Clearly The Best Way To Organize SMD Parts

February 11, 2016 by Voja Antonic 36 Comments

Have some plexiglas (acrylic) leftovers lying around? Well, they could be put to good use in making this SMD organizer. It comes in handy if you deal with a lot of SMD components in your work. No longer will you waste your time trying to find a 15K 1206 resistor, or that BAS85 diode… or any other component you can think of soldering on the PCB. The basic idea is fairly straightforword, which helped keep this short.

SMD resistors are packed in thick paper tapes that don’t bend easily, and thus need larger containers than other components, which are packed mainly in flexible PE tapes. The first version of this organizer was built with a 96mm diameter space for resistors and 63mm diameter for other components, but it seems that there is no need for such large compartments. If I were to make it again, I would probably scale everything down to about 80% of it’s current size.

The best way to join all plexiglass parts is to use four M4 threaded rods. There is also a 1.5mm steel rod which holds SMD tape ends in place and helps to un-stick the transparent tape which covers the components. At the top of the organizer there is a notch for paper, used for components labels. Most SMD components are packed in 8mm wide tapes, making the optimal compartment width 10mm. It is not easy to cut the 10mm thick acrylic and get a neat edge – instead, you could use more layers of thin sheets to make the spacers. Using 5mm acrylic you can combine more layers for any width of tape, which contains wider components, like SMD integrated circuits. The only thing that you have to be careful about, is to keep the distance between the thin steel rod and acrylic, which is marked as “2-4mm” on the drawing. It is good if this space is just a few tenths of a millimeter wider than the thickness of SMD tapes.

The CorelDraw file that can be used for laser cutting the acrylic parts, is available for download. If you scale the profiles, don’t forget to readjust the hole diameters and some other dimensions which have to remain intact. If you have 5mm acrylic pieces, you should probably use two layers of acrylic for every tape (red parts on the drawing). The barrier layers would be made of thin acrylic — for instance 2mm (the blue parts). Edge layers (green) are once again 5mm thick, and there are also the end pieces (yellow), glued to the previous borders and used to “round up” the whole construction and to protect your hands from the threaded rods and nuts.

While you’re building this for your bench, make a vacuum picking tool for SMDs out of a dispensing syringe with a thick needle. It’s a common trick for hackers to use an aquarium air pump, just turn the compressor unit by 180°, so that it creates vacuum instead of blowing the air outside. This process is described by R&TPreppers in the video below.

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China’s Fusion Reactor Hits Milestone

February 11, 2016 by Brian Benchoff 105 Comments

An experimental fusion reactor built by the Chinese Academy of Science has hit a major milestone. The Experimental Advanced Superconducting Tokamak (EAST) has maintained a plasma pulse for a record 102 seconds at a temperature of 50 million degrees – three times hotter than the core of the sun.

The EAST is a tokamak, or a torus that uses superconducting magnets to compress plasma into a thin ribbon where atoms will fuse and energy will be created. For the last fifty years, most research has been dedicated to the study of tokamaks in producing fusion power, but recently several projects have challenged this idea. The Wendelstein 7-X stellarator at the Max Planck Institute for Plasma Physics recently saw first plasma and if results go as expected, the stellarator will be the design used in fusion power plants. Tokamaks have shortcomings; they can only be ‘pulsed’, not used continuously, and we haven’t been building tokamaks large enough to produce a net gain in power, anyway.

Other tokamaks currently in development include ITER in France. Theoretically, ITER is large enough to attain a net gain in power at 12.4 meters in diameter. EAST is much smaller, with a diameter of just 3.7 meters. It is impossible for EAST to ever produce a net gain in power, but innovations in the design that include superconducting toroidal and poloidal magnets will surely provide insight into unsolved questions in fusion reactor design.

Digital Communications 1830s Style

February 11, 2016 by Al Williams 36 Comments

We think of digital communications as a modern invention. But the reality is that semaphores, smoke signals, and Aldis lamps are all types of digital communication. While telegraphs are not as old as smoke signals, they, too, are a digital mode. The problem with all of these is that they require the operator to learn some kind of code. People don’t like to learn code because it is difficult, and employers don’t like to pay high wages to trained operators.

In the late 1830s, a man named William Cooke proposed a complex telegraph to a railway company. The company didn’t care for it and asked for something simpler. The railway didn’t like that either, so Cooke joined up with Charles Wheatstone and patented something that was a cross between a telegraph and a Ouija board.

