Homebrew Linear Actuators Put The Moves On This Motion Simulator

October 4, 2018 by Dan Maloney 32 Comments

Breaking into the world of auto racing is easy. Step 1: Buy an expensive car. Step 2: Learn how to drive it without crashing. If you’re stuck at step 1, and things aren’t looking great for step 2 either, you might want to consider going with a virtual Porsche or Ferrari and spending your evenings driving virtual laps rather than real ones.

The trouble is, that can get a bit boring after a while, which is what this DIY motion simulator platform is meant to address. In a long series of posts with a load of build details, [pmvcda] goes through what he’s come up with so far on this work in progress. He’s building a Stewart platform, of the type we’ve seen before but on a much grander scale. This one will be large enough to hold a race car cockpit mockup, which explains the welded aluminum frame. We were most interested in the six custom-made linear actuators, though. Aluminum extrusions form the frame holding BLDC motor, and guide the nut of a long ball screw. There are a bunch of 3D-printed parts in the actuators, each of which is anchored to the frame and to the platform by simple universal joints. The actuators are a little on the loud side, but they’re fast and powerful, and they’ve got a great industrial look.

If car racing is not your thing and you’d rather build a full-motion flight simulator, here’s one that also uses DIY actuators.

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Pirates Don’t Stand A Chance Against This 3-D Printed Pan-Tilt Gimbal

October 2, 2018 by Dan Maloney 11 Comments

Attention: No ~~pirates~~ maritime wealth redistribution agents were harmed in the making of the video below.

Some projects are for work, some are for fun, and some, like this entirely 3D-printed camera pan-tilt gimbal, start out as work and then turn into fun. As professional digital FX artist [FlorianH] tells the tale, he was in need of such a rig for some motion-control work. Buying off the shelf is always an option, except when it’s boring, so [Florian] invested an untold number of hours in front of Fusion 360 meticulously designing every last part, except for some bearings, the NEMA 17 steppers, and some fasteners. ~~Ten~~ One hundred hours of printing later and the device was ready for assembly and a quick test, which showed that this thing is smooth as silk.

And the pirate snuff-vid? That was just for fun, and we enjoyed it immensely. [Florian] assures us that none of the explosions were added in post; all are practical effects, done with flash cotton and a bit of powdered charcoal. We asked – you know, for reference.

We’ve featured lots of pan-tilt rigs before, using everything from hobby servos to purely mechanical linkages. But this one has a certain flair to it that we really like.

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How To Build An Inverter, And Why Not To Bother

September 30, 2018 by Dan Maloney 30 Comments

It’s ridiculously easy to lay hands on a cheap DC-to-AC inverter these days. They’re in just about every discount or variety store and let you magically plug in mains powered devices where no outlets exist. Need 120- or 240-VAC in your car? No problem – a little unit that plugs into the lighter socket is available for a few bucks.

So are these commodity items worth building yourself? Probably not as [GreatScott!] explains, but learning how they work and what their limitations are will probably help your designs. The cheapest and most common inverters have modified square wave outputs, which yield a waveform that’s good enough for most electronics and avoids the extra expense of producing a pure sinusoidal output. He explains that the waveform is just a square wave with a slight delay at the zero-crossing points to achieve the stepped pattern, and shows a simple H-bridge circuit to produce it. He chose to drive the output section with an Arduino, to easily produce the zero-crossing delay. He uses this low-voltage inverter to demonstrate how much more complicated the design needs to get to overcome the spikes caused by inductive loads and the lack of feedback from the output.

Bottom line: it’s nice to know how inverters work, but some things are better bought than built. That won’t stop people from building them, of course, and knowing what you’re doing in this field has been worth big bucks in the past.

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Inductance In PCB Layout: The Good, The Bad, And The Fugly

September 28, 2018 by Bil Herd 39 Comments

When current flows through a conductor it becomes an inductor, when there is an inductor there is an electromagnetic field (EM). This can cause a variety of issues during PCB layout if you don’t plan properly, and sometimes we get burned even when we think we have planned for unwanted inductance and the effects that come with them.

When doing high speed logic we need to be able to deliver sudden changes in current to the devices if we want to have proper switching times and logic levels. Unfortunately inductance is usually not a friend in these circumstances as it resists those sudden changes in current. If the high speed devices are driving capacitive loads, which themselves are resisting changes in voltage, even more instantaneous current is needed.

Simply put, inductors resist a change of current, and can act as a low pass filter when in series with the signal or power supply flow. Inductors do this by storing energy in the flux surrounding the conductor. Alternatively capacitors resist a change in voltage (again by storing energy) and can act as a high pass filter when in series with the signal. This makes them a valuable tool in the fight against unwanted inductance in power supply distribution.

