hardware

1676 Articles

DIY MIDI Looper Controller Looks Fantastic!

October 13, 2019 by 4 Comments

Due to pedalboard size, complicated guitar pedals sometimes reduce the number of buttons to the bare minimum. Many of these pedals are capable of being controlled with an external MIDI controller, however, and necessity being the mother of invention and all, this is a great opportunity to build something and learn some new skills at the same time. In need of a MIDI controller, Reddit user [Earthwin] built an Arduino powered one to control his Boss DD500 Looper pedal and the result is great looking.

Five 16×2 LCD screens, one for each button, show the functionality that that button currently has. They are attached (through some neat wiring) to a custom-built PCB which holds the Arduino that controls everything. The screens are mounted to an acrylic backplate which holds the screens in place while the laser-cut acrylic covers are mounted to the same plate through the chassis. The chassis is a standard Hammond aluminum box that was sanded down, primed and then filler was used to make the corners nice and smooth. Flat-top LEDs and custom 3D printed washers finish off the project.

[Earthwin] admits that this build might be overkill for the looper that he’s using, but he had fun building the controller and learning to use an Arduino. He’s already well on his way to building another, using the lessons learned in this build. If you want to build your own MIDI controller, this article should help you out. And then you’re ready to build your controller into a guitar if you want to.

[Via Reddit]

Dealing With Missing Pin Allocations

October 12, 2019 by 3 Comments

Blindsided by missing pin allocations? Perhaps you’re working on a piece of hardware and you notice that the documentation is entirely wrong. How can you get your device to work?

[Dani Eichhorn]’s troubles began when running an IoT workshop using a camera module. Prior to the work, no one had through to check if all of the camera modules ordered for the participants were the same. As it turns out, the TTGO T-CAM module had a number of revisions, with some even receiving a temperature/pressure sensor fixed on top of the normal board.

While the boards may have looked the same, their pin allocations were completely different.Changing the pin numbers wouldn’t have been difficult if they were simply numbered differently, but because the configurations were different, errors started to abound: Could not initialize the camera

As it turns out, even the LillyGo engineers – the manufacturers of the board – may have gotten a bit lost while working on the pin allocations, as [Eichhorn] was able to find some of the pins printed right onto the PCB, hidden behind the camera component.

To find information not printed on the board, a little more digging was required. To find the addresses of the devices connected to the I2C bus, running a program to find peripherals listening on the bus did the trick. This was able to print out the addresses of the SSD1306 OLED display driver and the microphone for the board at hand.

To find the pins of peripherals not printed on the PCB or hidden on the silkscreen, a GPIO scanner did the trick. This in particular worked for finding the PIR (passive infrared) motion sensor.

We picked up a few tips and tricks from this endeavor, but also learned that reverse-engineering anything is hard, and that there isn’t any one method for finding pin allocations when the documentation’s missing.

Make Your Own Plasma Cutter

October 12, 2019 by 31 Comments

Of all the tools that exist, there aren’t many more futuristic than the plasma cutter, if a modern Star Wars cosplay if your idea of futuristic. That being said, plasma cutters are a powerful tool capable of making neat cuts through practically any material, and there are certainly worst ways to play with high voltage.

Lucky enough, [Plasanator] posted their tutorial for how to make a plasma cutter, showing the steps through which they gathered parts from “old microwaves, stoves, water heaters, air conditioners, car parts, and more” in the hopes of creating a low-budget plasma cutter better than any on YouTube or from a commercial vendor.

The plasma cutter does end up working up quite an arc, with the strength to slice through quarter-inch steel “like a hot knife through butter”.

Its parts list and schematic divide the systems into power control, high current DC, low voltage DC, and high voltage arc start:

  • The power control contains the step down transformer and contactor (allows the DC components to come on line)
  • The high current DC contains the bridge rectifier, large capacitors, and reed switch (used as a current sensor to allow the high voltage arc to fire right when the current starts to travel to the head, shutting down the high voltage arc system when it’s no longer necessary)
  • The low voltage DC contains the power switch, auto relays, 12V transformer, 120V terminal blocks, and a terminal strip
  • The high voltage arc start contains the microwave capacitor and a car ignition coil

At the cutting end, 13A is used to cut through quarter-inch steel. Considering the considerably high voltage cutter this is, a 20 A line breaker is needed for safety.

Once the project is in a more refined state, [Plasanator] plans on hiding components like the massive capacitors and transformer behind a metal or plastic enclosure, rather than have them exposed. This is mainly for safety reasons, although having the parts exposed is evocative of a steampunk aesthetic.

In several past designs, stove coils were used as current resistors and a Chevy control module as the high voltage arc start. The schematic may have become more refined with each build, but [Plasanator]’s desire to use whatever components were available certainly has not disappeared.

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Fail Of The Week: How Not To Re-Reflow

October 10, 2019 by 30 Comments

There’s no question that surface-mount technology has been a game-changer for PCB design. It means easier automated component placement and soldering, and it’s a big reason why electronics have gotten so cheap. It’s not without problems, though, particularly when you have no choice but to include through-hole components on your SMT boards.

