BLDC wire winding machine

Making A Brushless DC Motor Winding Machine

Over on his YouTube channel our hacker [Yuchi] is building an STM32 BLDC motor winding machine.

This machine is for winding brushless motors because manual winding is highly labor intensive. The machine in turn is made from four brushless motors. He is using the SimpleFOC library to implement closed-loop angle control. Closed-loop torque control is also used to maintain correct wire tension.

The system is controlled by an STM32G431 microcontroller. The motor driver used is the DRV8313. There are three GBM5208 75T Gimbal motors for close-loop angle control, and one BE4108 60T Gimbal motor for torque control. The torque control motor was built with this machine! [Yuchi] says that the Gimbal motors used are designed to be smooth, precise, and powerful at low speeds.

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A DIY Version Of The Franck-Hertz Experiment

The Franck–Hertz experiment was a pioneering physics observation announced in 1914 which explained that energy came in “packets” which we call “quanta”, marking the beginning of quantum physics. Recently, [Markus Bindhammer] wrote in to let us know he had redone the experiment for himself.

In the original experiment a mercury vacuum tube was used, but in his recreation of the experiment [Markus] uses a cheaper argon tube. He still gets the result he is looking for though, which is quite remarkable. If you watch the video you will see the current readings clump around specific voltage levels. These voltage levels indicate that energy is quantized, which was a revolutionary idea at the time. If you’re interested in how contemporary physics regards, particles, waves, and quanta, check out this excellent presentation: But What Actually Is a Particle? How Quantum Fields Shape Reality.

Before closing we have to say that the quality of [Markus]’s build was exceptional. He made a permanent enclosure for his power supplies, made custom PCBs, used ferrule crimps for all his wire interconnects, included multiple power switches and dials, professionally labeled and insulated everything, and even went to the trouble of painting the box! Truly a first class build. One thing that surprised us though was his use of rivets where we would almost certainly have used bolts or screws… talk about confidence in your workmanship!

If you’re interested in quantum physics it is certainly a topic we have covered here at Hackaday. Check out Quantum Mechanics And Negative Time With Photon-Atom Interactions or Shedding Light On Quantum Measurement With Calcite.

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Balancing Robot Gallery

Cube Teeter Totter: One Motor, Many Lessons

Balancing robots are always fun to see, as they often take forms we’re not used to, such as a box standing on its corner. This project, submitted by [Alexchunlin], showcases a cool single motor reaction cube, where he dives into many lessons learned during its creation.

At the outset, [Alexchunlin] thought this would be a quick, fun weekend project, and while he achieved that, it took longer than a weekend in the end. The cube’s frame was a simple 3D print with provisions to mount his MotorGo AXIS motor controller. This motor controller was initially designed for another project, but it’s great to see him reuse it in this build.

Once the parts were printed and assembled, the real work began: figuring out the best way to keep the cube balanced on its corner. This process involved several steps. The initial control code was very coarse, simply turning the motor on and off, but this didn’t provide the fine control needed for delicate balancing. The next step was implementing a PID control loop, which yielded much better results and allowed the cube to balance on a static surface for a good amount of time. The big breakthrough came when moving from a single PID loop to two control loops. In this configuration, the PID loop made smaller adjustments, while another control loop focused on the system’s total energy, making the cube much more stable.

By the end of the build, [Alexchunlin] had a cube capable of balancing in his hand, but more importantly, it was a great learning experience in controls. Be sure to visit the project page for more details on this build and check out his video below, which shows the steps he took along the way. If you find this project interesting, be sure to explore some of our other featured reaction wheel projects.

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Expanding rack structure

Expanding Racks In The Spirit Of The Hoberman Sphere

If you’re a mechanical engineering wonk, you might appreciate this latest video from [Henry Segerman] wherein he demonstrates his various expanding racks.

[Henry] explains how the basic “double-rack” unit can be combined to make more complex structures. These structures are similar in spirit to the Hoberman sphere, which is a compact structure that can be expanded to fill a large space.

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Mousa rotary dial and circuit

Adapting An Old Rotary Dial For Digital Applications

Today in old school nostalgia our tipster [Clint Jay] wrote in to let us know about this rotary dial.

If you’re a young whippersnapper you might never have seen a rotary dial. These things were commonly used on telephones back in the day, and they were notoriously slow to use. The way they work is that they generate a number of pulses corresponding to the number you want to dial in. One pulse for 1, two pulses for 2, and so on, up to nine pulses for 9, then ten pulses for 0.

We see circuits like this here at Hackaday from time to time. In fact, commonly we see them implemented as USB keyboards, such as in Rotary Dial Becomes USB Keyboard and Rotary Dialer Becomes Numeric Keypad.

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Back to the Future Lunchbox Cyberdeck

Back To The Future Lunchbox Cyberdeck

Our hacker [Valve Child] wrote in to let us know about his Back to the Future lunchbox cyberdeck.

Great Scott! This is so awesome. We’re not sure what we should say, or where we should begin. A lot of you wouldn’t have been there, on July 3rd, 1985, nearly forty years ago. But we were there. Oh yes, we were there. On that day the movie Back to the Future was released, along with the hit song from its soundtrack: Huey Lewis & The News – The Power Of Love.

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A Steady Vacuum For The Fastest Cassette Tape Drive Ever

If you think of a 1960s mainframe computer, it’s likely that your mental image includes alongside the cabinets with the blinkenlights, a row of reel-to-reel tape drives. These refrigerator-sized units had a superficial resemblance to an audio tape deck, but with the tape hanging down in a loop either side of the head assembly. This loop was held by a vacuum to allow faster random access speeds at the head, and this fascinates [Thorbjörn Jemander]. He’s trying to create a cassette tape drive that can load 64 kilobytes in ten seconds, so he’s starting by replicating the vacuum columns of old.

The video below is the first of a series on this project, and aside from explaining the tape drive’s operation, it’s really an in-depth exploration of centrifugal fan design. He discovers that it’s speed rather than special impeller design that matters, and in particular a closed impeller delivers the required vacuum. We like his home-made manometer in particular.

What he comes up with is a 3D printed contraption with a big 12 volt motor on the back, and a slot for a cassette on the front. It achieves the right pressure, and pulls the tape neatly down into a pair of loops. We’d be curious to know whether a faster motor such as you might find in a drone would deliver more for less drama, but we can see the genesis of a fascinating project here. Definitely a series to watch.

Meanwhile, if your interest extends to those early machine rooms, have a wallow in the past.

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