In the video below, and the remainder of this article, I’m going to dive into the concept of inductance and how it affects our design choices when laying out circuit boards.

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Minimal Blinky Project Makes The Chip The Circuit Board

September 25, 2018 by Dan Maloney 16 Comments

We’ve got a thing for projects that have no real practical value but instead seek to answer a simple yet fundamental question: I wonder if I can do that? This dead-bug style 555 blinky light is one of those projects, undertaken just to see how small a circuit can be. Pretty small, as it turns out, and we bet it can get even smaller.

[Danko]’s minimal circuit is about as small as possible for the DIP version of the venerable 555 chip. The BOM is stripped to the bone: just the chip, three resistors, a capacitor, and an LED. All the discrete components are SMDs in 0805. The chip’s leads are bent around the package to form connections, and the SMDs bridge those “traces” to complete the circuit. [Danko] shows the build in step-by-step detail in the video below. There’s some fairly fine work here, but we can’t help wondering just how far down the scale this could be pushed. We know someone’s made a smaller blinky using a tiny microcontroller, but we’d love to see this tried with the BGA version of the chip which is only 1.4 mm on a side.

Cheers to [Danko] for trying this out and having some fun with an old chip. He seems to have a bit of a thing for the 555; check out this cute robot sculpture that’s built around the chip.

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This Pinball Game Doesn’t Come In A Box… It Is The Box

September 23, 2018 by Mike Szczys 8 Comments

Pinball still has that bit of magic that makes it stand out from first person shooters or those screen mashers eating up your time on the bus. The secret sauce is that sense of movement and feedback, and the loss of control as the ball makes its way through the play field under the power of gravity. Of course the real problem is finding a pinball machine. Pinbox 3000 is swooping in to fix that in a creative way. It’s a cardboard pinball machine that you build and decorate yourself.

Pinbox with electronics

Pinbox with bell

Pinbox with plastic packaging as obstacles

We ran into them at Maker Faire New York over the weekend and the booth was packed with kids and adults all mashing flippers to keep a marble in play. The kit comes as flat-pack cardboard already scored and printed with guides for assembly which takes about an hour.

The design is quite clever, with materials limited to just cardboard, rubber bands, and a few plastic rivets. Both the plunger that launches the pinball and the flippers are surprisingly robust. They stand up to a lot of force and from the models on display it seems the friction points of cardboard-on-cardboard are the issue, rather than mechanisms buckling under the force exerted by the player.

When first assembled the playfield is blank. That didn’t stop the fun for this set of kits stacked back to back for player vs. player action. There’s a hole at the top of playfields which makes this feel a bit like playing Pong in real life. However, where the kit really shines is in customizing your own game. In effect you’re setting up the most creative marble run you can imagine. This task was well demonstrated with cardboard, molded plastic packaging (which is normally landfill) cleverly placed, plus some noisemakers and lighting effects. The company has been working to gather up inspiration and examples for building out the machines. We love the multiple layers of engagement rolled into Pinbox, from building the stock kit, to fleshing out a playfield, and even to adding your own electronics for things like audio effects.

Check out the video below to see the fun being had at the Maker Faire booth.

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Advanced Techniques For Using Git With KiCAD

September 19, 2018 by Kerry Scharfglass 4 Comments

For most developers “distributed version control” probably means git. But by itself git doesn’t work very well with binary files such as images, zip files and the like because git doesn’t know how to make sense of the structure of an arbitrary blobs of bytes. So when trying to figure out how to track changes in design files created by most EDA tools git doesn’t get the nod and designers can be trapped in SVN hell. It turns out though KiCAD’s design files may not have obvious extensions like .txt, they are fundamentally text files (you might know that if you’ve ever tried to work around some of KiCAD’s limitations). And with a few tweaks from [jean-noël]’s guide you’ll be diffing and merging your .pro’s and .sch’s with aplomb.

There are a couple sections to the document (which is really meant as an on boarding to another tool, which we’ve gotten to in another post). The first chunk describes which files should be tracked by the repo and which the .gitignore can be configured to avoid. If that didn’t make any sense it’s worth the time learning how to keep a clean repo with the magic .gitignore file, which git will look for to see if there are any file types or paths it should avoid staging.

The second section describes how you can use two nifty git features, cleaning and smudging, to dynamically modify files as they are checked in and out of the repo. [jean-noël]’s observation is that certain files get touched by KiCAD even if there are no user facing changes, which can clutter patch sets with irrelevant changes. His suggested filters prevent this by stripping those changes out as files get checked in. Pretty slick.