[James Clough] ran into this problem recently, and he tried to solve it by reflowing through-hole connectors onto assembled SMT boards. The boards are part of his electronic lead screw project, an accessory for lathes that makes threading operations easier and more flexible. We covered the proof-of-concept for the project; he’s come a long way since then and is almost ready to start offering the ELS for sale. The PCBs were partially assembled by the board vendor, leaving off a couple of through-hole connectors and the power jack. [James]’ thought was to run the boards back through his reflow oven to add the connectors, so he tried a few experiments first on the non-reflow rated connectors. The Phoenix-style connectors discolored and changed dimensionally after a trip through the oven, and the plastic on the pin headers loosened its grip on the pins. The female header socket and the power jack fared better, so he tried reflowing them, but it didn’t work out too well, at least for the headers. He blames poor heat conduction due to the lack of contact between the board and the reflow oven plate, and we agree; perhaps an aluminum block milled to fit snugly between the header sockets would help.

Hats off to [James] for trying to save his future customers a few steps on assembly, but it’s pretty clear there are no good shortcuts here. And we highly recommend the electronic leadscrew playlist to anyone interested in the convergence of machine tools and electronics.

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The Cutest Oscilloscope Ever Made

October 10, 2019 by 11 Comments

If you thought your handheld digital oscilloscope was the most transportable of your signal analyzing tools, then you’re in for a surprise. This oscilloscope made by [Mark Omo] measures only one square inch, with the majority of the space taken up by the OLED screen.

It folds out into an easier instrument to hold, and admittedly does require external inputs, so it’s not exactly a standalone tool. The oscilloscope runs on a PIC32MZ EF processor, achieving 20Msps and 1MHz of bandwidth. The former interleaves the processor’s internal ADCs in order to achieve its speed.

For the analog front-end the signals first enter a 1M ohm terminator that divide the signals by 10x in order to measure them outside the rails. They then get passed through a pair of diodes connected to the rails, clamping the voltage to prevent damage. The divider centers the incoming AC signal around 1.65V, halfway between AGND and +3.3V. As a further safety feature, a larger 909k Ohm resistor sits between the signals and the diodes in order to prevent a large current from passing through the diode in the event of a large voltage entering the system.

The next component is a variable gain stage, providing either 10x, 5x, or 1x gain corresponding to 1x, 0.5x, and 0.1x system gains. For the subsystem, a TLV3541 op-amp and ADG633 tripe SPDT analog switch are used to provide a power bandwidth around the system response due to driving concerns. Notably, the resistance of the switch is non-negligible, potentially varying with voltage. Luckily, the screen used in the oscilloscope needs 12V, so supplying 12V to the mux results in a lower voltage and thus a flatter response.

The ADC module, PIC32MZ1024EFH064, is a 12-bit successive approximation ADC. One advantage of his particular ADC is that extra bits of resolution only take constant time, so speed and accuracy can be traded off. The conversion starts with a sample and hold sequence, using stored voltage on the capacitor to calculate the voltage.

Several ADCs are used in parallel to sample at the same time, resulting in the interleaving improving the sample rate. Since there are 120 Megabits per second of data coming from the ADC module, the Direct Memory Access (DMA) peripheral on the PIC32MZ allows for the writing of the data directly onto the memory of the microcontroller without involving the processor.

The firmware is currently available on GitHub and the schematics are published on the project page.

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Building A Wind Power Generator In Your Backyard

October 5, 2019 by 53 Comments

For many environmental enthusiasts, horizontal-axis wind turbines (HAWTs) — the kind that look like windmills slowly spinning in the distance — are a pretty familiar sight. Unfortunately, there are quite a few caveats that make them harder to adopt despite the fact that harvesting renewable energy sources is more sustainable than relying on natural gas and fuels that can be depleted. Since they face in one axis, they need to be able to track the wind, or else trade off the ability to maximize energy output. In turbulent and gusty conditions, as well, HAWTs face accelerated fatigue when harvesting.

The development of the vertical-axis wind turbine (VAWT) solves several of these issues. In addition, the turbines are typically closer to the ground and the gearbox replacement is simpler and more efficient. Maintenance is more accessible due to the size of the turbines, so no heavy machinery is typically necessary to access crucial components on-site. In addition, the gearbox by nature of its operation takes on less fatigue and is able to function in turbulent winds, which reduces the rate of failure.

For a simple version of a VAWT that you can build yourself, [BlueFlower] has published several mechanical drawings that detail the layout of the design. The wind power generator uses 24 magnets, copper wire fashioned into coils, and a metal plate for the main generator. The coils are arranged in a circular formation on a static plate, while the magnets are equally spaced on a moving circular plate. As the magnets pass over coils, the flux induces a current, which increases as the plates spin faster.

The blades of the generator are made from blue foam with a metal bar running through it for structure. Three of the blades are attached with triangular bars to a central rod, which also holds the spinning magnetic plate.

In [BlueFlower]’s initial trials using the VAWT for charging a battery they were able to generate a max power of 15W on boost mode and 30-70W when charging in PWM mode. Not bad for a home-made wind power generator!

There aren’t only pros to the design, however. While VAWTs may be cheaper, more mobile, and more resistant to wear and tear, there are some design features that prevent the generators from functioning as well as HAWTs at harvesting energy. The blades don’t produce torque at the same time, with some blades simply being pushed along. This produces more drag on the blades when they rotate, limiting the efficiency of the entire system. In addition, higher wind speeds are typically found at higher altitudes, so the VAWTs will perform better if installed on a towering structure. Vibration forces close to the ground can also wear out the bearings, resulting in more maintenance and costs.

 

 

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