Simple Induction Heater Helps With Homebrew Shrink-Fitting

October 26, 2020 by Dan Maloney 14 Comments

Machinists have a lot of neat shop tricks, but one especially interesting one is shrink-fitting tools. Shrink-fitting achieves an interference fit between tool and holder by creating a temperature difference between the two before assembly. Once everything returns to temperature, the two parts may as well be welded together.

The easiest way to shrink-fit machine tooling is with induction heating, and commercial rigs exist for doing the job. But [Roetz 4.0] decided to build his own shrink-fitting heater, and the results are pretty impressive. The induction heater itself is very simple — a 48 volt, 20 amp power supply, an off-the-shelf zero-voltage switching (ZVS) driver, and a heavy copper coil. When the coil is powered up, any metal within is quickly and evenly heated by virtue of the strong magnetic flux in the coil.

To use the shrinker, [Roetz 4.0] starts with a scrupulously clean tool holder, bored slightly undersized for the desired tool. Inside the coil, the steel tool holder quickly heats to a lovely deep brown color, meaning it has gotten up to the requisite 250-300°C. The tool is quickly dropped into the now-expanded bore, which quickly shrinks back around it. The advantage of this method over a collet or a chuck is clear in the video below: practically zero runout, and the tool is easily released after another run through the heater.

You say you’ve got no need for shrink-fitting tools? How about stuck bolts? Induction heaters work great there too.

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Super-Simple VGA Adapter Sports Low-Res Output With Only Four TTL Chips

October 24, 2020 by Dan Maloney 20 Comments

Here at Hackaday we cast a wary eye at tips that come in with superlative claims. Generally, if we post something that claims to be the fastest or the smallest of all time, we immediately get slapped down in the comments by someone who has done it faster or smaller. So we present the simplest TTL video card ever knowing the same thing will happen, but eager to see how anyone might scale things down.

To be fair, [George Foot] does qualify his claim to the simplest usable VGA adapter, and he does note that it descends from [Ben Eater]’s “world’s worst video card”, which he uses for his 6502 breadboard computer. But where [Ben]’s VGA adapter uses about 20 TTL chips and an EEPROM, [George] has managed to decrease the BOM to just four TTL chips along with the memory and a crystal oscillator. This required a fair number of compromises, of course; the color depth is fairly low, as is the resolution. Each pixel appears as a thin horizontal bar rather than a small square, leading the images to be smeared out across the screen. They’re still surprisingly viewable, though, which probably says more about the quality of the pattern-recognition wetware between our ears than anything about the quality of the adapter. [George] gives a tour of the circuit in the brief video below.

It looks like [George] has posted a few improvements to the project since we first spotted it, so we’re looking forward to seeing how much the parts count went up. We’re also keen to see if anyone can outdo the simplicity of this effort — be sure to let us know if you give it a shot.

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Small Spotify Remote Broadens Musical Horizons

October 21, 2020 by Kristina Panos 9 Comments

When was the last time you tried listening to a new genre of music, or even explored a sub-genre of something you already like? That’s what we thought. It’s good to listen to other stuff once in a while and remind ourselves that there’s a whole lot of music out there, and our tastes are probably not all that diverse. As a reminder, [sorghum] made a spiffy little Spotify remote that can cruise through the musical taxonomy that is Every Noise at Once and control any Spotify-enabled device.

There’s a lot to like about this little remote, which is based upon a LilyGo TTGO ESP32 board with on-board display. The circuitry is basically that and a rotary encoder plus a tiny LiPo battery. Can we talk about the finish on those prints? Yes, those are both printed enclosures. Getting that buttery smooth finish took two grits of wet/dry sandpaper plus nine grits of polishing cloths.

As you can see in the brief demo after the break, there are several ways to discover new music. [sorghum] can surf through all kinds of Japanese music for example, or surf by the genre’s ending word and listen to metalcore, deathcore, and grindcore from all over the globe. For extra fun, there’s a genre-ending randomizer so you can discover just how many forms of *core there are.

Want everyone in the room to know what you’re listening to? Behold the Spotify split-flap display.

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Learn IC Decapping

October 21, 2020 by Al Williams 15 Comments

Decapsulating ICs used to be an exotic technique. (I should know, I did that professionally for one of the big IC vendors back in the 1980s.) These days, more and more people are learning to take apart ICs for a variety of reasons. If you are interested in doing it yourself, [Juan Carlos Jimenez] has a post you should read about using acid to remove epoxy from ICs.

[Juan Carlos] used several different techniques with varying degrees of success. Keep in mind, that using nitric acid is generally pretty nasty. You need safety equipment and be sure to plan for bad things to happen. Have eyewash ready because once you splash acid in your eye, it is too late to get that together.

