OpenPLC, For Industrial Automation To Halloween Displays

October 27, 2012 by Brian Benchoff 27 Comments

Stepping out onto just about any factory floor you’ll find complex automatons building anything and everything imaginable. These machines need to be controlled somehow and before the age of computers these manufacturing robots were controlled with relays wired together to produce a multitude of actions. Relays, no matter how reliable and bulletproof the are, can’t be programmed without rewiring the entire machine. Now, factories have programmable logic controllers to take care of their automation tasks.

[Thiago] built his own programmable logic controller and released it as open hardware.Included in the OpenPLC are four 24V inputs, four 24V outputs (two with PWM), 0-10V analog inputs, and USB, SPI, and I2C for programming and expansion.

If you’re building anything from an industrial machine in your garage, or simply want really awesome Halloween (or Christmas) decorations, the OpenPLC can take care of driving all the solenoids, motors, and actuators needed. With the extendable I2C and SPI busses, it’s possible to add a plethora of sensors to bring a project to life.

The OpenPLC is based on an ATMega328 and is compatible with Arduino code. There are a few extension boards for digital and analog IO, as well as Ethernet.

Fixing A First Generation GuruPlug’s Cooling Problems

October 25, 2012 by Mike Szczys 6 Comments

[Doragasu] had been using a hacked Xbox as his file server but upgraded to a single board Linux device when the GuruPlug was released. Unfortunately the first run of these devices had an overheating issue, which resulted in reboots even at moderate CPU load. The design was changed from a passively cooled heat sink to an internal fan, but that didn’t really help those who already had one of the early models. Above is [Doragasu’s] method of cooling down the overheating computer.

The original sink — which was really just a fin-less metal plate — was removed and replaced with a proper heat sink. This makes contact with the ARM, RAM, and Ethernet chips. They were all coated with thermal compound before installation and a silent fan was added to help whisk away the heat. This still fits inside of the original case, but to make way he did remove the original power source and cut a hole to allow for air movement.

The post also details an external LCD screen used to display system information. It’s along the same lines as this USB LCD screen project which inspired him to send us a link to the project.

Graphing The Efficiencies Of LED Light Strips

October 23, 2012 by Brian Benchoff 35 Comments

After adding a few LED light strips above his desk, [Bogdan] was impressed with the results. They’re bright, look awesome, and exude a hacker aesthetic. Wanting to expand his LED strip installation, [Bogdan] decided to see if these inexpensive LED strips were actually less expensive in the long run than regular incandescent bulbs. The results were surprising, and we’ve got to give [Bogdan] a hand for his testing methodology.

[Bogdan]’s test rig consists of a 15 cm piece of the LED strip left over from his previous installation. A Taos TSL2550 ambient light sensor is installed in a light-proof box along with the LED strip, and an AVR microcontroller writes the light level from the sensor and an ADC count (to get the current draw) of the rig every 6 hours.

After 700 hours, [Bogdan]’s testing rig shows some surprising results. The light level has decreased about 12%, meaning the efficiency of his LED strip is decreasing. As for projecting when his LEDs will reach the end of their useful life, [Bogdan] predicts after 2200 hours (about 3 months), the LED strip will have dropped to 70% of their original brightness.

Comparing his LED strip against traditional incandescent bulbs – including the price paid for the LED strip, the cost of powering both the bulb and the strip, the cost of the power supply, and the time involved in changing out a LED strip, [Bogdan] calculates it will take 2800 hours before cheap LEDs are a cost-effective replacement for bulbs. With a useful life 600 hours less than that, [Bogdan] figures replacing your workshop lighting with LED strips – inexpensive though they are – isn’t an efficient way to spend money.

Of course with any study in the efficiency of new technology there are bound to be some conflating factors. We’re thinking [Bogdan] did a pretty good job at gauging the efficiency of LED strips here, but we would like to see some data from some more expensive and hopefully more efficient LED strips.

Exploring The Mandelbrot Set In Real Time

October 23, 2012 by Brian Benchoff 33 Comments

The Mandelbrot set – the fractal ‘snowman turned on its side’ seen above – has graced the covers of magazines, journals, and has even been exhibited in art galleries. An impressive feat for what is nothing more than a mathematical function, and has become something of an obsession for [Chiaki Nakajima].

Even on modern computers, generating an image of a portion of the Mandelbrot set takes a good bit of time. When [Chiaki] discovered this fractal in the mid-1980s, the computers of the day took hours to generate a single, low-resolution image. Real-time zooming and scrolling was impossible but [Chiaki] made the best of what he had on hand and built Pyxis, a Mandelbrot set generator made entirely out of TTL logic chips (Google Translate here).

The original Pyxis connected to a desktop computer via a breakout box. while a special program toggled the bits and registers inside the Pyxis to generate pictures of the Mandelbrot set a thousand times faster than the CPUs of the day could muster.

Time marches on, and the original logic chip Pyxis is can be easily surpassed by even the slowest netbooks. There is, however, another way to build a hardware Mandelbrot set generator: FPGAs.

