Cutting A Wearable Display In Half Is Harder And Simpler Than It Seems

October 16, 2022 by 6 Comments

In the world of hardware hacking, you sometimes spend a ridiculous amount of time debugging a problem, only to find a simple solution that was right in front of you the whole time. [Zack Freedman] got a good dose of this while building the Optigon V2, a modified Epson Moverio wearable display he uses as a teleprompter in all his videos. He prefers having the teleprompter over his left eye only, but the newer version of the Moverio would shut off both sides if one is disconnected, so [Zack] needed a workaround.

Looking for some help from above, [Zack] requested developer documentation for the display module from Epson, but got declined because he wasn’t a manufacturer or product developer. Luckily, a spec sheet available for downloaded from the Epson website did contain a lot of the information he needed. An STM32 monitored the temperature of each display module over a pair of independent I2C interfaces, and would shut down everything if it couldn’t connect to either. This led [Zack] to attempt to spoof the I2C signals with an ATmega328, but it couldn’t keep up with the 400 kHz I2C bus.

However, looking at the logs from his logic analyzer, [Zack] found that the STM32 never talked to both display modules simultaneously, even though it is capable of doing so. Both displays use the same I2C address, so [Zack] could simply connect the two I2C buses to each other with a simple interface board, effectively making the left display “spoof” the signals from the right display.

Wearable displays need some fancy optics to be practical, you can’t just stick an OLED to your face. Two other interesting projects from [Zack] are his modular mechanical keyboard and the Gridfinity 3D printed storage system.

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Automatic Flag Waver Lets You Show Your Loyalty Without Getting Tired

October 16, 2022 by 31 Comments

A flag is a great tool to show your loyalty to a country, a sports team or even a philosophical movement. But there’s not so much you can actually do with a flag: you can either hang it somewhere, or wave it around to attact others to your cause. [Mellow] found that waving quickly becomes tiresome, and decided to design a machine that automates this task for him.

A man holding a device that waves two small rainbow flagsNow there’s a bit more involved in designing a proper flag-waver than simply moving the flag back and forth. Ideally, the fabric should flow smoothly from side to side and show both sides equally, in the same way a human would do when waving a big flag around. After a bit of research [Mellow] decided on a design that generates a rather complex motion using just a single servo: the mast is tilted from left to right, while gravity ensures the flag rotates around its axis. It’s probably best demonstrated visually, as [Mellow] does in the video embedded below.

The flag-waving mechanism is designed in Fusion 360 and 3D printed using white filament. Inside a little square box is a Wemos D1 Mini, powered by a lithium battery scavenged from a vape pen, as well as a battery management system and a power switch. The servo sits on top of the box and holds the flag in a little socket that allows the mast to rotate freely. [Mellow] also went one step further and built a two-flag waver, which still uses only one servo but creates two opposite motions through a set of spur gears. Both waver types bring a lively atmosphere to their surroundings, and we can actually imagine them being useful in places like sports bars.

Automatic flag-wavers are still rare devices, and as far as we can tell this is only the second one we’ve seen, after this hat-mounted example. That is, if you don’t count the automatic “flag” on this mailbox.

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Ebike Charges In The Sun

October 16, 2022 by 38 Comments

Ebikes are slowly taking the place of many cars, especially for short trips. Most ebikes can take riders at least 16 kilometers (10 miles) without too much effort, at a cost that’s often a single-digit percentage of what the same trip would have been with an internal combustion engine. If you’re interested in dropping the costs of your ebike trips even further, or eliminating it entirely, take a look at this small ebike with integrated solar panels.

While any battery can be charged with a sufficiently large array of solar panels and the correct electronics to match the two systems together, this bike has a key that sets it apart from most others: it can charge while it is being used to power the bike. Most ebikes don’t have charging enabled during rides, so if you want to use the sun while riding to extend the range of the bike you’ll need to find one like this. This bike uses two 50 W panels on the two cargo areas of the bike, attached to a 400 W MPPT charge controller. The Lectric XP 2.0 ebike has a motor with a peak rating of 850 W, but in a low pedal-assist mode the solar panels likely output a significant fraction of the energy used by the electric drivetrain.

Even if the panels don’t provide the full amount of energy needed for riding around, the project’s creator [Micah] lives in Florida, so just setting the bike outside in the sun for six to eight hours is enough to replenish most of the battery’s charge. It’s probably not going to win any solar-powered bike races anytime soon, but for an efficient, quick bike to ride around town it’s not too shabby.

Laser Engraving, Up Close

October 15, 2022 by 11 Comments

You know you aren’t supposed to watch your laser while it is cutting or engraving. But [Alex] hosted Wired in his studio and showed them how lasers engrave metal with a fiber laser. You can see the video below.

