Scrap A Hard Drive, Build A Rotary Encoder

January 7, 2018 by 26 Comments

There’s something to be said for the feel of controls. Whether it’s the satisfying snap of a high-quality switch or the buttery touch of the pots on an expensive amplifier, the tactile experience of the controls you interact with says a lot about a device.

[GreatScott!] knows this, and rather than put up with the bump and grind of a cheap rotary encoder, he decided to find an alternative. He ended up exploring hard drive motors as encoders, and while the results aren’t exactly high resolution, he may be onto something. Starting with a teardown of some old HDDs — save those magnets! — [Scott!] found that the motors fell into either the four-lead or three-lead categories. Knowing that HDD motors are brushless DC motors, he reasoned that the four-lead motors had their three windings in Wye configuration with the neutral point brought out to an external connection. A little oscilloscope work showed the expected three-phase output when the motor hub was turned, with the leading and lagging phases changing as the direction of rotation was switched. Hooked to an Arduino, the motor made a workable encoder, later improved by sending each phase through a comparator and using digital inputs rather than using the Nano’s ADCs.

It looks like [GreatScott!]’s current setup only responds to a full rotation of the makeshift encoder, but we’d bet resolution could be improved. Perhaps this previous post on turning BLDC motors into encoders will help.

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A Mini Stacker Arcade Cabinet

January 7, 2018 by 10 Comments

For [LumoW], what started as a school project turned into a passion project. He and his team made a hardware implementation of an arcade game called Stacker. Never heard of it? It’s pretty fun, kind of like an inverse Tetris. You can play the flash version here and see their mini arcade version after the break.

The game is based around the Mojo FPGA which the class required, and it’s programmed entirely in bitwise operators. It uses WS2812 RGB LEDs to represent the individual tower building blocks, and these are mounted on plywood in a matrix and separated into cells by a grid of foam board. After some trial and error, the team found the perfect shade of acrylic to diffuse the bright dots into glowing squares.

Since the game only needs one input, we don’t think [LumoW] should apologize at all for using the biggest, baddest button they could find. Besides, the game has that edge-of-your-seat action that can turn panic into heavy-handedness and cool DIY arcade games into shards of sadness.

Looking for something more advanced to do with an FPGA? Try your hand at vector games.

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The Secret Of Twinkling Christmas Lights

January 7, 2018 by 27 Comments

With the holidays over, many of us are braving the elements to take down all those holiday lights. LED lights have largely taken over the market, but in some places, you can still get classic incandescent bulbs. There are some effects that LEDs can’t quite mimic yet. One of those is the magic of “twinkling” light sets, which [Alec Watson] explains in a Technology Connections video. Everyone has seen bulbs that flash, and strings that dim. But the twinkle effect until recently has been hard to describe.

Typical flashing bulbs use a bimetallic strip. As the filament of the bulb heats up, the strip bends, opening the circuit. Then the strip cools and closes the circuit again. Twinkling lights do exactly the opposite. The bimetallic strip shorts the bulb out rather than open the circuit. Twinkling sets also use a lot of bimetallic strip bulbs – typically every fifth bulb has a strip. The result of the bulbs being shorted out is that all be the bulbs in set see a higher voltage. This makes the entire strip shimmer in time with the flashing. That’s where the twinkling magic comes from.

It occurs to us that the voltage on the strip would be a great source of random seeds. Sure, you’d have to replace bulbs now and again, but how many people can say they get their random numbers from a set of Christmas lights?

If you’re curious how incandescent Christmas lights can blow and not take out the whole strip, check out this article about anti-fuses.

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3D Printed Propellers Take To The Skies

January 6, 2018 by 10 Comments

In the world of drones, propeller choice is key to performance. Selecting the right props can have a major effect on things like flight time, vibration, and a whole host of other factors. Thinking it might be fun to experiment, [RCLifeOn] decided to 3D print some props and head out for a flight.

The props are a fairly simple 3-bladed design, which were printed in both PETG and PLA. No major difference is noted between the two materials, and the quadcopter under test is able to fly with either. It was noted that the props perform particularly poorly in a crash, with all props failing even in the softest of crashes. We would recommend some eye (and body) protection when spinning these props up for the first time.