A few years ago, [Chiaki] began work on the Pyxis2010 (translation), an FPGA-based Mandelbrot set generator able to dynamically zoom and pan around the world’s most popular fractal. Built around an Altera Cyclone III FPGA he picked up from Digikey for $600 (no, not a dev board, just a bare chip), [Chiaki] began deadbugging his circuit directly onto the pins of the hugely expensive FPGA. A man with a steady hand and no fear if there ever was one.

Instead of connecting his Mandelbrot generator to a computer and using it as a co-processor, [Chiaki] decided he wanted something more portable. He found an old Sony PSP, removed the LCD screen, and integrated it into his circuit. After a careful bit of dremeling and fabrication, [Chiaki] had a hand-held Mandelbrot generator that is able to display images of the world’s most famous fractal faster than any desktop computer.

It goes without saying this build is incredible. The technical skill to build an insanely fast Mandelbrot generator on an FPGA is astonishing, but basing it off a logic-chip based build reaches into the realm of godliness. You can check out a video of this amazing build after the break.

Props to [Ian Finder] for sending this one in.

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Storing User Data On Your FPGA

October 16, 2012 by Brian Benchoff 14 Comments

We’ve seen FPGAs used to recreate everything from classic arcade games to ancient computers, but with each of these builds a common problem arises. Once you’ve got the hardware emulated on an FPGA, you’ve also got to get the ROMs into the project as well. In a very interesting hack, [Mike] figured out that the serial Flash chip that stores the FPGA settings has a lot of space free, so why not store user data there?

[Mike] got the idea from seeing a recreation of the classic BombJack arcade game we featured last month. In that build, [Alex] needed to store 112Kb of game data stored in 16 ROM chips. Unfortunately, [Alex]’s FPGA only had space for 40Kb of data. After realizing his FPGA had a 512Kb SRAM chip, [Alex] decided to put all the sprites, sounds, and levels of BombJack in the SRAM.

Impressed with [Alex]’s build, [Mike] set to work generalizing the hack to work with other projects. [Mike] notes that only a few FPGA boards are capable of storing user data next to the configuration bitstream; the hack is impossible on the Digilent Basys2 board, but it works wonderfully on a Papilio One 250K.

As a very cool build that makes FPGA-related builds even easier, we’ve got to tip our hat to [Mike] for writing up a great tutorial.

Weird Processing Unit Only Has 4 Instructions

October 16, 2012 by Brian Benchoff 34 Comments

[Tomáš], a.k.a. [Frooxius] is playing around with computational theory and processor architectures – a strange hobby in itself, we know – and has created the strangest CPU we’ve ever seen described.

The Weird Processing Unit, or WPU, isn’t designed like the Intel or ARM CPU in your laptop or phone. No, the WPU is a thought experiment in computer design that’s something between being weird for the sake of being weird and throwing stuff at the wall and seeing what sticks.

The WPU only has four instructions, or attoinstructions, to change the state of one of the 64 pins on the computer – set to logical 1, set to logical 0, invert current state, and halt. These instructions are coded with two bits, and the operand (i.e. the wire connected to the computer) is encoded in another six bits.

These 64 wires are divided up into several busses – eight bit address and control busses make up the lowest 16 bits, a 32-bit data bus has a function akin to a register, and a 16-bit ‘Quick aJump bus’ provides the program counter and attocode memory. The highest bit on the WPU is a ‘jump bit’, implemented for unconditional jumps in code.

We’re not even sure the WPU can even be considered a computer. We realize, though, that’s probably not the point; [Tomáš] simply created the WPU to do something out of the ordinary. It’s not meant to be a real, or even useful, CPU; it’s simply a thought experiment to see what is possible by twiddling bits around.

Tip ‘o the hat to [Adam] for sending this one in.

Digital Marker Communicates With Touch Screen

October 13, 2012 by Brian Benchoff 27 Comments

In an effort to be more relevant to children that just aren’t impressed with crayons and markers anymore, Crayola released the ColorStudio HD pen. Instead of ink, this pen is filled with electronics that communicate with a tablet to draw different colors in the Crayola ColorStudio app.

[Rob Hemsley] had done some work with capacitive touch screens before, so when he heard the clicking of a tiny relay inside the pen, he automatically knew how it worked. Of course this meant tearing apart the Crayola marker to look at the electronics, but [Rob] also went so far as to replace the microcontroller, allowing you to craft your own ColorStudio HD pen.

The digital Crayola marker communicates with the app by switching a relay on and off very quickly. This completes a circuit between the user’s hand and the touch screen, allowing the tablet to interpret the desired color by measuring how many touches are received per second.

Inside the pen, [Rob] found an RGB LED, a relay, and a PIC microcontroller. Not having any experience with PICs, [Rob] changed out the ‘micro to an ATtiny44 and started writing some firmware with the help of the Arduino IDE.

[Rob]’s updated version functions exactly like the stock version, communicating with the Crayola app by pulsing the relay to indicate the selected color. Even though the Crayola app only has three possible colors, [Rob] says it’s feasible to program the digital pen to send an RGB color value to a tablet, allowing you to choose what color to draw with on the pen.

You can see a video of [Rob]’s updated pen after the break.

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