Circular Saw To Table Saw Conversion

October 19, 2013 by 90 Comments

Corded circular saws are a dime-a-dozen at any old thrift store, yet table saws are a bit more of a costly investment — have you ever wondered if you could just make one out of a circular saw? [Matthias Wandel] did, and he just so happens to be very good at woodworking! He makes a lot of great woodworking videos to share on YouTube, and in his latest blog post, he shows us a rather elaborate way to convert a plain old circular saw, into a functional table saw.

While the concept seems simple, unless you do a lot of woodworking, you’ll probably marvel at how easily making things comes to [Matthias] — we know we did. By the end of the video he has a fully functional table saw that can raise and lower in height, and cut at different angles.

If you’re interested in making one yourself, he does a very thorough job explaining the process in his video — check it out after the break!

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Build A Sensorless Brushless DC Motor Controller

October 19, 2013 by 43 Comments

[Davide Gironi] shows us how to implement a sensorless brushless DC motor controller (sensorless BLDC) using an ATmega8 microcontroller. In order to control a BLDC motor you need to know its rotational sequence position and speed so you can calculate and apply the correct current phase sequence to the motor windings at just the right time.

Simply said, sensorless BLDC means you’re not using a purpose built sensor to determine the motor’s position and speed, however, you are sensing the motor’s sequence position using the back EMF signal coming from one of motor’s coils that is not currently receiving power. When this back EMF signal crosses zero voltage a microcontroller can calculate the rotational speed and when to switch to the next power sequence. This technique is not good for position control motors but is great for continuous motors like computer fans and drives were the slightly reduced wiring costs make this type of BLDC control favored.

If you want to build a BLDC controller we recommend starting with [Davide’s] last project on sensor controlled BLDC motors. You can also checkout these interactive demonstrations for more understanding on the different BLDC configurations.

Follow along after the break to watch the video demonstration of [Davide’s] sensorless BLDC controller controlling a motor from CD-ROM drive.

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Alas, Poor Yorick! I Tweeted Him

October 19, 2013 by 9 Comments

yoreck the talking skull

You know Halloween is coming around when the tweet reading skulls start popping up. [Marc] wanted to bring the Halloween spirit into his workplace, so he built “Yorick”. In case you’re worried, no humans were harmed (or farmed for parts) in the creation of this hack. Yorick started life as an anatomical skull model, the type one might find in a school biology lab. Yorick’s skull provided a perfect enclosure for not one but two brains.

A Raspberry Pi handles his higher brain function. The Pi uses the Twitter API to scan for tweets to @wedurick. Once a tweet is found, it is sent to Google’s translate server. A somewhat well-known method of performing text to speech with Google translate is the next step. The procedure is simple: sending “http://translate.google.com/translate_tts?tl=en&q=hackaday” will return an MP3 file of the audio. To get a British accent, simply change to google.co.uk.

The Pi pipes the audio to a speaker, and to the analog input pin of an Arduino, which handles Yorick’s lower brain functions.  The Arduino polls the audio in a tight loop.  An average of the last 3 samples is computed and mapped to a servo position. This results in an amazingly realistic and automatic mouth movement. We think this is the best part of the hack.

It wouldn’t’ be fair for [Marc] to keep the fruits of his labors to himself, so Yorick now has his own Livestream channel. Click past the break to hear Yorick’s opinion on the Hack A Day comments section! Have we mentioned that we love pandering?

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Blender CAM – Open Source CAM Software

October 19, 2013 by 13 Comments

[Vilem] sent in a tip about a plugin he’s been working on for Blender, called Blender CAM. It allows for exporting directly from Blender to a G-code file. He has been working on it for several months, and releasing regular updates with various tweaks and improvements. While the project isn’t complete, [Vilem] has made some very impressive progress. It currently supports 2D and 3D strategies, various cutter types, simulation of 3D operations, and even automatic bridges.

The image above was made using the plugin, and it shows the level of detail possible. We can’t wait to see the 4 and 5-axis support that he is planning on adding.

