As hobbies go, stargazing has a pretty low barrier to entry. All you really need is a pair of Mark 1 eyeballs and maybe a little caffeine to help you stay up late enough. Astronomy, on the other hand, takes quite a bit more equipment, not least of which is a telescope and a way to get it pointed in the right direction at the right time, and to make up for the pesky fact that we’re on a moving, spinning ball of rock.
Yes, most of the equipment needed for real astronomy is commercially available, but [Mitsuru Yamada] decided to go his own way with this homebrew retro-style telescope motor controller. Dubbed MCT-6, the controller teams up with his dual-6502 PERSEUS-9 computer to keep his scope on target. There are a lot of literally moving parts to this build, including the equatorial mount which is made from machined aluminum and powered by a pair of off-the-shelf stepper-powered rotary stages for declination and right ascension. The controller that runs the motors is built completely from discrete 74HCxx logic chips that divide down a 7.0097-MHz crystal oscillator signal to drive the steppers precisely at one revolution per diurnal day. The pulse stream can also be sped up for rapid slewing, to aim the telescope at new targets using a hand controller.
As impressive as all this is, the real star (sorry) of the show here is the fit and finish. In typical [Yamada-san] fashion, the impeccably wire-wrapped mainboard fits in a robust die-cast aluminum case that fits the retro aesthetic of the whole project. The PERSEUS-9 is used mainly as a display and control terminal, running custom software to show where the telescope is pointed and calculate the coordinates of various heavenly bodies. As a bonus, the 40×7 alphanumeric red LED display should be easy on dark-adapted eyes.
Hats off to [Mitsuru Yamada] on another fabulous build. If you haven’t had enough of his build style yet, be sure to check out his PERSEUS-8 or even his foray into the analog world.
The trouble with building a business around selling low-margin widgets is that you have to find a way to make a lot of them to make it worth your while. And if the widget in question is labor-intensive to make, you’ve got to find ways to reduce your inputs. That sounds like a job for industrial automation, a solution that’s often out of reach of small shops, for all the obvious reasons. Not if you’re clever about things, though, as this fully automated CNC lathe work cell shows.
This build comes to us from the woodshop of [Maher Lagha], where he’s making wooden honey dippers. Wooden dowel blanks are dispensed from an infeed rack and chucked between centers on the headstock and pneumatic tailstock. A two-axis stage in front of the workpiece moves a tool against the spinning stock, carving out the honey dipper in just a few minutes. When the lathe work is done, the spindle stops, the tailstock pulls the honey dipper back off the headstock, and a pneumatic piston unceremoniously whacks the almost-finished part — it looks like it still needs a little manual post-processing — into a bin. Lather, rinse, repeat, profit.
[Maher] doesn’t provide many details, but just looking at the work cell shows a veritable feast of industrial automation equipment. The spindle and tailstock of the lathe sit on a bed made from a massive slab of aluminum extrusion, and the X- and Y-axes use linear rails and ballscrews. And mindful of the effects of wood chips on delicate mechanisms, [Maher] did a good job of containing the mess with a host of acrylic guards.
As we said when we saw [Maher]’s wooden coaster work cell a while back, the wood widget business must be pretty good to justify automation like this. What’s nice with both these rigs is that they look like they could be quickly reprogrammed and retooled to create other products. Pretty impressive.
Back in the old days, finding out your location on Earth was a pretty involved endeavor. You had to look at stars, use fancy gimballed equipment to track your motion, or simply be able to track your steps really really well. Eventually, GPS would come along and make all that a bit redundant for a lot of use cases. That was all well and good, until it started getting jammed all over the place to frustrate militaries using super-accurate satellite-guided weapons.
Today, there’s a great desire for more accurate navigational methods that don’t require outside communications that can easily be jammed. High-tech gyroscopes have long been a big part of that effort, allowing the construction of inertial navigation systems with greater accuracy than ever before.
After decades of delays and false starts, NASA is finally returning to the Moon. The world is eagerly awaiting the launch of Artemis I, the first demonstration flight of both the Space Launch System and Orion Multi-Purpose Crew Vehicle, which combined will send humans out of low Earth orbit for the first time since 1972. But it’s delayed.
While the first official Artemis mission is naturally getting all the attention, the space agency plans to do more than put a new set of boots on the surface — their long-term goals include the “Lunar Gateway” space station that will be the rallying point for the sustained exploration of our nearest celestial neighbor.
Launched aboard an Electron rocket in June, the large CubeSat will hopefully become the first spacecraft to ever enter into a NRHO. By positioning itself in such a way that the gravity from Earth and the Moon influence it equally, maintaining its orbit should require only periodic position corrections. This would not only lower the maintenance burden of adjusting the Lunar Gateway’s orbit, but reduce the station’s propellant requirement.
