A Gloriously Impractical Electromechanical Display

December 19, 2017 by Tom Nardi 28 Comments

For this year’s office holiday party, [Gavan Fantom] wanted to do something really special. Coworkers were messing with LEDs to come up with displays and decorations, but they lack that old-school feel of mechanical displays. He wanted to create something that had retro look of moving elements, but didn’t want to just recreate the traditional flip mechanism we’ve all seen over and over.

The mechanism to drive a single “pixel”.

What [Gavan] came up with is breathtakingly impractical 8×8 display that sounds as cool as it looks. Each “pixel” in the display is a 3D printed screw mechanism rotated by a hobby servo. As the pixel is rotated in its case, it becomes progressively more visible to the observer. The opacity of the pixel can even be adjusted by varying the degree of rotation, allowing for rudimentary display of grayscale images.

Each element in the display is made up of seven 3D printed parts and two nails, which the mechanism slides on to move forward and backward. An 8×8 display needs 64 elements, which means the entire display needs 64 servos, 128 nails, and a whopping 448 3D-printed parts. Even with two printers attacking the production in parallel, the printing alone took over two weeks to complete.

The display is powered by a Raspberry Pi and three “Mini Maestro” controllers which can each handle 24 servos. [Gavan] found some sample code in Python to pass commands to the Maestro servo controllers, which he used as a template when writing his own software. The Python script opens image files, converts them to grayscale, and then maps the value of each pixel to rotation of the corresponding servo. He says the software is a little rough and that there’s still some calibration to be done, but we think the results are phenomenal so far.

Mechanical displays are a favorite of hackers, due in no small part to the awesome noises they make while in operation. While we’ve seen some very creative approaches to this type of display before, what [Gavan] has created here is certainly in a league of its own.

Continue reading “A Gloriously Impractical Electromechanical Display” →

Geocache Locator Is The Gift That Keeps On Giving

December 18, 2017 by Tom Nardi 5 Comments

Depending on how you look at things, the holidays could be seen as either an excuse to spend money or an excuse to get creative. We imagine many Hackaday readers would rather head to their workbench than the mall when it comes time for gift giving, and [Sean Hodgins] is no different. He came up with the idea of hiding geocaches around his nephew’s neighborhood and building him a locator device to find them. The locator itself is intended to grow with his nephew, allowing him to reprogram it or use its parts for something completely different down the road.

The main components tucked inside of the 3D printed case of the locator are an Adafruit Trinket, a GPS receiver, and a compass module. The Adafruit NeoPixel Ring is of course front and center, serving as the device’s display. To power the device there’s an old battery, a LiPo charger circuit, and a 5V converter.

One of the goals for the project was that it could be constructed out of things [Sean] already had laying around, so some concessions had to be made. The Trinket ended up having too few pins, the compass lacks an accelerometer, and the switches and buttons are a bit clunky for the build. But in the end it comes together well enough to get the job done, and at least he was able to clear some stuff out of his parts bins.

To allow its owner to disassemble and potentially rebuild it into something else later, no soldered joints were used in the construction of the locator. Everything is done with jumper wires, which lead to some interesting problem solving such as using a strip of pin header as a bus bar of sorts. A bit of heat shrink over the bundle holds everything together and prevents shorts.

Location-aware gadgets happen to be an extremely popular gift choice among the hacker crowd. We’ve covered everything from devices cobbled together from trash to hardware which could pass for a commercial product.

Continue reading “Geocache Locator Is The Gift That Keeps On Giving” →

Machined Lightsaber Pen For A More Civilized Age

December 18, 2017 by Tom Nardi 13 Comments

In an increasingly paperless society, writing implements are becoming an obsolete technology for many of us. Certainly not the kind of thing the average person would think to spend more than a couple bucks on, to say nothing of machining one out of a solid piece of aluminum bar stock. But clearly [Bob] is not most people. He recently dropped us a line about a video he uploaded to his aptly-named YouTube channel “Making Stuff”, where he goes through the steps required to turn raw materials into a writing instrument worthy of a Jedi.

Starting with a piece of aluminum chucked up in the lathe, [Bob] cuts out the iconic ribbed profile of Luke’s saber and fills in the gaps with nothing more exotic than a black Sharpie. He then moves on to the more complex shape of the emitter, and then flips the handle over in the lathe and hollows it out so a brass tube can be inserted.

Somewhat surprisingly, it seems more effort ends up being put into the acrylic “blade” than the aluminum handle itself. A chunk of acrylic is drilled and tapped so that it can be mounted in the chuck, and then turned down into a long cylinder. A tip is then cut in the end, the length of the blade is hollowed out, and finally it gets polished up to a nice shine.

The build is completed by inserting a standard ink pen cartridge down the center of the now completed saber. Surely the pen aficionados will lament that he didn’t attempt to build his own ink cartridge as well, but we think he gets a pass considering the rest of it was made from scratch.

If even a glorious writing instrument such as this isn’t enough to get you to re-learn how to write your name, fear not. Whether you’re making music or capturing flags, we’ve played home to numerous other saber projects; eye-safe or otherwise.

Continue reading “Machined Lightsaber Pen For A More Civilized Age” →

DIY Cable Chain Looks Great, Stays Cheap

December 17, 2017 by Tom Nardi 50 Comments

If you’ve built a 3D printer, CNC, laser cutter, or basically any piece of electrical equipment that moves around, then you’ve run into the problem of securing the bundle of wires that such machines always require. The easy way out is to zip tie them all up into a tight harness or put them in commercially available wraps or sleeves, but these don’t really impart any mechanical strength on the wires. With repetitive motion it’s not unheard of to break a conductor or two, causing intermittent failures and generally leading to a painful diagnostic session trying to isolate the broken wire.

