the most powerful of the Espressif line-up, but it will find its place in home automation products and projects.

The ESP32-H2 joins a multitude of other IEEE 802.15.4 devices from manufacturers such as Microchip, ST, NXP, and Nordic in an increasingly crowded marketplace, so what can if offer that the others can’t? If previous ESP chips are anything to go by we’d expect it to compete on price as well as the obvious attraction for developers used to working with other Espressif products. We look forward as always to seeing what you do with it.

Better Mousetraps (or Screw Drives) Don’t Always Win

August 4, 2021 by 114 Comments

I’ve noticed, lately, that slotted screw heads are all but gone on new equipment. The only thing that I find remarkable about that is that it took so long. While it is true that slotted heads have been around for ages, better systems are both common and have been around for at least a century.

Check out those cool threads.

The reason slotted heads — technically known as the drive — are so common is probably because they are very easy to make. A hacksaw is sufficient for the job and there are other ways to get there, too. The only advantages I know of for the user is that you can easily clean a slotted drive and — possibly — use field expedient items like butter knives and quarters to turn the screw. I’ve heard people claim that it also is a feature that the screwdriver can pry things like paint can lids, but that’s a feature of the tool, not the screw drive.

The disadvantages, though, are significant. It is very hard to apply lots of torque to a slotted screw drive without camming it out or snapping the head off the screw. The screwdriver isn’t self-centering either, so applying force off-axis is common and contributes to the problem.

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We’re Hiring: Come Join Us!

August 4, 2021 by 11 Comments

You wake up in the morning, and check Hackaday over breakfast. Then it’s off to work or school, where you’ve already had to explain the Jolly Wrencher to your shoulder-surfing colleagues. And then to a hackspace or back to your home lab, stopping by the skull-and-cross-wrenches while commuting, naturally. You don’t bleed red, but rather #F3BF10. It’s time we talked.

The Hackaday writing crew goes to great lengths to cover all that is interesting to engineers and enthusiasts. We find ourselves stretched a bit thin and it’s time to ask for help. Want to lend a hand while making some extra dough to plow back into your projects? We’re looking for contributors to write a few articles per week and keep the Hackaday flame burning.

Contributors are hired as private contractors and paid for each article. You should have the technical expertise to understand the projects you write about, and a passion for the wide range of topics we feature. You’ll have access to the Hackaday Tips Line, and we count on your judgement to help us find the juicy nuggets that you’d want to share with your hacker friends.

If you’re interested, please email our jobs line (jobs at hackaday dot com) and include:

  • One example article written in the voice of Hackaday. Include a banner image, at least 150 words, the link to the project, and any in-links to related and relevant Hackaday features. We need to know that you can write.
  • Details about your background (education, employment, interests) that make you a valuable addition to the team. What do you like, and what do you do?
  • Links to your blog/project posts/etc. that have been published on the Internet, if any.

What are you waiting for? Ladies and Gentlemen, start your applications!

Semiconductor Shortage? Never Mind That, There’s A Vacuum Shortage!

August 4, 2021 by 28 Comments

As those of us who work in electronics are grappling with a semiconductor shortage making common devices unobtainable and less common ones very expensive, it’s worth noting that there’s another supply crunch playing out elsewhere in the electronics industry. It’s not one that should trouble most readers but it’s a vexing problem in the guitar amp business, as guitar.com reports. At its root is the Chinese Shuguang factory, which it is reported has been forced to close down and move its operations. There’s nothing about this on the Shuguang website, so we hope that the plant has been relocated successfully and production will resume.

The specialist audio market that forms the lion’s share of tube customers in 2021 is a relatively tiny corner of the electronics business, but it’s interesting to note that the three major plants which supply it, in Slovakia, Russia, and China, are still not enough to prevent it being vulnerable when one of them fails. The likelihood of a fourth tube plant emerging somewhere else in the 2020s to take up the slack is not high, but it’s evident that the demand remains healthy enough.

If you’d like to know more about the supply of new vacuum tubes, we went into the subject in greater detail last year.