Make A BLDC Motor From Scraps You Can Find In The Garage

April 10, 2016 by 15 Comments

Think you’ve got what it takes to build a homebrew brushless motor? As [JaycubL] shows us, it turns out that a bldc motor may be living in pieces right under your nose, in scraps that so many of us would otherwise toss aside. To get our heads turning, [JaycubL] takes us into the theory of brushless DC motors operate. He then builds a homebrew brushless motor using screws, a plastic container, a few bearings, a metal rod, some magnets, and a dab of epoxy. Finally, he gives it a whirl with an off-the-shelf motor controller.

This isn’t [JaycubL’s] first dive into homebrew brushless motors. For the curious, he’s also assembled a fully-functional brushless outrunner motor with a paint can housing.

Sure, understanding the principles is one thing, but being able to take the leap into the real world and find the functional beginnings of a motor from your scrap bin is an entirely different story! [JaycubL’s], dare we say, finesse of understanding the principles behind motor design makes us wonder: how many other functional higher-level electrical and mechanical components can we bootstrap from bitter scrap? To get you started, we’ll point you in the direction of this CNC router that’s just a few steps away from one trip to the hardware store.

Thanks for the tip, [John]!

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“World’s Brightest” Flashlight

April 10, 2016 by 46 Comments

With the crazy extremes of light flux density that are possible these days, we’re putting quotation marks around “world’s brightest”, but it’s abundantly clear that this flashlight build is very much too bright. No, really. Why would you want a flashlight so bright that you have to wear sunglasses to look at anything that’s within a twenty foot radius?

Because you can. [Mads Nielsen] combined 18, one hundred Watt LED units with some giant machined heatsinks, fans to cool those heatsinks, lenses, and other hardware to make a device that turns electrons into photons at an alarming rate. Each chip-on-board LED package requires 32 Volts, and they’re pairwise in series so it’s a 64 V system. A boot converter pushes up the twelve LiPo battery packs up to the required voltage.

Even with the relatively high voltage, this thing sucks in 27 A, so the power supply is distributed among four of these boost converters. All of this means thick cables and a rather hefty power switch. When you’re designing something ridiculous, all of these little details come out of the woodwork. We’ve included part one of the four-part build video here, because they’re full of great detail. [Mads] has a lot more interesting LED-related info on his YouTube channel. You can watch the showing-off video on your own time.

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Brazillian Class Creates Digital Board Game

April 10, 2016 by 10 Comments

A class in Brazil was given the assignment to make a board game. [Marcelo], presumably, heard his son lamenting how lame it was going to be if the board was just cardboard with some drawings on, and came to the rescue.

fusion between Operation and one of those disease transmitters at the doctors office
A match meant to be.

Working with the class, they came up with the rules of the game. We’re not certain what those are, but it involves a regular game board, a flashing light circle with numbers, and a fusion between Operation and one of those disease transmitters commonly found at the doctor’s office. You can try to puzzle them out from the video after the break.

The brains of the board is an Arduino with an external EEPROM for all the sound effects and other data needed for this construction. Everything is laid out on a beautifully done home etched PCB. It’s too bad the other side of the board isn’t visible.

We’re sure the kids learned a lot working with [Marcelo]. It would have been nice if a traveling wizard came to some of our earlier classes in school and showed us just how much cool stuff you can do if you know electronics.

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Gameboy Case Lives On With A Pi Zero

April 10, 2016 by 25 Comments

After scoring a non-functioning Gameboy in mint condition for $10, [Chad] decided it was time for a fun electronics project, so he ordered an LCD and bought a Pi Zero.

He started with a 3.5″ LCD off eBay for about $25, and got it running with the Pi Zero. It’s only 320×240 resolution, but hey, we’re recreating a Gameboy — not a smartphone. The next step was rather finicky: cutting up the case to fit the new components in.

Using a collection of files he whittled down the screen opening in the case to make room for the LCD, a few hours later and it looked surprisingly good.