An alternative are what are generally referred to as “cable chains”. These are rigid enclosures for your wiring that not only keep things tidy, but give the wires the mechanical support necessary to prevent fatigue. Unfortunately, they are often many times more expensive than a simple wire wrap or pack of zip ties. But [Brad Parcels] has written into our tip line to share with us a sort of hybrid approach to wire management that has many of the same advantages as a traditional cable chain, but at a greatly reduced cost.

The key to the design is using the metallic tape from a cheap tape measure to give the bundle of wires some mechanical strength. As anyone who’s ever played around with a tape measure knows, if you bend the tape over into a U shape it will hold the bend even if you extend and retract it. Thanks to this principle, [Brad] realized that all he need to do was add some wire sleeves and he would have a cheap and effective way to keep his wiring neat and sag-free.

[Brad] punches holes in the tape to secure it to his 3D printed mounting arms, but really any method of securing the tape to the frame of your machine will work just as well. He then slides a cable sleeve over the tape itself to protect from any possibility of the edge of the tape nicking a wire, and then finally a larger wire sleeve over the entire assembly.

After running the wires between the two sleeves, heatshrink can be used on the ends to neatly close everything up. Just make sure you remember all your wires before you seal it, [Brad] learned that one the hard way. But overall, he reports this DIY cable chain arrangement has been working wonderfully in his machine, providing smooth and silent movement for only a few bucks.

Cable management for projects that move is one of those things that doesn’t always get the attention it deserves. Not only can it keep your project looking professional, but it just might save you some time down the road by preventing failures.

Final Project For Better Sleep

December 17, 2017 by Michael Uttmark 14 Comments

It’s that time of year again, and students around the world are scrambling (or have already scrambled) to finish their final projects for the semester. And, while studying for finals prevents many from sleeping an adequate amount, [Julia] and [Nick] are seeking to maximize “what little sleep the [Electrical and Computer Engineering] major allows” them by using their final project to measure sleep quality.

To produce a metric for sleep quality, [Julia] and [Nick] set out to measure various sleep-related activities, specifically heart rate, motion and breath frequency. During the night, an Arduino Nano mounted to a glove collects data from the various sensors mounted to the user, all the while beaming the data to a stationary PIC for analysis and storage. When the user awakes, they can view their sleep report on a TFT display at the PIC base station. Ideally, users would use this data to test different habits in order to get the best nights sleep possible.

Interestingly, the group chose to implement their own heart rate sensor. With an IR transmitter, IR phototransistor and an OP amp, the group illuminates user’s fingers and measure reflection to detect heartbeats. This works because the amount of IR reflected from the user’s finger changes with blood pressure and blood oxygen level, which also happen to change when the heart is beating. There were some bumps along the road when it came to the heartbeat sensor (the need to use a finger instead of the wrist forced them to use a glove instead of a wristband), but we think it’s super cool and totally worth it. In addition to heart rate, motion is measured by an accelerometer and breath is measured by a flex sensor wrapped around the user’s chest.

With all of their data beamed back by a pair of nRF24L01s, the PIC computes the sleep “chaos” which is exactly what it sounds like: it describes just how chaotic the user slept by looking for acyclic and sudden movement. Using this metric, combined with information from breathing and heart rate, the PIC computes a percentage for good sleep where 100% is a great night and 0% means you might have been just as well off pulling an all-nighter. And, to top it all off, the PIC saves your data to an SD card for easy after-the-fact review.

The commented code that powers the project can be found here along with a parts list in their project write-up.

This device assumes that sleeping is the issue, but if waking up if your problem, we’ve already got you covered, aggressive alarm clock style. For those already on top of their sleep, you might want some help with lucid dreaming.

Video of the project explained by [Julia] and [Nick] after the break.

Continue reading “Final Project For Better Sleep” →

If 3D Printer, Then Custom Aluminum Extrusion Brackets

December 16, 2017 by Donald Papp 63 Comments

Aluminum extrusions are a boon for mechanical assemblies, but they require a stock of brackets and other hardware to be kept on hand. [mightynozzle] has decided to make things a little easier for prototyping and low-stress assemblies by creating a collection of 3D printable brackets for aluminum extrusions. 3D printing your own bracket hardware means faster prototyping, and if the assemblies don’t need the extra strength and rigidity of metal brackets you can just stick with the 3D printed versions.

The files are on Thingiverse, and include STL files of common brackets as well as an OpenSCAD script for customizing. Not familiar with OpenSCAD? No problem, we have a quick primer with examples.

This project showcases two things well. The first is that while brackets are not particularly expensive or hard to obtain, it can still be worth 3D printing them to reduce the overall amount of hardware one needs to keep on hand to make prototyping faster. The other is that 3D printing can shine when it comes to the creation of things like brackets: a few dimes’ worth of plastic can be turned into precise yet geometrically simple objects that would be a pain to make by other means. It certainly beats sitting on one’s hands waiting for parts to be delivered.

Statistics And Hacking: A Stout Little Distribution

December 13, 2017 by Sean Boyce 18 Comments

Previously, we discussed how to apply the most basic hypothesis test: the z-test. It requires a relatively large sample size, and might be appreciated less by hackers searching for truth on a tight budget of time and money.

As an alternative, we briefly mentioned the t-test. The basic procedure still applies: form hypotheses, sample data, check your assumptions, and perform the test. This time though, we’ll run the test with real data from IoT sensors, and programmatically rather than by hand.

The most important difference between the z-test and the t-test is that the t-test uses a different probability distribution. It is called the ‘t-distribution’, and is similar in principle to the normal distribution used by the z-test, but was developed by studying the properties of small sample sizes. The precise shape of the distribution depends on your sample size. Continue reading “Statistics And Hacking: A Stout Little Distribution” →