Restoring $5 Busted Synthesizer Made Easy, Thanks To Thermal

July 16, 2022 by 19 Comments

[D. Scott Williamson] paid $5 for a Roland JV-30 synthesizer at a garage sale. Score! There was only one catch: it didn’t work and didn’t include the power supply. Luckily, restoring it was made easier by breaking out a thermal camera.

As mentioned, the keyboard was missing a 9 VDC power supply (rated 800 mA) with a center-negative barrel connector. Slightly oddball, but nothing an enterprising hacker can’t deal with. After supplying power with a bench supply, not only did the keyboard not come to life, but the power supply clamped the current draw at 1.5 A! Something was definitely not right.

This shorted glass-bodied diode might look normal to the naked eye, but thermal imaging makes it clear something’s amiss.

Inside, there was no visible (or olfactory) sign of damage, but looking closer revealed that a little SMT capacitor by the power connector was cracked in two. Fixing that didn’t bring the keyboard to life, so it was time to break out the thermal imager. Something was soaking up all that current, and it’s a fair bet that something is getting hot in the process.

The culprit? The reverse polarity protection diode was shorted, probably as a result of damage by an inappropriate power supply or a surge of some kind. Replacing it resulted in a working keyboard! Not bad at all for $5, a diode, an SMT cap, and a little workbench time. The finishing touch was replacing a missing slider knob, which took some work in OpenSCAD and a 3D printer. Overall, not bad!

Thermal imaging used to be the stuff of staggering price tags, but it’s downright accessible these days, and makes it easy to spot things that are hot when they shouldn’t be. And if a thermal camera’s lens isn’t what you think it should be? It’s even possible for a sufficiently motivated and knowledgeable hacker to modify those.

Hands-On Review: TCam-Mini WiFi Thermal Imager

July 27, 2021 by 30 Comments

A thermal camera is a tool I have been wanting to add to my workbench for quite a while, so when I learned about the tCam-Mini, a wireless thermal camera by Dan Julio, I placed an order. A thermal imager is a camera whose images represent temperatures, making it easy to see things like hot and cold spots, or read the temperature of any point within the camera’s view. The main (and most expensive) component of the tCam-Mini is the Lepton 3.5 sensor, which sits in a socket in the middle of the board. The sensor is sold separately, but the campaign made it available as an add-on.

Want to see how evenly a 3D printer’s heat bed is warming up, or check whether a hot plate is actually reflowing PCBs at the optimal temperature? How about just seeing how weird your pets would look if you had heat vision instead of normal eyes? A thermal imager like the tCam-mini is the tool for that, but it’s important to understand exactly how the tCam-mini works. While it may look like a webcam, it does not work like one.

Continue reading “Hands-On Review: TCam-Mini WiFi Thermal Imager” →

DIY Thermal Imager Uses DIY Gaussian Blur

September 29, 2019 by 18 Comments

Under the right circumstances, Gaussian blurring can make an image seem more clearly defined. [DZL] demonstrates exactly this with a lightweight and compact Gaussian interpolation routine to make the low-resolution thermal sensor data display much better on a small OLED.

[DZL] used an MLX90640 sensor to create a DIY thermal imager with a small OLED display, but since the sensor is relatively low-resolution at 32×24, displaying the data directly looks awfully blocky. Gaussian interpolation to improve the display looks really good, but it turns out that the full Gaussian interpolation isn’t a trivial calculation write on your own. Since [DZL] wanted to implement it on a microcontroller, the lightweight implementation was born. The project page walks through the details of Gaussian interpolation and how some effective shortcuts were made, so be sure to give it a look.

The MLX90640 sensor also makes an appearance in the Open Thermal Camera, one of the entries for the 2019 Hackaday Prize. If you’re interested in thermal imaging, don’t miss this teardown of a thermal imaging camera.