If you haven’t used a fiber laser, you might be surprised that while a 60 W model can burn metal, it does absolutely nothing to [Alex’s] hand. We wouldn’t try that, by the way, with the common diode lasers you see in most hacker’s labs these days. The video isn’t terribly technical, but it is interesting to see different metals succumb to the powerful laser. There are a few tips about marking different metals in different ways and how to deal with thermal expansion and other effects.

Fiber lasers aren’t as common as diode engravers in private shops, but we assume it is just a matter of time before they get cheaper. Not to mention their widespread use commercially means surplus units might become available, too.

If you are interested in lasers, [Alex’s] YouTube channel has quite a few interesting videos to check out. If you need more power, how’s 200 kW? Then again, even 20 W will get you something useful.

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An LCD mounted inside a Roland synthesizer

Reverse-Engineering A Display Protocol To Repair A Roland Synthesizer

October 15, 2022 by 26 Comments

Repairing electronic devices isn’t as hard as it used to be. Thanks to the internet, it’s easy to find datasheets and application notes for any standard component inside your gadget, and once you’ve found the faulty one, you simply buy a replacement from one of a million web shops — assuming you don’t end up with a fake, of course. When it comes to non-standard components, however, things get more difficult, as [dpeddi] found out when a friend asked him for help in repairing a Roland Juno-G synthesizer with a broken display.

The main issue here was the fact that the display in question was a custom design, with no replacement or documentation available. The only thing [dpeddi] could figure out from the service manual was the basic pinout, which showed a parallel interface with two lines labelled “chip select” — an indication that the display contained two separate controllers. But the exact protocol and data format was not documented, so [dpeddi] brought out his logic analyzer to try and decode the signals generated by the synthesizer.

After a bit of trial and error, he was able to figure out the protocol: it looked like the display contained two KS0713-type LCD controllers, each controlling one half of the screen. Finding a compatible replacement was still proving difficult, so [dpeddi] decided instead to decode the original signals using a microcontroller and show the picture on a modern LCD driven by SPI. After some intial experiments with an ESP32, it turned out that the task of reading two reasonably fast parallel buses and driving an even faster serial one was a bit too much for the ESP, so [dpeddi] upgraded to a Raspberry Pi Pico. This worked a treat, and thanks to a 3D-printed mounting bracket, the new display also fit snugly inside the Roland’s case.

The Pico’s code is available on [dpeddi]’s GitHub page, so if you’ve also got a dodgy display in your Juno-G you can simply download it and use it to plug in a brand-new display. However, the method of reverse-engineering an existing display protocol and translating it to that of a new one is pretty universal and should come in handy when working with any type of electronic device: say, a vintage calculator or multimeter, or even another synthesizer.

A 3D Printed Ratchet That Can Really Take The Torque

October 15, 2022 by 5 Comments

Printed tools aren’t exactly known for their durability, but [Gladius] shows us that with some thoughtful design, it’s possible to print a ratcheting wrench that can handle surprising amounts of torque.

Look closely, and you can see that the parts are almost entirely made up of perimeters (click to enlarge).

This particular wrench is inspired by NASA’s 3D printed ratcheting wrench, and also from an early 1900s design. It sports a 1/2 inch square socket into which modern adapters can be fitted, allowing those steel parts to do their job while the wrench itself delivers the muscle.

[Gladius] found that the strongest results came from slicing parts — especially the handle — so that they come out consisting almost entirely of perimeters, with virtually no traditional infill. Want to know more? There’s a discussion on reddit where [Gladius] goes into added detail about measurements and performance.

Over the years, we’ve seen our share of powerful prints. For example, what the Crimson Axlef*cker can do looks downright intimidating. Speaking of printing things that move, we want to remind you about this handy tip for easily and reliably joining motor shafts to printed parts by (mis)using jaw couplings.

Organizational Inspiration From The Discount Tool Company

October 15, 2022 by 13 Comments

When in need of any tool to get a job done quickly, or only for a small number of times, it’s great to have a local “discount tool” company locally for some working, yet often low-quality solution to whatever problem might arise. While there are some gems, most of these tools won’t last through heavy, sustained use like their more expensive counterparts will. On the other hand, there are other things to be had at these discount shops, such as inspiration for tackling a storage problem.

This particular storage system comes from Harbor Freight, and uses a set linked crosshairs, the center of which is hollowed out. A set of movable compartments sits on top with feet that can interlock inside the crosshairs. This allows much more efficient use of space within the toolboxes, but [Alan] wanted it to be useful for more that that. He designed and implemented the Storage Case Base Template (SCBT) which allows for a container of any size to be fitted with a similar crosshair network.

With this non-proprietary system implemented and printed, the original goal of reducing the clutter in [Alan]’s workspace was accomplished. The 3D printing files can be modified easily for any space, and are available both on Thingiverse and Printables. For some other ways of packing a lot into a small space, we featured this tiny workshop a while back that’s packed with storage hacks.