Making A Guitar Go To Eleven, The Hard Way

December 21, 2023 by 10 Comments

At the end of the day, all it takes to make a guitar go to eleven is a new knob. Making the knob is another thing — that takes a shop full of machine tools, the expertise to use them, and a whole bunch of time. Then again, if you’re pressed for time, it looks like a 3D printer will do nicely too.

While the 3D printing route is clearly the easier option, it sure seems as if [Chronova Engineering] is more about the journey than the destination. In need of some knob bling for an electric guitar, he takes us through the lengthy process (nicely summarized in the video below) of crafting one from a bar of solid brass. Like all good machining projects, this one starts with making the tools necessary to start the actual build; in this case, it’s a tool to cut the splines needing to mate with the splines on the guitar’s potentiometer shaft. That side quest alone represents probably a third of the total effort on this project, and results in a tool that’s used for all of about 30 seconds.

Aside from spline cutting, there are a ton of interesting machining tidbits on display here. We particularly liked the use of a shaping technique to form the knurling on the knob, as opposed to a standard rotary method, which would have been difficult given the taper on the knob body. Also worth noting are the grinding step that puts a visually interesting pattern on the knob’s top surface, as well as the pantograph used to etch the knob’s markings.

Congrats to [Chronova Engineering] for a great-looking build, and the deep dive into the machinist’s ways. If you’re still interested in custom brass knobs but don’t have a machine shop, we can help with that.

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Bed Sensors Do More Than You’d Think

December 21, 2023 by 24 Comments

Bed sensors do sort of sound like a gimmick — after all, who cares whether someone is occupying the bed? But if you think about it, that information is quite useful from a home automation standpoint. A person could do all sorts of things in this state, from ensuring the overhead lights in the room can’t come on, to turning off other smart devices that are likely not being used while both occupants are sleeping.

[The Home Automation Guy] presents a couple of ways of doing this, but both center around a fairly inexpensive pressure-sensing mat.

In the first method, he connects the pressure mat up to a Zigbee Aqara Leak Sensor, which conveniently has two terminals on the back to accept the wires from the pressure sensor. Then he simply connects it up to a Zigbee-compatible home assistant like the Aqara Hub.

In slightly harder mode, he forgoes the Aqara Leak Sensor and connects the pressure mat up to an ESP32 using a nifty screw terminal dev board. Then he sets up the sensor and all the desired actions in ESPHome. Of course, with an ESP32, it’s easy to add a second pressure mat for [Mrs. The Home Automation Guy]’s side of the bed.

Now, once they’ve both gone off to bed, the house goes into night mode — all the smart plugs, Sonos devices, and other things are powered down, and the alarm system is put into night mode. Be sure to check out the build video after the break.

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Displays We Love Hacking: SPI And I2C

December 21, 2023 by 17 Comments

I’ve talked about HD44780 displays before – they’ve been a mainstay of microcontroller projects for literal decades. In the modern hobbyist world, there’s an elephant in the room – the sheer variety of I2C and SPI displays you can buy. They’re all so different, some are LCD and some are OLED, some have a touchscreen layer and some don’t, some come on breakouts and some are a bare panel. No matter which one you pick, there are things you deserve to know.

These displays are exceptionally microcontroller-friendly, they require hardly any GPIOs, or none extra if you already use I2C. They’re also unbelievably cheap, and so tiny that you can comfortably add one even if you’re hurting for space. Sure, they require more RAM and a more sophisticated software library than HD44780, but with modern microcontrollers, this is no problem at all. As a result, you will see them in almost every project under the sun.

What do you need for those? What are the requirements to operate one? What kind of tricks can you use with them? Let’s go through the main aspects.

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Teardown Of FGM-148 Javelin Missile’s Guidance Computer

December 21, 2023 by 45 Comments

You know it’s a good teardown when [Michel] starts off by saying to not ask him where exactly he got the guidance section of an FGM-148 Javelin from. This shoulder-launched anti-tank guided missile (ATGM) is a true marvel of engineering that has shown its chops during recent world events. As a fire-and-forget type guided missile it is designed to use the internal IR tracker to maintain a constant lock on the target, using its guidance system to stay exactly on track.