If you’re keen to try them out yourself, the STL file can be had here. The video notes that when printing 4 props, 2 must be reversed in the Y-axis to print a counter-rotating set of 4. The instructions used for creating propellers in Fusion3D are available here.

It’s a worthy experiment, and something we’d like to see more of. With a 3D printer, it’s possible to experiment with all manner of propeller designs, and we’d love to see the best and worst designs that are still capable of flight. We’ve also seen 3D printed props before, like this effort from [Anton].

PCB Production On The Sienci Mill One

January 6, 2018 by 10 Comments

A complete start to finish electronics prototyping workshop is nirvana for many of us: being able to go from design on the computer to real hardware without having to get up from your rolling chair. The falling prices of 3D printers have helped make at least part of this a reality: $200 USD is enough to get you a printer that can churn out decent looking enclosures. But there’s more to producing your own hardware than creating slick looking project boxes; at some point you’ll need to put some electronics in there.

For [Chuck Hellebuyck] at least, the last piece of the puzzle has just fallen into place. He’s recently put up a YouTube video describing how he converted his $399 Sienci Mill One into a capable PCB mill. With a 3D printer and this new PCB mill, he’s happy to say he can now go from concept to production all on the same workbench.

The Sienci Mill One is a solid enough mill in its own right but did need some modification to attain the accuracy necessary for cutting at a depth of only .9 mm. First, a block of wood was cut to the same size as the original plastic bed of the Sienci, and then the mill itself was used to drill holes through the wood block and plastic bed. The wood was attached to the bed using a nut and bolt in each corner, being sure to torque it down enough that the head of the bolt is pulled down flush with the surface of the wood.

Pulling the head of the bolts flush wasn’t just to keep the surface free of any snags, [Chuck] uses them in conjunction with a probe in the mill’s chuck as a simple way of adjusting the Z height. With a continuity meter attached between the two, he could lower the probe down until they were touching just enough to make a circuit.

Click through the break for the rest of the story!

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3D Printing Wearables With A Net

January 6, 2018 by 4 Comments

If you want to build wearables, you need to know how to sew, right? Maybe not. While we’re sure it would come in handy, [Drato] (also known as [RobotMama]) shows how she prints designs directly on a net-like fabric. You can see a video of the process below.

The video after the break shows an Ultimaker, but there’s really nothing particularly special about the printer. The trick is to print a few layers, pause, and then insert the fabric under the printer before resuming the print.

[Drato] holds the fabric down after inserting it, and mentions you can use glue to hold it down, too. We wondered if some bulldog or alligator clips might work. The only thing we worried about is if the fabric were made of some synthetic, it might not take hot plastic without melting.

[Drato] mentions she uses Organza, which is a sheer fabric often found on wedding gowns. However, she doesn’t mention if she is using the polyester, silk, or nylon type of the fabric. A little research shows that polyester and nylon fabrics melt at about 295 C. Silk was harder to track down, but since you can iron it on a medium setting, that might work, too. Of course, the temperature where it melts and the temperature where it just deforms beyond use might be different, so some experimentation is probably wise.

What really piqued our interest was the application to creating wearables without sewing. We’ll be curious what other applications you could find for printing directly on a fabric substrate.

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3D Printed Wave Lamp Forecasts The Weather

January 6, 2018 by 4 Comments

While browsing Thingiverse, [Dushyant Ahuja] found a rather pleasing wave lamp, and since a mere lamp on its own would not quite be enough, he added a means by which his lamp could provide weather alerts by means of changing its color.

It’s fair to say that the wave lamp is not a print for the faint-hearted, and it took him 30 hours to complete. However, it has the interesting feature of not requiring a support or raft. There is also a base for the lamp designed to take a strip of addressable LEDs, and he modified its design to mount a small PCB containing an ESP8266 module and a level shifter chip. The code for the ESP relies on the OpenWeatherMap API, and changes the LED color based on the rainfall forecast.

Casting our minds back a decade, this lamp is reminiscent of the long-departed Nabaztag product, best described as an internet-connected plastic anthropomorphic rabbit that could keep you updated with information such as weather or stock market trends through lighting up and the movement of its ears. It was an overpriced idea tied into a proprietary online back end that was probably well before its time back in 2004. Perhaps repackaged for 2017 with a commodity microcontroller board Nabaztag has finally found its application.

There is a short video showing the color change and an LED animation, which we’ve put below the break.

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