Turn A Decommissioned Robot Into A CNC Machine

September 26, 2013 by 42 Comments

adeptRobot

Some of us may have been accused of living in Mom’s basement – [Benjamin] kicks it up a notch by keeping an industrial robot in his parent’s attic shed loft.
[Benjamin] was tasked with stripping down some retired equipment at work. It turns out the “retired equipment” was three Cartesian robots from Adept Robotics. These are large industrial XYZ platforms capable of high speed movements (3000 IPM rapids!).

Getting from a decommissioned machine to a working CNC is never a simple path. In this case [Ben] was able to make the transition relatively easily. Each axis of the robot has a 400 Watt Yaskawa servo with a 65k encoder and brake. The original Adept servo amps and control system was still working, so he kept it. The controllers were new enough that they communicate over a daisy chained IEEE1394 (Firewire) link. That is relatively modern compared to some of the conversions we’ve seen in the past.  The final piece of the puzzle was G-code creation Translating common G-code to a format his machine could recognize. Ben chose MeshCAM for the task.

One problem [Ben] ran into was stuttering on the X-axis. The original machines only had a single sided drive system on the X-axis. Single side is fine for an assembly machine that doesn’t see any tool load. However for a CNC machine that will see spindle loads, a single side drive creates a twisting force which threatens to rack the entire frame. He used one of the drive systems from his spare robot to convert his main machine to a double-sided drive, eliminating the issue.

Continue reading “Turn A Decommissioned Robot Into A CNC Machine” →

Breadboard Sequencer Does A Lot With Very Little Hardware

September 26, 2013 by 14 Comments

breadboard-sequencer

[Jan Cumpelik] squeezes a lot of performance out of very few components with his breadboard sequencer which he calls Lunchbeat. We really like his awesome breadboard which has a series of trenches perpendicular to the bus strips framing the long sides. All of our breadboards have just one trench down the middle. This, combined with his mad breadboard skills, results in a really clean prototype.

The chip nearest his hand is the ATmega328 which drives the sequencer. It takes inputs from that row of 10k trimpots as well as a series of tactile switches. Feedback is given with the row of eight LEDs. Those are driven from a 595 shift register to save pins on the microcontroller. The remaining chip is an OpAmp which works in conjunction with a 3-bit R2R ladder DAC to output audio. Turn your speakers down just a bit before taking in the demonstration below. There you will also find an image version of his schematic that we made for your convenience. It is only available as a PDF in the code repository he posted.

Continue reading “Breadboard Sequencer Does A Lot With Very Little Hardware” →

Opening Up The Settings In MakerWare

September 26, 2013 by 4 Comments

ProfTweak

[Rich Olson] really likes MakerWare and the Makerbot slicer – the software package that comes with every Makerbot – but sometimes he needs to change a few settings. Makerware doesn’t allow the user access to 90% of the setting for slicing and printing, so [Rich] did something about that. He came up with ProfTweak, a tool to change all the MakerWare slicing and printing parameters, giving him precise control over every print.

ProfTweak handles common settings changes such as turning the fan on or off, adjusting the filament diameter, changing feed rate options, and turning your infills into cats. It’s a handy GUI app that should work under Windows, OS X, and Linux, so if you’re running MakerWare right now, you can get up and running with this easily.

One thing [Rich] has been using his new software for is experimenting with alternative filaments. With his Makerbot, he’s able to print in nylon, the wood and stone PLAs, flex PLA, and PET. That’s a lot more material than what the Makerbot natively supports, so we have to give [Rich] some credit for that.

Fail Of The Week: Capturing Data From A Laser Rangefinder

September 26, 2013 by 44 Comments

fotw-laser-measuring-tape

We’re changing it up this week with a reverse engineering fail which [Itay] pointed out to us. A couple of years ago [Nate] over at Sparkfun agreed to help a friend with a project that required precise distance measurement. He knew that laser rangefinders are a good way to go and mentions their use in golfing and the building trades. He picked up this handheld version billed as a laser tape measure. He put up a valiant effort to reverse engineer the PCB in hopes of finding a hook for the measurement data.

Obviously his endeavor failed or we wouldn’t be talking about it in this column. But there’s a lot to learn about his methods, and a few of the comments associated with his original post help to shed light on a couple of extra things to try.

Continue reading “Fail Of The Week: Capturing Data From A Laser Rangefinder” →

Thecontrollerproject’s First Contest, With Prizes

September 26, 2013 by 22 Comments

contest-prizes

One of [Caleb]’s side projects before he left us was TheControllerProject, a place for controller and console modders to hook up with gamers with disabilities. Things must be hopping over there, because [Caleb] just announced his first contest, with prizes, even.

The goal of this contest is to make the trigger buttons on XBox and PS3 controllers able to be controlled from the top of the controller. This is a huge problem for gamers with disabilities, and no open system currently exists to solve this problem. If you can make some sort of mechanical device to turn shoulder-mounted buttons into top-mounted actuators, just host it somewhere and win a prize.

The prizes are an iFixit toolkit and magnetic mat. The first five people to send in a solution to the shoulder mounted button problem get this prize. Originally, [Caleb] thought about tearing apart these controllers and soldering extra buttons, but a snap-on mechanical solution is much easier to install.

If you design a solution to this problem, send it in (but send it to [Caleb] first!) and we’ll probably feature it too.

Continue reading “Thecontrollerproject’s First Contest, With Prizes” →

Self-balancing Arduino Does It Without An IMU

September 26, 2013 by 15 Comments

The miniscule size of this self-balancing robot makes it a cool project. It actually uses the motor and wheels from a small toy car. But when you look into how the balancing act is performed it gets way more interesting. The larger versions of this trick pretty much all use Inertial Measurement Units (IMUs) which are usually made up of an accelerometer and a gyroscopic sensor. This has neither.

The black PCB seen to the right of the robot is an IR reflectance sensor. It shines an IR led at the floor and picks up what reflects back. [Sean] added this hack because the gyro sensor he ordered hasn’t arrived yet. The board has a trimpot which is used to adjust the sensitivity. You have to tweak it until it stands on its own. See for yourself after the break.

Self balancing robot builds are a great way to teach yourself about Proportional-Integral-Derivate (PID) algorithms used in a lot of these projects.

Continue reading “Self-balancing Arduino Does It Without An IMU” →

Maxim App Note Reuses Lithium Ion Cells — Plus Extras

September 26, 2013 by 26 Comments

Now we don’t sit around reading application notes for fun. But if hard pressed we would have to admit that we do read quite a few of them even if the concepts aren’t currently on our project list. That’s because they’re a great way to learn stuff and for the most part the information within is trustworthy.

The latest one that we looked at is this Maxim app note 5681 on recycling Lithium-ion batteries. It’s more a reuse than a recycle but you get the point. If you have some Lithium-Ion cells left over from older equipment this resource delivers a lot of good information on how to use them to power something else.

Obviously they’re showing off their own hardware here, but that’s okay. The MAX8677A chips has a ton of features and can be had for $3-5 depending on your vendor. It automatically switches between powering your device from the battery, or from the charging source if connected. This allows you to source up to 500mA when connected to USB or 2A when charging from an external DC supply. There is also all of the protection you would normally want with a Li-ion setup, including temperature monitoring.

The catch is the not-so-hand-solderable QFN package. They’ve got a solution to this as well. The diagram on the right shows how to hand solder the chip — albeit with a hot air pencil — by drilling through the board to get at the ground pad from the underside of the PCB.

[Thanks Jaded and Amos]