CAPSTONE is also set to test out an experimental navigation system that uses the Lunar Reconnaissance Orbiter (LRO) as a reference point instead of ground-based stations. In a future where spacecraft are regularly buzzing around the Moon, it will be important to establish a navigation system that doesn’t rely on Earthly input to operate.
So despite costing a relatively meager $30 million and only being about as large as a microwave oven, CAPSTONE is a very important mission for NASA’s grand lunar aspirations. Unfortunately, things haven’t gone quite to plan so far. Trouble started just days after liftoff, and as of this writing, the outcome of the mission is still very much in jeopardy.
I hope last week’s introduction to bulk material handling got you all thinking up amazing hacks, and we’ll soon be reporting on DIY Cap’n Crunch Robots galore. This week we’ll look at how to measure particle sizes, separate particles, and even grind them up when you need to.
Measuring Material Properties
Last week we talked about cohesive strength. Bulk material behaves somewhere between a solid and a liquid — if you’ve done your homework, it flows down the funnel just fine. But if you haven’t, it sticks together and holds up the rest of the material. Cohesive strength is the measure of how much weight the material at the bottom of the funnel can hold up.
You can get a rough measurement by packing material in a box with a square hole at the bottom. One side of the hole should have a retractable slide. Slowly withdraw the slide, making the hole rectangular. Material will bridge over, and then at some point a larger chunk will fall out. This is about the size of the minimum opening that will not arch, and a practical measure of the material’s cohesive strength.
Many materials cohere better when wet. Dry a sample in a microwave to determine the percent moisture by weighing it before and after.
Cohesive strength is closely allied to shear strength. If you want to measure shear strength, cut two 1 cm wide rings of 5 cm diameter PVC pipe, stack them, pack with material, put a disk atop the material and load it, then drag the top ring off the bottom with a spring scale. The force per unit area is the shear strength at that pressure. If it starts packing you’ll see it in the curve.
Packing factor is another useful measurement. Gently shake material to fill a rigid container and weigh it. Now empty the container and refill, packing the material as hard as you can with a length of 1” dowel. Reweigh, and the ratio of the two weights tells you how well the material packs.
Real bulk material is almost always made up of particles of varying sizes, shapes, and compositions. Dirt is particles of different kinds of mineral and organic matter varying from outright rocks to sub micron clay particles. If you’re having problems, getting a graph of material size distribution can be helpful.
For particles above about 75 μM, you can measure the sizes with sieves. If you want to be fancy, they sell nice sets of metal sieves with wire mesh in the bottom. Screen assortments are cheaper. Below 75 μM, you have to use a hydrometer. This is messy and takes a while, but does work.
The idea is to mix the material with soapy water and then use a hydrometer from the auto parts store to measure the density. The particles fall out by Stokes law, big ones first. Stokes law is just that the drag force on a sphere is proportional to the square of the radius. Mass will go up as cube of the radius, so large particles fall faster than small ones. As they fall out, the density of the fluid decreases. This page describes how to do it, and this page has a handy calculator for interpreting the results.
Grinding
You can also change the size of particles in your mix. If particles are too large, they can be crushed or ground. You can separate by size and only grind some of the sizes or discard some of the material. There’s a whole science to grinding. The finer you grind, the harder it gets to grind. Cosmetics and pharmaceutical companies are full of grinding experts.
In general, there are three ways to make something smaller – crush it, cut it, or hit it.
Crushing is straightforward. Use rollers or jaws, a rolling pin or a rock crusher. Don’t overlook the vise. A jaw crusher only crushes particles larger than the jaw space, useful to make a certain size. Rock crushers have a complex motion (video) that should nonetheless be easily imitated by a hacker project. Amateur/hobby gold prospectors have an accessible community.
Crushing action in rollers only works until the particle is small enough that the surface of the roller deforms instead of the particle. Stones have been used to crush grain into flour for most of history.
Cutting is best for soft things, like gummy worms, and tough things (video.). Make sure the cut material has an easy path out. Think of an old fashioned kitchen meat grinder. .
If you want small particles, you need an impact grinder. A coffee mill or blender works by striking the particle with a fast moving impactor. This can be a blade – useful if the material first needs to be cut up, as in a coffee mill – or blunt. Many industrial mills use two pivoting weights on a shaft, and this unit just uses chains (video).
Another impact mill is the ball mill. Rotate a drum on it’s side with steel balls and the material. The balls travel up the side, then fall back down, striking the material.
All these work by fracturing the material. What if you’re trying to powder something that doesn’t fracture, say rubber O rings? For that, there’s cryogenic grinding.