The Easiest Thermal Camera Build You’ll Ever See

March 1, 2019 by 41 Comments

Thermal cameras are one of those tools that we all want, but just can’t justify actually buying. You don’t really know what you would do with one, and when even the cheap ones are a couple hundred dollars, it’s a bit out of the impulse buy territory. So you just keeping waiting and hoping that eventually they’ll drop to the price that you can actually own one yourself.

Well, today might be the day you were waiting for. While it might not be the prettiest build, we think you’ll agree it can’t get much easier than what [vvkuryshev] has put together. His build only has two components: a Raspberry Pi and a thermal camera module he picked up online for about $80 USD. There isn’t even any wiring involved, the camera fits right on the Pi’s GPIO header.

Of course, you probably wouldn’t be seeing this on Hackaday if all he had to do was just buy a module and solder it to the Pi’s header. As with most cheap imported gadgets, the GY-MCU90640 module that [vvkuryshev] bought came with some crusty Windows software which wasn’t going to do him much good on the Raspberry Pi. But after going back and forth a bit with the seller, he was able to get some documentation for the device that put him on the right track to writing a Python script which got it working under Linux.

The surprisingly simple Python script reads a frame from the camera four times a second over serial and run it through OpenCV. It even adds some useful data like the minimum and maximum temperatures in the frame to the top of the image. Normally the script would output to the Pi’s primary display, but if you want to use it remotely, [vvkuryshev] says he’s had pretty good luck running it over VNC. In fact, he says that with a VNC application on your phone you could even use this setup on the go, though the setup is a bit awkward for that in its current incarnation.

This isn’t the first DIY thermal camera build we’ve seen, and it isn’t even the first one we’ve seen that leveraged a commercially available imaging module. But short of buying a turn-key camera, we don’t see how it could get any easier to add heat vision to your bag of tricks.

Teardown Of A (Relatively) Cheap Thermal Camera

November 7, 2018 by 32 Comments

The cost of tools and test equipment has largely been on the downward trend for years, making it now more affordable than ever to get into the hacking and making scene. This is particularly visible with something like the venerable oscilloscope: a piece of equipment that was near unobtainium for the home hacker a decade ago, you can now get digital pocket scope for as little as $20 USD. But there are still pieces of gear which haven’t quite hit the sort of prices we’d like to see.

A perfect example are thermal imaging cameras. The cheap ones are usually so low resolution they might as well just be thermometers, but the higher resolution ones can cost thousands. [Rob Scott] recently wrote in to tell us about a very promising middle ground, the HTI HT-A1. But he didn’t just point it out to us, he also tore it down and laid its internal’s bare for our entertainment. Now that’s our kind of introduction.

[Rob] walks us through the disassembly of the device, which is made unnecessarily difficult due to the fact that half the screws are hidden under a glued on screen bezel. That means a heat gun, a thin tool, and patience are in order if you want to get inside the device. It’s bad enough they use these kinds of construction techniques on modern smartphones, but at least they’re so thin that we can understand the reasoning. Why this chunky thing needs to resort to such measures is beyond us.

Eventually he cracks the HT-A1 open and is greeted with a single double-sided PCB. The top side is pretty much bare except for the buttons and the LCD display, and the flip side is largely just a breakout for a quad-core Allwinner A33 daughterboard. [Rob] theorizes this is to keep costs down by allowing reuse of the modular A33 board on other devices. Given the A33’s use in so many cheap tablets, it’s also possible HTI simply purchased these daughterboards as a drop-in component and designed their own board around it.

There’s not much else inside the HT-A1 beyond the rechargeable battery pack and thermal camera, both attached to the device’s rear panel. [Rob] noticed that the date on the thermal camera PCB is a full two years older than the date on the main PCB, leading one to wonder if HTI might have gotten a good deal on a bunch of these slightly outdated sensors and spun up a whole device around them.

The HT-A1 is high enough resolution that you can actually pick out individual components on a PCB, and at $400 USD is approaching a reasonable price point for the individual hacker. Which is not to say it’s cheap, but at least you get a useful tool for your money. We wouldn’t suggest you buy this device on a whim, but if you do a lot of diagnostic work, it might pay for itself after a couple repairs.

