Printing Strain Wave Gears

June 19, 2018 by 20 Comments

We just wrapped up the Robotics Module Challenge portion of the Hackaday Prize, and if there’s one thing robots need to do, it’s move. This usually means some sort of motor, but you’ll probably want a gear system on there as well. Gotta have that torque, you know.

For his Hackaday Prize entry, [Johannes] is building a 3D printed Strain Wave Gear. A strain wave gear has a flexible middle piece that touches an outer gear rack when pushed by an oval central rotor. The difference in the number of teeth on the flexible collar and the outer rack determine the gear ratio.

This gear is almost entirely 3D printed, and the parts don’t need to be made of flexible filament or have weird support structures. It’s printed out of PETG, which [Johannes] says is slippery enough for a harmonic drive, and the NEMA 17 stepper is completely contained within the housing of the gear itself.

Printing a gear system is all well and good, but what do you do with it? As an experiment, [Johannes] slapped two of these motors together along with a strange, bone-like adapter to create a pan/tilt mount for a camera. Yes, if you don’t look at the weird pink and blue bone for a second, it’s just a DSLR on a tripod with a gimbal. The angular resolution of this setup is 0.03 degrees, so it should be possible to use this setup for astrophotography. Impressive, even if that particular implementation does look a little weird.

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Federico Faggin: The Real Silicon Man

June 19, 2018 by 45 Comments

While doing research for our articles about inventing the integrated circuit, the calculator, and the microprocessor, one name kept popping which was new to me, Federico Faggin. Yet this was a name I should have known just as well as his famous contemporaries Kilby, Noyce, and Moore.

Faggin seems to have been at the heart of many of the early advances in microprocessors. He played a big part in the development of MOS processors during the transition from TTL to CMOS. He was co-creator of the first commercially available processor, the 4004, as well as the 8080. And he was a co-founder of Zilog, which brought out the much-loved Z80 CPU. From there he moved on to neural networking chips, image sensors, and is active today in the scientific study of consciousness. It’s time then that we had a closer look at a man who’s very core must surely be made of silicon.

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Lawn From Hell Saved By Mower From Heaven

June 19, 2018 by 94 Comments

It’s that time of year again, at least in the northern hemisphere. Everything is alive and growing, especially that narrow-leafed non-commodity that so many of us farm without tangible reward. [sonofdodie] has a particularly hard row to hoe—his backyard is one big, 30° slope of knee-ruining agony. After 30 years of trudging up and down the hill, his body was telling him to find a better way. But no lawn service would touch it, so he waited for divine inspiration.

And lo, the answer came to [sonofdodie] in a trio of string trimmers. These Whirling Dervishes of grass grazing are mounted on a wheeled plywood base so that their strings overlap slightly for full coverage. Now he can sit in the shade and sip lemonade as he mows via rope and extension cord using a mower that cost about $100 to build.

These heavenly trimmers have been modified to use heavy nylon line, which means they can whip two weeks’ worth of rain-fueled growth with no problem. You can watch the mower shimmy down what looks like the world’s greatest Slip ‘n Slide hill after the break.

Yeah, this video is two years old, but somehow we missed it back then. Ideas this fresh that tackle age-old problems are evergreen, unlike these plots of grass we must maintain. There’s more than one way to skin this ecological cat, and we’ve seen everything from solar mowers to robotic mowers to mowers tied up to wind themselves around a stake like an enthusiastic dog.

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What Is Our Martian Quarantine Protocol?

June 19, 2018 by 89 Comments

If you somehow haven’t read or watched War of the Worlds, here’s a spoiler alert. The Martians are brought down by the common cold. You can argue if alien biology would be susceptible to human pathogens, but if they were, it wouldn’t be surprising if aliens had little defense against our bugs. The worrisome part of that is the reverse. Could an astronaut or a space probe bring back something that would ravage the Earth with some disease? This is not science fiction, it is both a historically serious question and one we’ll face in the near future. If we send people to Mars are they going to come back with something harmful?

A Bit of News: Methane Gas Fluctuations on Mars

What got me thinking about this was the mounting evidence that there could be life on Mars. Not a little green man with a death ray, but perhaps microbe-like life forms. In a recent press release, NASA revealed that they not only found old organic material in rocks, but they also found that methane gas is present on Mars and the amount varies based on the season with more methane occurring in the summer months. There’s some dispute about possible inorganic reasons for this, but it is at least possible that the variation is due to increased biological activity during the summer.