From there he started laying out the components inside of the case, trying to figure out the best layout for everything to fit nicely. To power the unit he’s using a lithium ion battery from a Samsung Note which should give him some serious play-time. It fits right in where the game card is suppose to go.

To add some extra control functionality he’s added the game-pad buttons from a SNES onto the back where the battery door is, he’s also got a USB port on the side, a MicroSD card slot, and even a new audio pre-amp with potentiometer for controlling the speaker volume.

In case you can’t find a mint condition Gameboy case like [Chad] did, you could just print one from scratch

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Tiny ATtiny85 Game Console

April 10, 2016 by 10 Comments

[Ilya Titov] has made a game console. Not just any game console, but an extremely small ATtiny85-based console suitable for putting on a key ring and assembled into a very professional product with PCB and 3D printed case. This is a project that has been on the go since 2014, but the most recent update is a new version designed for tighter and more easy assembly.

All construction is through-hole rather than SMD, and aside from the ATtiny85 the console uses an OLED screen, piezo buzzer, tactile switches and a handful of passive components. Power comes from a single CR2032 coin cell which sits under the screen. Best of all the PCB design is available as a PDF and the 3D printed case can be found on Thingiverse.

There are two games for the console, as well as the Breakout clone whose code is in the 2014 piece linked above he’s written UFO Escape, an obstacle-avoiding side-scroller. You’ll have to burn both game and 8MHz internal clock bootloader to the ATtiny85 yourself. There are no cartridges with this console, though if the processor sits in a DIP socket the game can be changed over simply by swapping processors programmed with the appropriate game.

He’s produced a full assembly video with some UFO Escape gameplay thrown in, shown here below the break.

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Everyman’s Turbomolecular Pump

April 9, 2016 by 61 Comments

What can you do with a very good vacuum pump? You can build an electron microscope, x-ray tubes, particle accelerators, thin films, and it can keep your coffee warm. Of course getting your hands on a good vacuum pump involves expert-level scrounging or a lot of money, leading [DeepSOIC] and [Keegan] to a great entry for this year’s Hackaday Prize. It’s the Everyman’s Turbomolecular Pump, a pump based on one of [Nikola Tesla]’s patents. It sucks, and that’s a good thing.

The usual way of sucking the atmosphere out of electron microscopes and vacuum tubes begins with a piston or diaphragm pump. This gets most of the atmosphere out, but there’s still a little bit left. To get the pressure down even lower, an oil diffusion pump (messy, but somewhat cheap) or a turbomolecular pump (clean, awesome, and expensive) is used to suck the last few molecules of atmosphere out.

The turbomolecular pump [DeepSOIC] and [Keegan] are building use multiple spinning discs just like [Tesla]’s 1909 patent. The problem, it seems, is finding a material that can be made into a disc and can survive tens of thousand of rotations per minute. It’s a very, very difficult build, and a mistake in fabricating any of the parts will result in a spectacular rapid disassembly of this turbomolecular pump. The reward, though, would be great. A cheap turbomolecular pump would be a very useful device in any hackerspace, fab lab, or workshop garage.

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Meet Cartesio, Robot Artist

April 9, 2016 by 4 Comments

[Robottini] released plans for his robot, Cartesio, that is essentially an Arduino-controlled plotter made to create artwork. The good part about Cartesio is the low cost. [Robottini] claims it cost about $60 to produce.

The robot has an A3-size drawing bed and is practically the XY part of a 3D printer. In fact, most of the parts are 3D printed and the mechanical parts including M8 smooth rod. LM8UU bearings, and GT2 belts and pulleys. If you’ve built a 3D printer, those parts (or similar ones) should sound familiar.

The Arduino uses GRBL to drive the motors from GCODE. [Robottini] has three different workflows to produce drawings from applications like Inkscape. You can see some of the resulting images below.

We’ve covered GRBL before, and it is the heart of many motion control projects. If you’d rather draw on something less permanent, you might try this project.

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