Mixed Mode Bench PSU Delivers High Performance

If you have an electronics bench, it follows that you will need some form of bench power supply. While many make do with fixed-voltage supplies it’s safe to say that the most useful bench power supplies have variable voltage and a variable current limiter. These are available in a range of sizes and qualities, and can be had from the usual online suppliers starting with a surprisingly small outlay.

There is however a problem with inexpensive bench power supplies. They are invariably switch-mode designs, and their output will often be noisy. Expensive linear supplies provide a much more noise-free output, but do so at the expense of excessive heat loss when regulating a high voltage drop.

One solution is a mixed-mode design, in which a switch-mode supply does the hard work of reducing the voltage most of the way, and a linear regulator drops the last couple of volts to provide a noise-free output. [Andrei] shows us his design for just such a mixed-mode supply, and it’s one you can have a go at building yourself.

His primary supply is an off-the-shelf switcher that turns mains AC into 24 V DC. This then feeds an LTC1624 buck converter that brings the voltage down to about 1.2 V above the final output voltage, this is in turn fed to a parallel pair of LT3081 linear regulators that deliver the final noise-free output. There is an INA260 for voltage and current measurement, and an Arduino with LCD display as a user interface. His prototype has been nicely constructed using a four-layer PCB, though he suggests it could be made on stripboard with the appropriate SMD adaptors. The cardboard chassis he’s used looks slightly alarming though.

We’ve covered numerous bench power supplies here over the years here at Hackaday. If it is an author’s favourite you are seeking though, take a look at the 723.

Hacked Car Axle Yields Custom 90° Gearbox

Need a sturdy angle gearbox to handle power transmission for your next big project? Why not harvest a rear axle from a car and make one yourself?

When you think about it, the axle of a rear-wheel drive vehicle is really just a couple of 90° gearboxes linked together internally, and a pretty sturdy assembly that’s readily available for free or on the cheap. [Donn DIY]’s need for a gearbox to run a mower lead him to a boneyard for the raw material. The video below shows some truly impressive work with that indispensable tool of hardware hackers, the angle grinder. Not only does he amputate one of the half axles with it, he actually creates almost perfect splines on the remaining shortened shaft. Such work is usually done on a milling machine with a dividing head and an end mill, but [DonnDIY]’s junkyard approach worked great. Just goes to show how much you can accomplish with what you’ve got when you have no choice.

We’re surprised to not see any of [DonnDIY]’s projects featured here before, as he seems to have quite a body of hacks built up. We hope to feature some more of his stuff soon, but in the meantime, you can always check out some of the perils and pitfalls of automotive differentials.

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A Magic Light Bulb For All Your Bright Ideas

[Uri Shaked]’s lamentation over the breaking of his smart bulb was brief as it was inspiring — now he had a perfectly valid excuse to hack it into a magic light bulb.

The first step was disassembling the bulb and converting it to run on a tiny, 130mAh battery. Inside the bulb’s base, the power supply board, Bluetooth and radio circuits, as well as the LED board didn’t leave much room, but he was able to fit in 3.3V and 12V step-up voltage regulators for the LiPo battery.

[Shaked]’s self-imposed bonus round was to also wedge a charging circuit — which he co-opted from a previous project — into the bulb instead of disassembling it every time it needed more juice. Re-soldering the parts together: easy.  Fitting everything inside a minuscule puzzle-box: hard. Kapton tape proved eminently helpful in preventing shorts in the confined space.

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Big Slew Bearings Can Be 3D Printed

Consider the humble ball bearing. Ubiquitous, useful, and presently annoying teachers the world over in the form of fidget spinners. One thing ball bearings aren’t is easily 3D printed. It’s hard to print a good sphere, but that doesn’t mean you can’t print your own slew bearings for fun and profit.

As [Christoph Laimer] explains, slew bearings consist of a series of cylindrical rollers alternately arranged at 90° angles around an inner and outer race, and are therefore more approachable to 3D printing. Slew bearings often find application in large, slowly rotating applications like crane platforms or the bearings between a wind turbine nacelle and tower. In the video below, [Christoph] walks us through his parametric design in Fusion 360; for those of us not well-versed in the app, it looks a little like magic. Thankfully he has provided both the CAD files and a selection of STLs for different size bearings.

[Christoph] is no stranger to complex 3D-printable designs, like his recent brushless DC motor or an older clock build. The clock is cool, but the bearings and motors really get us — we’ll need such designs to get to self-replicating machines.

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Electronics That Can Handle The Pressure

Deep-sea exploration is considered as a relatively new area of research and the electronics involved has to be special in order to survive some of the deepest parts of the ocean. Pressure Tolerant Electronics is a new subject and has its own challenges as explained by [Nic Bingham] of the Schmidt Ocean Institute.

[Nic Bingham] was one of the speakers at the Supplyframe office for ‘The Hardware Developers Didactic Galactic’ held April 20th 2017. His talks was based on his experience with ambient-pressure electronics and autonomous solar-diesel power plants at the Antarctic plateau. Due to high pressures at large depths, the selection of components becomes critical. Low density components such as electrolytic capacitors have either air or fluids which are susceptible to compression under water and prone to damage. Since pressure tolerance is not part of most datasheet figures, component selection becomes difficult and subject to prior testing.

There are other challenges as well as [Nic Bingham] explains that revolve around the procurement of special parts as well as spare for older components. In his whitepaper, [Nic Bingham] chalks out everything from the development process to different testing methodologies and even component selection for such applications.

A video of his talk is worth a watch along with the nice writeup by [Chris Gammell] on his first hand experience of the lecture. For those who are looking for something on a budget, the underwater glider project is a good start. Continue reading “Electronics That Can Handle The Pressure”

Helix Display Brings Snake Into Three Dimensions

Any time anyone finds a cool way to display in 3D — is there an uncool way? — we’re on board. Instructables user [Gelstronic]’s method involves an array of spinning props to play the game Snake in 3D.

The helix display consists of twelve props, precisely spaced and angled using 3D-printed parts, each with twelve individually addressable LEDs. Four control groups of 36 LEDs are controlled by the P8XBlade2 propeller microcontroller, and the resultant 17280 voxels per rotation are plenty to produce an identifiable image.

In order to power the LEDs, [Gelstronic] used wireless charging coils normally used for cell phones, transferring 10 W of power to the helix array.  A brushless motor keeps things spinning, while an Arduino controls speed and position via an encoder. All the links to the code used are found on the project page, but we have the video of the display in action is after the break.

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Mitosis: Anatomy Of A Custom Keyboard

Ergonomic. Wireless. Low-latency. Minimalist. Efficient. How far do you go when you design your own open-source keyboard? Checking off these boxes and providing the means for others to do so, Redditor [reverse_bias] presents the Mitosis keyboard, and this thing is cool.

The custom, split– as the namesake implies — mechanical keyboard has 23 keys on each 10 cm x 10 cm half, and, naturally, a custom keymapping for optimal personal use.

Upper and lower PCBs host the keys and electronic circuits respectively, contributing to the sleek finished look. Key caps and mechanical switches were ripped from sacrificial boards: two Waveshare core51822 Bluetooth modules are used for communication, with a third module paired with a Pro Micro make up the receiver. Continue reading “Mitosis: Anatomy Of A Custom Keyboard”