Ask Hackaday: Auto Bed Leveling And High Temperature Force Sensitive Resistors

March 19, 2014 by 39 Comments

FSR

[Johann] over on the RepRap wiki has an ingenious solution for making sure a borosilicate glass bed is completely level before printing anything on his Kossel printer: take three force sensitive resistors, put them under the build platform, and wire them in parallel, and connect them to a thermistor input on an electronics board. The calibration is simply a bit of code in the Marlin firmware that touches the nozzle to the bed until the thermistor input maxes out. When it does, the firmware knows the print head has zeroed out and can calculate the precise position and tilt of the bed.

Great, huh? A solution to bed leveling that doesn’t require a Z-probe, uses minimal (and cheap) hardware, and can be retrofitted into just about any existing printer. There’s a problem, though: these force sensitive resistors are only good to 70° C, making the whole setup unusable for anything with a heated bed. Your challenge: figure out a way to use this trick with a heated bed.

The force sensitive resistors used – here’s a link provided by [Johann] – have a maximum operating temperature of 70° C, while the bed temperature when printing with ABS is around 130° C. The FSRs are sensitive to temperature, as well, making this a very interesting problem.

Anyone with any ideas is welcome to comment here, on the RepRap forums, the IRC, or anywhere else. One idea includes putting an FSR in the x carriage, but we’re thinking some sort of specialized heat sink underneath the bed and on top of the FSRs would be a better solution.

Video of the auto bed leveling trick in action below.

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Massive LED Display Makes Use Of Reused Soda Bottles

March 19, 2014 by 15 Comments

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What better way to make a giant LED display than out of old empties and bottle crates? This is the Mate Light (pronounced Mah-Tay).

We were first introduced to the ever popular Club-Mate soda at one of the first hackerspaces we visited during our Hackerspacing in Europe Tour. It’s a soft drink produced in Germany, which seems to be the exclusive non-alcoholic drink of choice for almost all hackerspaces in Western Europe. The spaces in the Netherlands and Belgium would even make road trips to Germany just to load up a van with the drink to bring back home. Personally we didn’t really understand what was so special about it, but maybe we just didn’t drink enough!

Anyway, this impressive display makes use of 640 empties arranged in 4 rows of 8 crates for a decent 16 x 40 resolution. Each bottle is wrapped in aluminum foil and contains one RGB LED with a WS2801 driver. Each row of crates is connected to a TI Stellaris Launchpad, which has four hardware SPI interfaces — conveniently the number of rows of crates used! From there, an ancient ThinkPad T22 laptop runs the control program over USB to the microcontroller board. Their first software implementation used a Python script which was painfully slow — they’re now putting the finishing touches on using a C script instead.

Stick around to see the display in all of its awesomeness.

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Etching Designs Into Denim With A Laser Cutter

March 19, 2014 by 49 Comments

JeansEtchLaser

Finding new uses for your tools and equipment can be very exciting. [Foamy] wrote in to tell us about a blog post by [qbotics] that demonstrates etching designs into denim with a laser cutter. What a cool unexpected use for a laser cutter!

According to the Epilog laser cutter’s website, “we have engraved everything from denim to acrylic with fantastic results”. This inspired the author of “Science with denim” to try engraving jeans. After some experimentation,  [qbotics] found that setting the 75W laser cutter to 15% power at 100% speed worked best. The results are quite impressive; the engraved pattern looks like naturally faded jeans. Amazing.

In the past, we have seen lasers engrave everything from calculators to wood. We would be curious to see if some of the DIY laser cutters could engrave denim as well. Give it a try and tell us about it!

Mug Music Is Good To The Last Drop

March 19, 2014 by 6 Comments

[Bonnie] is majoring in CS at Princeton and minoring in Awesome. She is taking an electronic music class and had to produce a digital instrument for her midterm project. She and her friend [Harvest] came up with Mug Music, which turns a ceramic mug of water into an instrument.

The circuit is very easy to replicate with an Arduino, a coil, and a few resistors and capacitors. [Bonnie] wanted to experiment with Disney Research Lab’s Touché method of touch detection, and Mug Music is based on this Touché for Arduino Instructable. The inputs are turned into MIDI notes with ChucK, a real-time sound synthesis language developed at Princeton.

