Enormous CNC Router Uses Clever Tricks To Improve Performance

December 16, 2020 by 32 Comments

CNC machines made from wood and 3D-printed parts may be popular, but they aren’t always practical from a precision and repeatability standpoint. This is especially true as the machines are scaled up in size, where the compliance of their components starts to really add up. But can those issues be resolved? [jamie clarke] thinks so, and he’s in the process of building a CNC router that can handle a full sheet of plywood. (Video, embedded below.)

This is very much a work in progress, and the videos below are only the very beginning of the process. But we found [jamie]’s build interesting even at this early point because he has included a few clever tricks to control the normal sources of slop that plague larger CNC machines. To provide stiffness on a budget, [jamie] went with a wooden torsion-box design for the bed of his machine. It’s the approach taken by the Root CNC project, which is the inspiration for this build. The bed is formed from shallow boxes that achieve their stiffness through stressed skins applied to rigid, lightweight frames.

Upon the torsion-box bed are guide rails made from commodity lengths of square steel tubing. Stiff these may be over short lengths, but over the three meters needed to access a full sheet of plywood, even steel will bend. [jamie]’s solution is a support that moves along with the carriage, which halves the unsupported length of the beam at all points of travel. He’s using a similar approach to fight whip in the ball screw, with a clever flip-down cradle at the midpoint of the screw.

So far, we’re impressed by the quality of this build. We’re looking forward to seeing where this goes and how well the machine performs, so we’re paying close attention to the playlist for updates. At an estimated build cost of £1,500, this might be just the CNC build you’ve been looking for.

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Tracking Satellites: The Nitty Gritty Details

December 16, 2020 by 18 Comments

If you want to listen to satellites, you have to be able to track them as they pass over the sky. When I first started tracking amateur satellites, computing the satellite’s location in the sky was a part of the challenge. Nowadays, that’s trivial. What’s left over are all the extremely important real-world details.  Let’s take a look at a typical ham satellite tracking setup and see how it all ties together.

Rotators for Steering

The popularity of robotics, 3D printing, and CNC machines has resulted in a deluge of affordable electric motors and drivers. It’s hard to imagine that an electric motor for rotating an antenna would be anything special, but in fact, antenna rotators are non-trivial engineering designs. Most of the challenges are mechanical, not electrical — the antennas that they drive can be huge, have significant wind loading and rotational inertial, and just downright weigh a lot. A rotator design has to consider bearings, weather exposure, all kinds of loads, not just rotational. And usually a brake is required to keep the antenna pointed in windy conditions.

There’s been a 70-some year history of these mechanisms from back in the 1950s when Cornell Dubilier Electronics, the company you know as a capcacitor manufacturer, began making these rotators for television antennas in the 1950s. I was a little surprised to see that the rotator systems you can buy today are not very different from the ones we used in the 1980s, other than improved electronic controls. Continue reading “Tracking Satellites: The Nitty Gritty Details” →

Sit Up Straight!: Open Source Bluetooth Posture Sensing

December 16, 2020 by 4 Comments

As more and more people spend their working hours behind a computer, bad posture and the accompanying back pain and back problems become a growing epidemic. To combat this in his own daily life, [ImageryEel] made PosturePack, a wearable Bluetooth-enabled posture sensor.

The PosturePack is designed to fit into a small pocket sewn into the pack of an undershirt, between the shoulder blades. It consists of a custom PCB with an ATmega32U4, BNO055 IMU, Bluetooth module,  small LiPo and power circuitry. Based on the orientation data from the IMU, a notification is sent over Bluetooth to a smartphone whenever the user hunches forward.

[ImageryEel] says although the mobile notifications worked, haptic feedback integrated into the unit would be a better option. This could also be used to remind the user to stand up and take a break now and then, and provide an alternative to a smartwatch for activity monitoring without sending every movement to someone else’s servers. Software will always be the hardest part for projects like these, especially as the device become “smarter”. Learning to recognize activity and postures is actually a good place for tiny machine learning models.

Compared The posture sensors we covered before had to be installed and set up at a specific workstation, like an ultrasound-based version attached to a chair, and a webcam-based version.

