Circuit Plotting With An HP Plotter

January 18, 2015 by 13 Comments

Over the last few years we’ve seen a few commercial products that aim to put an entire PCB fab line on a desktop. As audacious as that sounds, there were a few booths showing off just that at CES last week, with one getting a $50k check from some blog. [Connor] and [Feiran] decided to do the hacker version of a PCB printer: an old HP plotter converted to modern hardware with a web interface with a conductive ink pen.

The plotter in question is a 1983 HP HIPLOT DMP-29 that was, like all old HP gear, a masterpiece of science and engineering. These electronics were discarded (preserved may be a better word) and replaced with modern hardware. The old servo motors ran at about 1.5A each, and a standard H-Bridge chip and beefy lab power supply these motors were the only part of the original plotter that were reused. For accurate positioning, a few 10-turn pots were duct taped to the motor shafts and fed into the ATMega1284p used for controlling the whole thing.

One of the more interesting aspects of the build is the web interface. This is a small JavaScript app that is capable of drawing lines on the X and Y axes and sends the resulting coordinates from a server to the printer. It’s very cool, but not as cool as the [Connor] and [Feiran]’s end goal: using existing Gerber files to draw some traces. They’re successfully parsing Gerber files, throwing out all the superfluous commands (drills, etc), and plotting them in conductive ink.

The final iteration of hardware wasn’t exactly what [Connor] and [Feiran] had in mind, but that’s mostly an issue with the terrible conductivity of the conductive ink. They’ve tried to fix this by running the pen over each line five times, but that introduces some backlash. This is the final project for an electrical engineering class, so we’re going to say that’s alright.

Video below.

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3D Printed LED Guitar Chord Chart

January 18, 2015 by 12 Comments

Learning to play guitar can involve a lot of memorization – chords, scales, arpeggios, you name it. [MushfiqM] has made the process a bit easier with his Digital Chord Chart. Just about every beginning guitarist keeps a chord app, chord book, or even a chord poster handy. Usually these chord charts are in the form of tablature, which is a shorthand method of showing where each finger should go on the instrument. [MushfiqM] took things a step further by actually placing that chart on a 3D printed model of a guitar fretboard.

ledmatrixx[MushfiqM] started by rendering a 3D model of an abbreviated guitar using Autodesk Inventor. He then printed his creation in 3 parts: headstock, neck, and fretboard. The neck of the guitar was hollowed out to allow room for a matrix of LEDs which would show the finger positions. [MushfiqM] then painstakingly soldered in a charlieplexed matrix of 30 leds, all connected by magnet wire. The LEDs are controlled by an Arduino UNO, which has the chord and scale charts stored in flash.

For a user interface, [MushfiqM] used a 2×16 character based LCD and a low-cost IR remote control. All the user has to do is select a chord or scale, and it’s displayed on the fretboard.

There are a couple of commercial products out there which perform a similar function, most notably the Fretlight guitar. Those can get a bit pricy though – costing up to $400.00 USD for an LED enabled guitar.

[via Instructables]

Hackaday Retro Edition: Pen Computing

January 17, 2015 by 20 Comments

Although we’re well past the heyday of ‘pen computing’, and seemingly into a retro revival with laptops and tablets that come with Wacom styluses and digitizers, this doesn’t mean the pen computers of old weren’t useful. While they were mostly used for industrial applications, they were useful and some of the first practical applications of touch screen displays.

[Jason] got his hand on one of these ruggedized handheld PCs – specifically, an Itronix T5200. This three-pound mini notebook runs Windows CE Handheld PC Edition 3.01. The specs include a 74MHz RISC processor, 16 MB of RAM, 16MB of Flash, and a 7.3 inch monochrome touch screen with 640×240 resolution. It’s odd and old: when closed, it’s over two inches thick. You’ll be hard pressed to find a modern laptop that thick. [Jason]’s hardware is a pre-production version.

Unlike a lot of retro submissions that have somehow managed to pull up the Hackaday Retro Edition on old hardware, this machine actually has a browser. It’s old, it’s clunky, but it works. There are three options for getting this old computer up on the Internet – either IrDA, an RJ11 modem port, or RS232. [Jason] didn’t tell us which port he used to load up the retro edition, but he did send in a few pictures. You can check those out below.

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Handheld Linux Terminal Gets An A+

January 17, 2015 by 40 Comments

Are you all thumbs when it comes to Linux? If you follow [Chris]’s guide to building a handheld Linux terminal, that particular condition could work to your advantage. His pocket-sized machine is perfect for practicing command line-fu and honing your scripting skills on the go.

[Chris]’s creation is built around a Raspberry Pi A+ that he stripped to its essentials by removing the GPIO pins, HDMI and USB ports, the audio port, and the camera and display ports. It’s housed in a pair of plastic 2.5″ hard drive enclosures connected with a piano hinge, making it about the size of a Nintendo DS. The display is an Adafruit PiTFT touch screen and in order to save space, he soldered it directly to the Pi.