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How A Professional Resin Caster Duplicates Parts

February 11, 2016 by Gerrit Coetzee 14 Comments

[Gregg Eshelman] reproduces plastic parts for antique car restorations for a living; likewise, he’s very good at it. Greg always chimes in with helpful hints whenever we post about resin casting. Shown above is a lens for a car turn signal. Manufactured in 1941, having [Gregg] cast a few copies is an easy option for replacing the rare part.

[Gregg] uses a similar method to us, but it is easy to see that he has done it more and his process has been refined by lots of experience. We really liked how he avoids using expensive foam core by wrapping cardboard in packing tape, or using the kind that has a plastic coating on it; the kind most retail packaging is made out of. He also has better techniques for keying the part to be manufactured, and prepping difficult geometry between different mold halves. It also never would have occurred to us to use Dremel cutting disks to cut the sprues and air vents in the silicone, a surprisingly tricky material to cut precisely with a knife.

It’s always nice when a professional takes time to write about their processes for the hobbyist trying to emulate it. We hope [Gregg] writes more tutorials, and continues to contribute in the comment section. If you have your own fabrication techniques to share we’d love to hear about it on the tips line.

Robot Does The Worm To Get Around

February 11, 2016 by Dan Maloney 6 Comments

Walking, jumping, rolling, flying, swimming – robotic locomotion is limited only by the imagination of the inventor. [Roger Rabbit] apparently has a pretty vivid imagination, because he’s building robots that move like worms.

Version 1 of [Roger]’s robot is only semi-vermiform and is more of tube climber. It has a pair of 3D-printed pantographs that expand and contract with servos and move along the robot’s axis on a stepper-driven lead screw. An Arduino reads sensors and coordinates the expansion of the pantographs to grip the internal diameter of a pipe and push the worm-bot along. It’s a slow but effective way to get around in the limited confines of a pipe.

The next iteration, dubbed [Wolly], is much more worm-like and not restricted to pipe-running. It has four expandable triangular frames connected to each other with rack-and-pinion backbones. The first frame contracts, the racks push it forward, it expands, the next contracts, and soon it’s doing the worm across the floor. Still slow, but pretty neat to watch, and you can see how it can be steered. It might even be able to roll around its long axis, and it’d make a decent tube climber as well.

This creepy autonomous worm-bot seems very similar to [Wolly], but aside from that we haven’t covered too many robots like these. There’s a lot of thought and effort in these worm-bots, and we’re keen to see where [Roger] takes this unique robot body plan.

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Pi-Powered Robot Plays Puzzle & Dragons

February 10, 2016 by Kristina Panos 8 Comments

Have you heard of the iPhone game Puzzle & Dragons? We understand it’s big in Japan. The puzzle part is all about rearranging colored orbs and grouping them together so they disappear and give you points. It’s also part RPG—each color is linked to a little guy, and every combo makes the matching-colored guy a little stronger. Then you fight monsters and take loot.

A YouTube user named [Junya Sakamoto] built a robot to play the game for him. It analyzes the board to come up with the best possible series of moves and then executes them using a Raspberry Pi. You can see what the robot is planning on the screen of a connected laptop. A couple of motors controlled with a Gertbot move a stylus up and down the screen and the phone itself back and forth.

There are two videos after the break. The first one is a combination build and demo video that proves this robot can do a lot more than just while away the hours playing Puzzle & Dragons. The second video demonstrates just how awesome it is at playing Puzzle & Dragons.

We like game-playing robots quite a bit around here. Here’s a Legoduino robot that plays Jurassic Park Builder. This other robot was built to test apps, but it plays Angry Birds in its spare time.

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Dumping U8Plus Smartwatch ROM Via Vibration Motor

February 10, 2016 by Al Williams 24 Comments

[Lee] continues with his exploration of the U8Plus (a cheap smartwatch). He hasn’t got it all cracked, yet, but he did manage to get a dump of the device’s ROM using an unusual method. At first, [Lee] thought that the JTAG interface (or, at least, the pins presumed to be the JTAG interface) would be a good way to explore the device. However, none of the people experimenting with the device have managed to get it to work.

Instead, [Lee] went through the serial bootloader and dumped the flash memory. He found out, though, that the bootloader refused to read the ROM area. It would, however, load and run a program. Unfortunately, no one has found how to access the UART device directly, but they have found how to drive the vibration motor.

[Lee] took off the vibration motor and used it as an output port for a simple program to dump the ROM. An Arduino picked up the data at a low baud rate and produced an output file. This should allow more understanding of how to drive the watch hardware.

We covered the initial teardown of this watch earlier this year. Of course, if you don’t want to reverse engineer a smartwatch, you could always build your own.