If that’s still a little too rich for your blood, we’ve covered a handful of DIY options which might better fit your budget.

Continue reading “Teardown Of A (Relatively) Cheap Thermal Camera” →

Hot Camera Contest: Build A Battery Powered Thermal Camera

July 18, 2018 by 36 Comments

Here’s a challenge for all you hardware hackers out there. Peter Jansen has opened up the Hot Camera Contest on Hackaday.io to use a thermal imaging camera in a battery-powered project.

The challenge here is simple. Use a Flir Lepton thermal imaging camera module in a battery-powered configuration. There’s a catch, though: this is a project to use the Lepton in radiometric mode, where the camera spits out an actual temperature value for each pixel. Yes, this is a documented feature in the Flir Lepton module, but so far very few people are using it, and no one has done it with a small, battery-powered device.

The rules for this challenge are to use the Flir Lepton 2.5 in radiometric mode using either the Raspberry Pi Zero W or ESP32. Any software in this challenge must spit out absolute temperature values in a text format, and there must be a demonstration of putting the Flir Lepton into low-power mode. There are two challenges here, one for the Raspi and one for the ESP32; and winner will be named for each.

Getting More from a Fascinating Sensor

The Flir Lepton is a tiny little thermal camera that’s been available to the Maker community for some time now, first through GroupGets and now through Sparkfun. For a pair of Benjamins, the specs are very impressive: the Lepton has a resolution of 60×80 pixels and everything is can be read over an SPI port. The Lepton gives any project thermal imaging, and the PureThermal board turns the Lepton into a USB device.

Peter Jansen is the creator of the Open Source Science Tricorder (yes, it’s a tricorder) which took Fourth Prize in the 2014 Hackaday Prize. You can understand how he became interested in portable, and we’re sure whatever project he has in mind for this battery-powered Flir will be awesome.

This really is a great example of what the Hackaday.io community is capable of. The goal here is to create useful Open Source drivers for some very interesting hardware, and there’s some prizes to sweeten the pot. Peter has a $125 Sparkfun gift card on offer for each of the two winners. And the challenge of solving a tricky problem and making designs easier for others is a powerful motivator. Who doesn’t like a challenge?

Adding Optics To A Consumer Thermal Camera

March 8, 2018 by 16 Comments

[David Prutchi] writes in to tell us about his recent experiments with building lenses for thermal imaging cameras, which to his knowledge is a first (at least as far as DIY hardware is concerned). With his custom designed and built optics, he’s demonstrated the ability to not only zoom in on distant targets, but get up close and personal with small objects. He’s working with the Seek RevealPro, but the concept should work on hardware from other manufacturers as well.

In his detailed whitepaper, [David] starts by describing the types of lenses that are appropriate for thermal imaging. Glass doesn’t transmit the wavelengths that thermal camera is looking for, so the lenses need to be made of either germanium or zinc selenide. These aren’t exactly the kind of thing you can pick up at the local camera shop, and even small lenses made of these materials can cost hundreds of dollars. He suggests keeping an eye out on eBay for surplus optics you could pull them out of to keep costs down.

Creating the macro adapter is easy enough, you simply put a convex lens in front of the thermal camera. But telephoto is a bit more involved, and the rest of the whitepaper details the math and construction techniques used to assemble it the optics. [David] gives a complete bill of materials and cost breakdown for his telephoto converter, but prepare for a bout of sticker shock: the total cost with all new hardware is nearly $500 USD. The majority of that is for the special lenses though, so if you can score some on the second-hand market it can drop the cost significantly.

We’ve seen an impressive array of thermal camera hacks and projects recently, no doubt due to the falling prices of consumer-level imaging hardware. Given their utility as a diagnostic tool, a thermal camera might be something worth adding to your bag of tricks.