A basic tutorial video is embedded after the break. As with anything Blender-related, it isn’t incredibly automatic, but another free tool is definitely a good thing. It looks like [Vilem] is looking for some other developers who could help out. If you have the knowledge, you might consider contributing.

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Woodcut Stamps And Conductive Ink

October 18, 2013 by 43 Comments

circuit

Even though it’s been a while since the Rome Maker Faire, we’re still getting some tips from the trenches of Europe’s largest gathering of makers. One of these is a 30-minute experiment from [Luong]. He wondered if it would be possible to create SMD circuit boards by using a 3D printer to fabricate a stamp for conductive ink.

[Luong] told this idea  to a few folks around the faire, and the idea eventually wound up in the laps of the guys from TechLab. the Chieri, Italy hackerspace. They suggested cutting a wooden stamp using a laser cutter and within 30 minutes of the idea’s inception a completed stamp for an Atari Punk Console PCB was in [Luong]’s hands.

As an experiment, the idea was a tremendous success. As a tool, the stamp didn’t perform as well as hoped; the traces didn’t transfer properly, and there’s no way this wooden laser cut stamp could ever create usable PCBs.

That being said, we’re thinking [Luong] is on the right track here with printed PCBs. One of the holy grails of home fabrication is the creation of printed circuit boards, and even a partial success is too big to ignore.

This idea for CNC-created PCB stamps might work with a different material – linoleum or other rubber stamp material, or even a CNC milled aluminum plate. If you have any ideas on how to use this technique for PCB creation, leave a note in the comments, or better yet, try it out for yourself.

Quadruped Robot Thinks It’s A Puppy

October 18, 2013 by 12 Comments

puppybotBack at New York MakerFaire 2012, we noticed an amazing little steampunk quadruped robot walking around in the crowd outdoors. The robot was amazingly well executed, and had a unique ability to draw children over with it’s puppy like animations. It turns out this is [Drew’s] Little Walking Robot (AKA Puppy Bot).

Puppy Bot has actually been around for quite a while. He was born from the spare parts [Drew] had left over after competing in Robot Wars and Battlebots. The robots in these competitions were often controlled by Radio Control plane or car transmitters. Most of these systems are sold as packs for an RC car or plane. In addition to the transmitter and receiver, the pack usually included a battery and 3 or 4 servos. Standard RC servos were much too weak for use in battle robots, so they remained in his parts box.

On what [Drew] calls a slow weekend, he started putting the servos together, and ended up with a basic robot that could crawl around the room. After that the robot took on a life of its own. [Drew] improved the battery system, and added a microcontroller to automate the various gaits and animations. He brought the robot along with him to one of his battlebot competitions, and it took home the “Coolest Robot” award – even though it wasn’t actually competing!

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Rebuilding A 1940s TV

October 18, 2013 by 30 Comments

TV

There’s a lot of cool stuff to be found under piles of trash in an antique store. [dijt] discovered this when he found a tiny 7″ Motorola television from the 1940s under a stack of trinkets from earlier eras. We can understand [dijt]’s impulse buy, and the trials of rebuilding this ancient TV more than qualifies it as a hack.

If you know where to look, there are hundreds of resources available for old televisions, Hi-Fis, and radio equipment from the dawn of the electrical era to the modern day. After consulting with a few forums, [dijt] got his hands on a schematic for his television set and began work on diagnosing what was wrong with it.

It turned out the original ballast tube in this set had long since given up the ghost. Luckily, this is a common problem in old TVs, and after consulting some forums [dijt] had a schematic to replace this ballast tube with some newer caps and resistors.

After constructing the circuit and testing it out, [dijt] mounted it in the old ballast tube to replicate the original look and feel of the 1949 television. Interestingly, this is the second time this TV had been restored; the 1960s-era caps and resistors told [djit] this TV had once went into a television repair shop. Let’s just hope [djit] remembered to glue the schematics to the inside of the chassis this time.