Many rubbery materials are really glasses — materials that are a gloppy liquid at a higher temperature, often brittle at a cool temperature, and soft in-between. The glass you’re probably thinking of is a brittle, breakable material at room temperature, but at high temperature is a liquid. The transition point is the ‘glass transition temperature’.
So what about our O rings? If they’re natural rubber their transition point is about -70° C. Below that temperature they’re brittle and can be ground up. Unfortunately, grinding is going to put heat back in. So consider grinding slowly – some labs grind biological materials like skin samples with a special mortar and pestle cooled beforehand with liquid nitrogen. Just be sure everything in contact with the material has been cooled, and use a thick walled container with lots of thermal mass.
Separating Wheat From Chaff
Sometimes you have a mix and need to separate it. Your roommate dumped all the gummy bears and all those weird ginger candies into a bowl or whatever. Last week we introduced particle segregation as a bad thing. But when you want to un-mix a mixture, it can be a good thing. Any of the techniques from last week can be an aid.
Sieves and screens work to separate by size. They clog unless the material keeps moving over them. One simple way to do this is to flow the material over sieves on a slanted board, finest sieve first. Another is to mechanically shake the screen. Paper filters are just fine screens, and do clog.
A trommel is a slowly turning cylinder with walls of different sized screens along it’s length. Material is fed into the fine screen end and slowly moves towards the other.
Stokes law provides another way to separate materials as we saw above. Make an upward air draft in a vertical pipe. Deliver the material into the pipe part way up. Materials with more drag than weight will go up, larger materials will go down. You can use the air speed to control the size of particle. An industrial machine called an air classifier does this with higher velocity air blowing material into the rim of a spinning set of blades.
It could be the air (or another gas) you want to remove. There are a couple ways to do it. The first is the cyclone familiar to wood shops. The second is even simpler – inject the air/material mix into the top of a tall, slender container with a tube that extends about halfway into the container. Let the air out from an outlet pipe in the roof. The air flow expands, slows down, and the material falls out.
You can just blow the material sideways – the age old system of threshing wheat works this way. Wheat comes from the plant with a husk, you beat it with a flail to loosen the husk, giving you wheat grains and chaff mixed. Put the mix on a blanket and have four peasants toss it repeatedly. The chaff blows away in the wind.
Inertial Separation
A very sensitive separation technique is inertial separation. Here’s a mix of gummy colas and jelly beans. We separated them by tilting and gently shaking the sheet. A material moves on a sheet by staying in place until the acceleration is more than some critical value. Then it rolls or slides.
If your material is dirt or such, run a magnet through it. There’s iron ore and bits of human generated iron in a lot of soil. It can get into motors and such. If you need it out run the material past magnets. An eddy current separator uses AC magnetic effects to do the same with nonferrous metals.
You can also segregate materials by dissolving them. A mixture of table salt and white sand would seem impossible, but if you stir it into water, then decant and boil off the water, the salt and sand can be recovered separately. But we think we’re veering into chemistry now, and we should stop.
Next time we’ll finish up by looking at controlling movement: building gates and contraptions that move your bulk material without clogging up.
When looking at the performance of a vehicle, weight is one of the most important factors in the equation. Heavier vehicles take more energy to accelerate and are harder to stop. They’re also more difficult to control through the corners. Overall, anything that makes a vehicle heavier typically comes with a load of drawbacks to both performance and efficiency. You want your racecar as light as possible.
However, now and then, automakers have found reason to intentionally add large weights to vehicles. We’ll look at a couple of key examples, and discuss why this strange design decision can sometimes be just what the engineers ordered.
Hanging around in earth orbit is like walking into the middle of a Wild West gunfight — bullets are flying around everywhere, and even though none are purposefully aimed at you, one might have your name on it. Many of these bullets are artificial satellites that are actively controlled and monitored, but we also find dead satellites, remnants of satellites, discarded rocket stages, tools lost during spacewalks, and even flecks of paint and rust, much of it zipping around at multiple kilometers per second without any guidance.
While removing this space debris directly would be ideal, the reality is that any spacecraft and any spacesuit that has to spend time in orbit needs to be capable of sustaining at least some hits by space debris impacting it.
Orbital Mechanics
That it’s easy to create new debris should come as no surprise to anyone. What may take a bit more imagination is just how long it can take for this debris to make its way towards earth’s atmosphere, where it will uneventfully burn up. Everything in orbit is falling toward the earth, but its tangential velocity keeps it from hitting — like a marble spinning around the hole in a funnel. Drag from the planet’s atmosphere is the friction that eventually slows the object down, and where it orbits in the planet’s atmosphere determines how long this descent will take. Continue reading “Orbital Safety: The Challenges Of Surviving Space Junk”→