The 2.4GHz wireless thumb keyboard has all the special characters necessary for Linuxing, but the four USB ports from a dismantled hub provide flexibility. If [Chris] were to make another one, he might use this slightly larger screen from Tindie and add some charging ports to the case.

[Thanks for the tip, ar0cketman]

Arduino Reads Punch Cards

January 17, 2015 by 14 Comments

Punch cards were a standard form of program and data storage for decades, but you’d never know it by looking around today. Card punches and even readers are becoming rare and expensive. Sometimes it takes a bit of hacking [YouTube link] to get that old iron running again!

[Antiquekid3] managed to score an old punch card reader on Ebay, but didn’t have a way to interface with it. The reader turned out to be a Documation M-1000-L. After a bit of searching, [Antiquekid3] managed to find the manual [PDF link] on BitSavers. It turns out that the Documation reader used a discrete output for each row of data. One would think the Documation reader would be a perfect fit for the PDP-8 lurking in the background of [Antiquekid3’s] video, but unfortunately the ‘8 lacks the necessary OMNIBUS card to interface with a reader.

Undaunted, [Antiquekid3] threw some modern hardware into the mix, and used an Arduino Uno as a Documation to Serial interface. The Arduino had plenty of I/O to wire up with the card reader’s interface. It also had a serial interface which made outputting data a snap. The ATmega328 even had enough power to translate each card from one of IBM’s many keypunch formats to serial.

[Antiquekid3’s] test deck of cards turned out to be a floating point data set. Plotting the data with a spreadsheet results in a nice linear set of data points. Of course, no one knows what the data is supposed to mean! Want more punch card goodness? Check out this tweeting punch card reader, or this Arduino based reader which uses LEGO and a digital camera to coax the data from the paper.

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Husband Uses MRI Images To 3D Print Wife’s Skull And Tumor

January 17, 2015 by 35 Comments

[Michael Balzer] shows us that you are your own best advocate when it comes to medical care – having the ability to print models of your own tumors is a bonus. [Michael’s] wife, Pamela, had been recovering from a thyroidectomy when she started getting headaches. She sought a second opinion after the first radiologist dismissed the MRI scans of her head – and learned she had a 3 cm tumor, a meningioma, behind her left eye.  [Michael], host of All Things 3D, asked for the DICOM files (standard medical image format) from her MRI.  When Pamela went for a follow-up, it looked like the tumor had grown aggressively; this was a false alarm. When [Michael] compared the two sets of DICOM images in Photoshop, the second MRI did not truly show the tumor had grown. It had only looked that way because the radiologist had taken the scan at a different angle! Needless to say, the couple was not pleased with this misdiagnosis.

However, the meningioma was still causing serious problems for Pamela. She was at risk of losing her sight, so she started researching the surgery required to remove the tumor. The most common surgery is a craniotomy: the skull is sawed open and the brain physically lifted in order to access the tumor below it. Not surprisingly, this carries a high risk of permanent damage to any nerves leading to loss of smell, taste, or sight if the brain is moved the wrong way. Pamela decided to look for an alternative surgery that was less invasive. [Michael] created a 3D print of her skull and meningioma from her MRIs. He used InVesalius, free software designed to convert the 2D DICOM files into 3D images. He then uploaded the 3D rendered skull to Sketchfab, sharing it with potential neurologists. Once a neurologist was found that was willing to consider an alternative surgery, [Michael] printed the skull and sent it to the doctor. The print was integral in planning out the novel procedure, in which a micro drill was inserted through the left eyelid to access the tumor. In the end, 95% of the tumor was removed with minimal scarring, and her eyesight was spared.

If you want to print your own MRI or CT scans, whether for medical use or to make a cool mug with your own mug, there are quite a few programs out there that can help. Besides the aforementioned InVesalius, there is DeVIDE, Seg3D, ImageVis3D, and MeshLab or MeshMixer.

Twisted String Actuators

January 17, 2015 by 39 Comments

[Travis] tells us about a neat actuator concept that’s as old as dirt. It’s capable of lifting 7kg when powered by a pager motor, and the only real component is a piece of string.

The concept behind the twisted string actuator, as it’s known to academia, is as simple as putting a motor on one end of a piece of string, tying the other end off to a load, and putting a few twists in the string. It’s an amazingly simple concept that has been known and used for thousands of years: ballistas and bow-string fire starters use the same theory.

Although the concept of a twisted string actuator is intuitively known by anyone over the age of six, there aren’t many studies and even fewer projects that use this extremely high gear ratio, low power, and very cheap form of linear motion. A study from 2012 (PDF) put some empirical data behind this simple device. The takeaway from this study is that tension on the string doesn’t matter, and more strands or larger diameter strands means the actuator shrinks with a fewer number of turns. Fewer strands and smaller diameter strands take more turns to shrink to the same length.

As for useful applications of these twisted string actuators, there are a few projects that have used these systems in anthropomorphic hands and elbows. No surprise there, really; strings don’t take up much space, and they work just like muscles and tendons do in the human body.

Thanks [ar0cketman] for the link.