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Arduino Bobbin Winding Machine Is Freaky Fast

October 20, 2020 by Kristina Panos 16 Comments

One of the worst things about sewing is finding out that your bobbin — that’s the smaller spool that works together with the needle and the larger spool to make a complete stitch — ran out of thread several stitches ago. If you’re lucky, the machine has a viewing window on the bobbin so you can easily tell when it’s getting dangerously close to running out, but many machines (ours included) must be taken halfway apart and the bobbin removed before it can be checked.

Having spare bobbins ready to go is definitely the answer. We would venture to guess that most (if not all) machines have a built-in bobbin winder, but using them involves de-threading the machine and setting it up to wind bobbins instead of sew. If you have a whole lot of sewing to do and can afford it, an automatic bobbin winder is a godsend. If you’re [Mr. Innovative], you build one yourself out of acrylic, aluminium, and Arduinos.

Here’s how it works: load up the clever little acrylic slide with up to twelve empty bobbins, then dial in the speed percentage and press the start button. The bobbins load one at a time onto a drill chuck that’s on the output shaft of a beefy 775 DC motor. The motor spins ridiculously fast, loading up the bobbin in a few seconds. Then the bobbin falls down a ramp and into a rack, and the thread is severed by a piece of nichrome wire.

An important part of winding bobbins is making sure the thread stays in place at the start of the wind. We love the way [Mr. Innovative] handled this part of the problem — a little foam doughnut around a bearing holds the thread in place just long enough to get the winding started. The schematic, BOM, and CAD files are available if you’d like to make one of these amazing machines for yourself. In the meantime, check out the demo/build video after the break.

Still not convinced that sewing is cool enough to learn? Our own [Jenny List] may be able to convert you. If that doesn’t get you, you might like to know that some sewing machines are hackable — this old girl has a second life as a computerized embroidery machine. If those don’t do it, consider that sewing machines can give you a second life, too.

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Let KiCad And Python Make Your Coils

October 19, 2020 by Al Williams 16 Comments

We like to pretend that our circuits are as perfect as our schematics. But in truth, PCB traces have unwanted resistance, capacitance, and inductance. On the other hand, that means you can use those traces to build components. For example, it isn’t uncommon to see a very small value current sense resistor be nothing more than a long PC board trace. Using PC layers for decoupling capacitance and creating precise transmission lines are other examples. [IndoorGeek] takes us through his process of creating coils on the PCB using KiCad. To help, he used a Python script that works out the circles, something KiCAD has trouble with.

The idea is simple. A coil of wire has inductance even if it is a flat copper trace on a PCB. In this case, the coils are more for the electromagnetic properties, but the same idea applies if you wanted to build tuned circuits. The project took inspiration from FlexAR, an open-source flexible PCB magnet.

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Retro Calculator Design Has Creative Tactile Touchscreen

October 18, 2020 by Lewin Day 25 Comments

We’ve all heard it a thousand times – they don’t make ’em like they used to. Sometimes, that’s for good reason, but there is a certain build quality to electronics of the mid-20th century that is hard to find in hardware today. This inspires great nostalgia and dedication in some, like [Michael Park], who set out to build a calculator reminiscent of the best HP designs from yesteryear.

The scissor mechanism allows the touch screen to move linearly and activate the tactile switch without twisting, no matter where along its surface it is pressed.

One of the major factors for [Michael] was the great feel of the keys on these classic units. Wanting to experiment with different layouts without a lot of rewiring, the idea of keys with individual displays became attractive. Existing parts on the market were prohibitively expensive, however. Instead, [Michael] used a single touchscreen with a switch mounted underneath to provide tactile feedback with a nifty scissor-arm guide mechanism. Combined with individual see-through plastic overlays, the MP-29 has a fully reconfigurable pad of 30 keys with dynamically updatable labels.

It’s a creative choice, and one that looks highly satisfying to use. It has all the tactile benefits of individual keys, both in the keypresses and being able to navigate the keypad without looking. Combined with the benefit of reconfigurable keys thanks to the touch screen underneath, it’s a great way to build a user-interface.

The rest of the calculator design closely mimics the HP-29, though [Michael] is also experimenting with alternative layouts too. There are plenty of religious wars in the calculator community over usability, after all – mostly over which side of the pad has the arithmetic functions.

We’ve lamented the demise of the standalone calculator recently; with so many smart devices around, it’s hard to see it making a major comeback anytime soon. Of course, if you’re opinionated on the topic, sound off in the comments below. Video after the break.

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