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An Arduino Powered Tank Built To Pull Planes

June 19, 2018 by 39 Comments

Surely our readers are well aware of all the downsides of owning an airplane. Certainly the cost of fuel is a big one. Birds are a problem, probably. That bill from the traveling propeller sharpener is a killer too…right? Alright fine, we admit it, nobody here at Hackaday owns an airplane. But probably neither do most of you; so don’t look so smug, pal.

But if you did own a plane, or at least work at a small airport, you’d know that moving the things around on the ground is kind of a hassle. Smaller planes can be pulled by hand, but once they get up to a certain size you’ll want some kind of vehicle to help out. [Anthony DiPilato] wanted a way to move around a roughly 5,200 pound Cessna 310, and decided that all the commercial options were too expensive. So he built his own Arduino powered tank to muscle the airplane around the tarmac (if site is down try Google cache), and his journey from idea to finished product is absolutely fascinating to see.

So the idea here is pretty simple. A little metal cart equipped with two beefy motors, an Arduino Mega, a pair of motor controllers, and a HC-08 Bluetooth module so you can control it from your phone. How hard could it be, right? Well, it turns out combining all those raw components into a little machine that’s strong enough to tow a full-scale aircraft takes some trial and error.

It took [Anthony] five iterations before he fine tuned the design to the point it was able to successfully drag the Cessna without crippling under the pressure. The early versions featured wheels, but eventually it was decided that a tracked vehicle would be required to get enough grip on the blacktop. Luckily for us, each failed design is shown along with a brief explanation about what went wrong. Admittedly it’s unlikely any of us will be recreating this particular project, but we always love to see when somebody goes through the trouble of explaining what went wrong. When you include that kind of information, somewhere, somehow, you’re saving another maker a bit of time and aggravation.

Hackers absolutely love machines with tank treads. From massive 3D printed designs to vaguely disturbing humanoid robots, there’s perhaps no sweeter form of locomotion in the hacker arsenal.

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Tables Are Turned As Robots Assemble IKEA Furniture

June 19, 2018 by 15 Comments

Hackaday pages are rife with examples of robots being built with furniture parts. In this example, the tables are turned and robots are the masters of IKEA pieces. We are not silly enough to assume that these robots unfolded the instructions, looked at one another, scratched their CPUs, and began assembling. Of course, the procedure was preordained by the programmers, but the way they mate the pegs into the ends of the cross-members is a very human thing to do. It reminds us of finding a phone charging socket in the dark. This kind of behavior is due to force feedback which tell the robots when a piece is properly seated which means that they can use vision to fit the components together without sub-millimeter precision.

All the hardware used to make the IKEA assembler is publicly available, and while it may be out of the typical hacker price range, this is a sign of the times as robots become part of the household. Currently, the household robots are washing machines, smart speakers, and 3D printers. Ten years ago those weren’t Internet connected machines so it should be no surprise if robotic arms join the club of household robots soon. Your next robotics project could be the tipping point that brings a new class of robots to the home.

Back to our usual hijinks, here is a robot arm from IKEA parts and a projector built into a similar lamp. or a 3D printer enclosed in an IKEA cabinet for a classy home robot.

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Hybrid Lab Power Supply From Broken Audio Amp

June 18, 2018 by 9 Comments

The lab power supply is an essential part of any respectable electronics workbench. However, the cost of buying a unit that has all the features required can be eye-wateringly high for such a seemingly simple device. [The Post Apocalyptic Inventor] has showed us how to build a quality bench power supply from the guts of an old audio amplifier.

We’ve covered our fair share of DIY power supplies here at Hackaday, and despite this one being a year old, it goes the extra mile for a number of reasons. Firstly, many of the expensive and key components are salvaged from a faulty audio amp: the transformer, large heatsink and chassis, as well as miscellaneous capacitors, pots, power resistors and relays. Secondly, this power supply is a hybrid. As well as two outputs from off-the-shelf buck and boost converters, there is also a linear supply. The efficiency of the switching supplies is great for general purpose work, but having a low-ripple linear output on tap for testing RF and audio projects is really handy.

The addition of the linear regulator is covered in a second video, and it’s impressively technically comprehensive. [TPAI] does a great job of explaining the function of all the parts which comprise his linear supply, and builds it up manually from discrete components. To monitor the voltage and current on the front panel, two vintage dial voltmeters are used, after one is converted to an ammeter. It’s these small auxiliary hacks which make this project stand out – another example is the rewiring of the transformer secondary and bridge rectifier to obtain a 38V rail rated for twice the original current.

The Chinese DC-DC switching converters at the heart of this build are pretty popular these days, in fact we’re even seeing open source firmware being developed for them. If you want to find out more about how they operate on a basic level, here’s how a buck converter works, and also the science behind boost converters.

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