As you may have guessed and will see in the demonstration video after the jump, you aren’t limited to touching the water. The entire mug will produce sounds as well. [Bonnie] says you can trigger a thunderclap if you touch the water and a grounded surface simultaneously.

This would be a great project to explore with kids, especially as a music therapy vehicle for kids on the autism spectrum. It isn’t as physical as these portable musical stairs, but it may draw less attention from lawyers.

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GEVCU – An Open Generalized Electric Vehicle Control Unit

March 19, 2014 by 32 Comments

At Hackaday we’re very happy to see the increasing number of open hardware devices that appear everyday on the internet, and we’re also quite thrilled about open-source electric cars. Pictured above is the GEVCU, an open source electric vehicle control unit (or ECU). It is in charge of processing different inputs (throttle position, brake pressure, vehicle sensors) then send the appropriate control commands to electric motor controllers (aka inverters) via CAN bus messages or digital / PWM signals.

The project started back in December 2012 and was originally based on an Arduino Due. Since then, the GEVCU went through several revisions and ultimately a complete custom board was produced, while still keeping the Cortex M3 ATSAM3X8E from the Due. As you may have guessed, the board also includes a Wifi transceiver so users may adjust the ECU parameters via a web based platform. All resources may be downloaded from the official GitHub.

3D Printers Can Only Make Trinkets — What About Kayaks?

March 19, 2014 by 66 Comments

Wow. [Jim Smith] of Grass Roots Engineering has just put the finishing touches on his entirely 3D printed kayak. And it floats.

The individual parts were printed on [Jim’s] massive home-made 3D printer, which is loosely based off a RepRap — except that its maximum build volume is a whopping 403 x 403 x 322.7mm.

The kayak itself is made of 28 printed sections, and to hold it all together, he has installed brass threaded thermoplastic inserts, which then allow the pieces to be bolted together. Silicone caulking is applied before assembly to ensure a watertight seal.

It was originally based off of a Siskiwit Bay kayak by [Bryan Hansel] but [Jim] has heavily modified it to suit 3D printing. It was printed at a layer height of 0.65mm to reduce print time, which still ended up being over 1000 hours! He even optimized the design to improve performance based on his own height and weight.

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Prophet 600: A Classic Synthesizer Gets Processor Upgrade

March 18, 2014 by 20 Comments

proph-600

We love classic synthesizers here at Hackaday. So does [gligli], but he didn’t like the processor limitations of the Prophet 600. That’s why he’s given it a new brain in the form of a Teensy++. The Sequential Circuits Prophet 600 was a big deal when it was released back in 1982/1983. The 600 was the first commercially available synthesizer to include a MIDI interface. The original design of the 600 could be called a hybrid. A Zilog Z80 microprocessor controlled modular analog voice chips. The Z80 was a bit stressed in this configuration though, and a few limitations were evident. An 8 bit processor just wasn’t quite enough for software driven envelopes and a Low Frequency Oscillator (LFO) control. This was further exacerbated by the fact that everything was driven through a 14 bit DAC.

[gligli] discovered most of the limitations in the 600 were due to the processor. By beefing up the processing power he could really unlock the potential within 600. Since he didn’t actually have a Prophet 600, he started with the schematic. [gligli] created a PC based emulator for the digital circuits, learning the whole system as he worked. With that phase complete, [gligli] bought a used Prophet and started hacking. The Teensy++ required a few hardware mods to fill the Z80’s shoes, including cutting off a pin and adding a few jumper wires. We really like the fact that no changes to the Prophet 600 itself are required. Pull out the Teensy++, drop in the Z80, and you’re ready to party like it’s 1982 again.

The new processor interfaces directly with the Z80’s 8 bit bus. Since the AVR on the Teensy has built-in RAM and ROM, it simply ignores the ROM and RAM address spaces of the original system. Interfacing a fast micro with older parts like an 8253 timer and a 68B50 UART does have its pitfalls though. The system bus had to run slow enough to not violate timing requirements of the various peripheral chips. To handle this, [gligli] added a number of wait statements in his firmware. Once the system was working, [gligli] was free to start adding new features. He began by smoothing out the stepped envelope and filter generators, as well as adding new exponential modes. From there he added new keyboard polyphony modes as well as pitch and mod wheel changes. The full lineup of new features are listed in the instruction manual (PDF link). Since this is an open source project, adding a feature is as simple as cracking open your favorite editor and writing it up.

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