Teardown: Siemens 8mm SMD Parts Feeder

December 16, 2020 by 22 Comments

Many of Hackaday’s readers will be no stranger to surface mount electronic components, to the extent that you’ll likely be quite comfortable building your own surface-mount projects. If you have ever built a very large surface-mount project, or had to do a number of the same board though, you’ll have wished that you had access to a pick-and-place machine. These essential components of an electronics assembly line are CNC robots that pick up components from the reels of tape in which they are supplied, and place them in the appropriate orientation in their allotted places on the PCB. They are an object of desire in the hardware hacker community and over the years we’ve seen quite a few home-made examples. Their workings are easy enough to understand, but there is still much to gain by studying them, thus it was very interesting indeed to see a friend acquiring a quantity of surplus Siemens component feeders from an older industrial pick-and-place machine. A perfect opportunity for a teardown then, to see what makes them tick.

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3D Printing With VHS Tape Filament

December 16, 2020 by 53 Comments

If you have a pile of old VHS tapes collecting dust in your attic or basement that you know you’ll never watch again, either because all of those movies are available on DVD or a streaming service, or because you haven’t had a working VCR since 2003, there might be a way of putting them to good use in another way. With the miles of tape available in just a few cassettes, [brtv-z] shows us how to use that tape as filament for a 3D printer.

The first step of the build is to actually create the filament. He uses a purpose-built homemade press to spin several tapes into one filament similar to how cotton or flax is spun into yarn. From there the filament is simply fed into the 3D printer and put to work. The tape filament needs to be heated higher than a standard 3D printer filament so he prints at a much slower rate, but the resulting product is indistinguishable from a normal print except for the color. It has some other interesting properties as well, such as retaining its magnetism from the magnetic tape, and being a little more brittle than PET plastic although it seems to be a little stronger.

While the VHS filament might not be a replacement for all plastic 3D prints, it’s still a great use for something that would likely otherwise head straight to the landfill. There are some other uses for this magnetic tape as well, like if you wanted to build a DIY particle accelerator.

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RC Lawn Mower Cuts With Impunity

December 16, 2020 by 19 Comments

Grass is a lovely thing to have, but unfortunately it tends to grow excessively long if left unattended. Obviously, one can use a regular lawn mower, but [Daniel] of [rctestflight] decided to build something remote-control instead. (Video, embedded below.)

To get started, [Daniel] fitted X-acto blades to a brushless outrunner motor, and tested their ability to cut grass. Satisfied with the performance, he built a trailer to tow behind an RC tank mounted to such a setup, with some success. With the concept beginning to bear fruit, he went with a clean sheet design for maximum performance.

The final build relies on an RC rock-crawler chassis, fitted with a brushless motor using field oriented control for maximum torque at low speeds. This allows the RC mower to slowly push through the grass without overwhelming the cutter heads. As for the cutter heads, the final rig has eight motors, each sporting two blades to chop down long field grasses with impunity.

[Daniel] notes that it’s remarkably fun to cut the grass in this way, and is surprised not to have seen more builds in this area. (Editor’s note: he needs to read more Hackaday.) Of course, we’ve seen plenty of autonomous builds, too.

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Micro:bit Put On Plant Minding Duty

December 15, 2020 by 1 Comment

The BBC has a long history of supporting technology education in schools. The BBC Micro introduced a whole generation of students to computers, and more recently the Micro:bit is teaching today’s children about embedded systems. [Michael Klements] happens to be a grown adult, but has whipped up a project using the little board to build an automatic plant watering system.

Rather than a simple timer-based system, [Michael’s] build measures soil moisture using a capacitive sensor. This has the benefit of not needing to be in direct contact with the soil as resistive sensors do, and thus the sensor can be built in a fashion that minimises corrosion. The Micro:bit reads this sensor using an analog input, and displays the moisture level using its inbuilt LED matrix as a graph. Once levels dip below a set threshold, a pump is activated to deliver water to the plant until the soil is suitably moist again.

It’s a simple project, but one that would be a great way to teach students about interfacing with pumps and sensors, as well as the basics of control systems. [Michael] also notes that further work could involve interfacing multiple Micro:bits using their onboard wireless hardware. We’ve thus far seen the Micro:bit used for everything from handheld gaming to gumball delivery. Video after the break.

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