FGM-148 Javelin schematic overview. (Source: U.S. Army, FM 3-22.37)
FGM-148 Javelin schematic overview. (Source: U.S. Army, FM 3-22.37)

Initially designed in 1989 and introduced into service in 1996, it has all the ceramic-and-gold styling which one would expect from a military avionics package from the era. Tasked with processing the information from the IR sensor, and continuously adjusting the fins to keep it on course, the two sandwiched, 3 mm thick PCBs that form the main section of the guidance computer are complemented by what looks like a milled aluminium section which holds a sensor and a number of opamps, all retained within the carbon-fiber shell of the missile.

In the video [Michel] looks at the main components, finding datasheets for many commercially available parts, with the date codes on the parts confirming that it’s a late 80s to early 90s version, using presumably a TMS34010 as the main CPU on the DSP board for its additional graphics-related instructions. Even though current production FGM-148s are likely to use far more modern parts, this is a fun look at what was high-end military gear in the late 1980s and early 1990s.

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How Do You Test If An EEPROM Can Hold Data For 100 Years?

December 21, 2023 by 40 Comments

Data retention is a funny thing. Atmel will gladly tell you that the flash memory in an ATmega32A will retain its data for 100 years at room temperature. Microchip says its EEPROMs will retain data for over 200 years. And yet, humanity has barely had a good grasp on electricity for that long. Heck, the silicon chip itself was only invented in 1958. EEPROMs and flash storage are altogether younger themselves.

How can these manufacturers make such wild claims when there’s no way they could have tested their parts for such long periods of time? Are they just betting on the fact you won’t be around to chastise them in 2216 when your project suddenly fails due to bit rot.

Well, actually, there’s a very scientific answer. Enter the practice of accelerated wear testing.

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Tesla’s Plug Moves Another Step Closer To Dominance

December 21, 2023 by 46 Comments

Charging an EV currently means making sure you find a station with the right plug. SAE International has now published what could be the end to the mishmash of standards in North America with the J3400 North American Charging Standard.

The SAE J3400TM North American Charging Standard (NACS) Electric Vehicle Coupler Technical Information Report (TIR), which just rolls off the tongue, details the standard formerly only available on Tesla vehicles. We previously talked about the avalanche of support from other automakers this year for the connector, and now that the independent SAE standard has come through, the only major holdout is Stellantis.

Among the advantages of the NACS standard over the Combined Charging System (CCS) or CHAdeMO is a smaller number of conductors given the plug’s ability to carry DC or AC over the same wires. Another benefit is the standard using 277 V which means that three separate Level 2 chargers can be placed on a single 3-phase commercial line with no additional step down required. Street parkers can also rejoice, as the standard includes provisions for lampost-based charger installations with a charge receptacle plug instead of the attached cable required by J1772 which leads to maintenance, clutter, and ADA concerns.

Now that J3400/NACS is no longer under the purview of a single company, the Federal Highway Administration has announced that it will be looking into amending the requirements for federal charger installation subsidies. Current rules require CCS plugs be part of the installation to qualify for funds from the Bipartisan Infrastructure Bill.

If you want to see how to spice up charging an EV at home, how about this charging robot or maybe try fast charging an e-bike from an electric car plug?

Arduino Measures Remaining Battery Power With Zero Components, No I/O Pin

December 21, 2023 by 22 Comments

[Trent M. Wyatt]’s CPUVolt library provides a fast way to measure voltage using no external components, and no I/O pin. It only applies to certain microcontrollers, but he provides example Arduino code showing how handy this can be for battery-powered projects.

The usual way to measure VCC is simple, but has shortcomings.

The classical way to measure a system’s voltage is to connect one of your MCU’s ADC pins to a voltage divider made from a couple resistors. A simple calculation yields a reading of the system’s voltage, but this approach has two disadvantages: one is that it constantly consumes power, and the other is that it ties up a pin that you might want to use for something else.

There are ways to mitigate these issues, but it would be best to avoid them entirely. Microchip application note 2447 describes a method of doing exactly that, and that’s precisely what [Trent]’s Arduino library implements.

What happens in this method is one selects Vbg (a fixed internal voltage reference that is temperature-independent) as Vin, and selects Vcc as the ADC’s voltage reference. This is essentially backwards from how the ADC is normally used, but it requires no external hookup and is only a bit of calculation away from determining Vcc in millivolts. There is some non-linearity in the results, but for the purposes of measuring battery power in a system or deciding when to send a “low battery” signal, it’s an attractive solution.

Being an Arduino library, CPUVolt makes this idea very easy to use, but the concept and method is actually something we have seen before. If you’re interested in the low-level details, then check out our earlier coverage which goes into some detail on exactly what is going on, using an ATtiny84.