Harmonic Drive Uses Compliant Mechanism To Slim Down

April 7, 2021 by Dan Maloney 15 Comments

[Levi Janssen] has a secret: he doesn’t like harmonic drives. But rather than abandon the torque-amplifying transmission completely, he decided to see about improving them using 3D-printed compliant mechanisms.

For the uninitiated, harmonic drives, also known as strain-wave gears, are a compact, high-torque gearbox that has become popular with “robotic dog” makers and other roboticists. The idea is to have a rigid, internally-toothed outer ring nested around an externally-toothed, flexible cup. A wave generator rotates within the inside cup, stretching it so that it meshes with the outer ring. The two gears differ by only a couple of teeth, meaning that very high gear ratios can be achieved, which makes them great for the joints of robot legs.

[Levi]’s problem with the harmonic drive is that due to the depth of the flexible spline cup, compactness is not among its virtues. His idea is to couple the flex spline to the output of the drive through a flat spring, one that allows flexion as the wave generator rotates but transmits torque efficiently. The entire prototype is 3D-printed, except for the wave generator bearings and stepper motor, and put to the test.

As the video below shows after the excellent introduction to harmonic drives, the concept works, but it’s not without its limitations. Even lightly loaded, the drive made some unpleasant crunching sounds as the PLA springs gave out. We could easily see that being replaced with, say, a steel spring, either machined or cut on a water-jet machine. That might solve the most obvious problem and make [Levi]’s dream of a compact harmonic drive a reality. Of course, we have seen pretty compact strain-wave gears before.

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The Simplest Wind Turbine Is The Most Satisfying

April 7, 2021 by Jenny List 37 Comments

Sometimes there’s a satisfaction to be found not in the more complex projects but the simplest ones. We’ve featured wind turbines of all types here at Hackaday over the years, but HowToLou’s one is probably one of the least sophisticated. That notwithstanding, it does its job admirably, and provides a handy reminder of a parts source many of us might have overlooked.

At its heart is a motor from an exercise treadmill, which appears to be quite a powerful DC motor so that’s a source worth noting away for any future projects. To that he attaches the blades from a desk fan, and when placed outdoors on a windy day it generates enough power to run an LED head torch and charge his phone.

Of course, this most basic of wind turbines is not displaying its true potential in the video below the break. Were it mounted in a high position free from ground based wind obstacles it would no doubt catch a lot more wind, and in particular were it hooked up to a charge controller and a battery it could provide a much more useful power source. Then you could start optimizing fan blade designs… But this is a fun project that isn’t trying to masquerade as anything sophisticated, and it still has that potential.

This isn’t the first such simple turbine we’ve brought you.

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Field Guide To Shipping Containers

April 7, 2021 by Kristina Panos 94 Comments

In the 1950s, trucking magnate Malcom McLean changed the world when he got frustrated enough with the speed of trucking and traffic to start a commercial shipping company in order to move goods up and down the eastern seaboard a little faster. Within ten years, containers were standardized, and the first international container ship set sail in 1966. The cargo? Whisky for the U.S. and guns for Europe. What was once a slow and unreliable method of moving all kinds of whatever in barrels, bags, and boxes became a streamlined operation — one that now moves millions of identical containers full of unfathomable miscellany each year.

When I started writing this, there was a container ship stuck in the Suez canal that had been blocking it for days. Just like that, a vital passage became completely clogged, halting the shipping schedule of everything from oil and weapons to ESP8266 boards and high-waist jeans. The incident really highlights the fragility of the whole intermodal system and makes us wonder if anything will change.

A rainbow of dry storage containers. Image via xChange

Setting the Standard

We are all used to seeing the standard shipping container that’s either a 10′, 20′, or 40′ long box made of steel or aluminum with doors on one end. These are by far the most common type, and are probably what come to mind whenever shipping containers are mentioned.

These are called dry storage containers, and per ISO container standards, they are all 8′ wide and 8′ 6″ tall. There are also ‘high cube’ containers that are a foot taller, but otherwise share the same dimensions. Many of these containers end up as some type of housing, either as stylish studios, post-disaster survivalist shelters, or construction site offices. As the pandemic wears on, they have become so much in demand that prices have surged in the last few months.

Although Malcom McLean did not invent container shipping, the strict containerization standards that followed in his wake prevent issues during stacking, shipping, and storing, and allow any container to be handled safely at any port in the world, or load onto any rail car with ease. Every bit of the container is standardized, from the dimensions to the way the container’s information is displayed on the end. At most, the difference between any two otherwise identical containers is the number, the paint job, and maybe a few millimeters in one dimension.

Standard as they may be, these containers don’t work for every type of cargo. There are quite a few more types of shipping containers out there that serve different needs. Let’s take a look at some of them, shall we?

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Diving Into The Details Of Keyboard Interfaces At The Gate-Level

April 7, 2021 by Dan Maloney 5 Comments

Never doubt the value of a good teacher. Even if you know — or think you know — the material being presented, a good teacher can open your eyes to new ways of looking at things that will pay dividends you never expected.

That’s the feeling we got while watching [Ben Eater]’s latest video on building a keyboard interface (embedded below) for his breadboard 6502 computer. On the face of it, getting a keyboard to talk to a computer should be a simple job. [Ben] had previously looked at the serial protocol used by the old PS/2 keyboard and even built a wildly complex circuit out of discrete shift register chips to visualize the data being sent by the keyboard. The video below continues that work, this time concentrating on using the keyboard with his 6502 breadboard computer.

After some instructive preliminaries on interrupt programming, [Ben] dives into the logic-level details of teasing useful signals from the keyboard. His signal processing starts with some inverters and an RC network to turn multiple clock pulses into one logic level transition. Walking through this circuit step by step was the really interesting bit; even if you know that the answer is eventually going to be “Schmitt trigger,” getting to that point was really instructive.

Of course, what [Ben]’s videos mainly accomplish is making us want to follow along with him and build a breadboard computer of our own. From a low-rez VGA card to a reliable UART, following along with his discrete chip builds is always educational.

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Review: What On Earth Is An Electromagnetic Radiation Tester And Why Would I Need One?

April 7, 2021 by Jenny List 75 Comments

One of the joys of an itinerant existence comes in periodically being reunited with the fruits of various orders that were sent to hackerspaces or friends somewhere along the way. These anonymous parcels from afar hold an assortment of wonders, with the added element of anticipation that comes from forgetting exactly what had been ordered.

So it is with today’s subject, a Mustool MT525 electromagnetic radiation tester. At a cost not far above £10 ($13.70), this was an impulse purchase driven by curiosity; these devices claim to measure both magnetic and electric fields, but what do they really measure? My interest in these matters lies in the direction of radio, but I have never examined such an instrument. Time to subject it to the Hackaday treatment.

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AN ESP32 Walkie-Talkie, For Those Spy Radio Moments

April 7, 2021 by Jenny List 29 Comments

One of the most thrilling childhood toys for the adventurous 1970s or 1980s kid was probably the toy walkie-talkie. It didn’t matter that they were a very simple AM low-end-VHF radio with a range of about 500m and a Morse key of debatable utility, you could talk clandestinely with your friends, and be a more convincing spy, or commando, or whatever was the game of the moment. It’s a memory conjured up for grown-ups by [Chris G] with his ESP32 walkie-talkie, which replaces a shaky 49MHz connection with one a bit more robust through the magic of WiFi.

The hardware is a collection of modules on a custom PCB, aside from the ESP32 there’s an I2S microphone and I2S audio amplifier, which along with battery and speaker are housed in a neat 3D printed case. I2S is used for simplicity, but there is no reason why analogue components couldn’t be used with a few code changes. Connection is made via UDP over a WiFi network, or should there be no network via ESP-NOW. We’re not sure the range will be brilliant with those little on-board chip antennas, but with the wide range of 2.4GHz antennas to be had it’s likely a better result could easily be achieved if the stock item disappoints.

We like this project, and it’s one that’s especially pleasing to see given that we saw the potential a few years ago in a less successful walkie-talkie using the ESP8266.

Soviet Axe Restoration: Replace Or Repair?

April 7, 2021 by Kristina Panos 12 Comments

What do you do with a cool-looking misfit guitar that has non-working built-in effects and some iffy design aspects? Do you try to fix it and keep it original, or do you gut it and strut your stuff with new bits from around the shop? This is the conundrum that [Tim Sway] finds himself in with this late 70s/early 80s Formanta Solo II straight out of the USSR. (Video, embedded below.)

[Tim] likes a lot of things about it (and we do, too), especially the acid green pick guard, the sparkly pickups, and the beefy bridge that lets him set the string spacing individually, on the fly. It even has a built-in phaser and distortion, but those aren’t working and may never have worked that well at all.

As you can see in the video below, [Tim] has already spent a few hours making it playable and a little more palatable in order to figure out what to do with it electronics-wise. He started by making the 9 V compartment big enough to actually fit a battery inside, and drilled out bigger holes for new tuners.

Interestingly, these guitars had a 5-pin DIN receptacle instead of a 1/4″ jack. [Tim] bought an adapter just in case, but once someone dug up a schematic and sent it over, he decided to rewire it with a 1/4″.

For all of its plus sides, [Tim] doesn’t like the headstock on this thing at all and found the neck to be too chunky for the modern guitarist, so he cut down the headstock, shaved down the neck a bit, and stained it dark. He also made a new nut out of what looks like rosewood. Then it was on to the more standard stuff — file down the frets and polish them, oil the fretboard, and clean up the body.

The point of this exercise is to make a usable guitar for the modern musician. As [Tim] says, this is not a particularly valuable guitar, nor is it rare, and it wasn’t built that well to begin with. One of the issues is the switches — they’re kind of light and cheesy feeling, and one of them is directly in the strum path. Will [Tim] change those out but fix the original effects, or will he make the thing completely his own? We wait with bated breath.

Want to mess around with cheap old guitars, but don’t know where to start? Our own [Sven Gregori] has your back with Axe Hacks.