Semi-automated Winder Spins Rotors For Motors

August 17, 2018 by Dan Maloney 8 Comments

What’s your secret evil plan? Are you looking for world domination by building a machine that can truly replicate itself? Or are you just tired of winding motor rotors and other coils by hand? Either way, this automated coil winder is something you’re probably going to need.

We jest in part, but it’s true that closing the loop on self-replicating machines means being able to make things like motors. And for either brushed or brushless motors, that means turning spools of wire into coils of some sort. [Mr Innovative]’s winder uses a 3D-printed tube to spin magnet wire around a rotor core. A stepper motor turns the spinner arm a specified number of times, pausing at the end so the operator can move the wire to make room for the next loop. The rotor then spins to the next position on its own stepper motor, and the winding continues. That manual step needs attention to make this a fully automated system, and we think the tension of the wire needs to be addressed so the windings are a bit tighter. But it’s still a nice start, and it gives us some ideas for related coil-winding projects.

Of course, not every motor needs wound coils. After all, brushless PCB motors with etched coils are a thing.

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Converting A 3-in-1 Printer Into A WiFi Scanner, Just Because

August 13, 2018 by Steven Dufresne 24 Comments

[Zaprodk] had trash-picked a defunct HP Envy 450 AIO, a 3-in-1 printer, scanner, and copier. Normally there usually isn’t much use for these unless you’re willing to hunt down the cartridges which it used, so your next step is to dismantle it for parts. That’s what he was going to do but then decided to see if he could remove as much as possible while leaving just the scanner.

He ran into trouble after he’d “fixed” the lid-open sensor and unplugged pretty much everything. He was getting too many error messages on the LCD panel to reconfigure the WiFi. Luckily he could connect it to his computer using USB and do the configuration from there. One dubious mod involved turning an “unflipped” flexible flat cable into a “flipped” one by doing a little cutting, scraping and gluing. Check out his write-up for the full hack.

Interested in more dumpster hardware recovery? Check out how [Adil Malik] rescued a scope with some reverse engineering and an FPGA. And then there’s how [Matt] turned a dumpster-found WiFi router into a 3D printing server.

The Ins And Outs Of Geiger Counters, For Personal Reasons

August 12, 2018 by Dan Maloney 28 Comments

There are times in one’s life when circumstances drive an intense interest in one specific topic, and we put our energy into devouring all the information we can on the subject. [The Current Source], aka [Derek], seems to be in such a situation these days, and his area of interest is radioactivity and its measurement. So with time to spare on his hands, he has worked up this video review of radioactivity and how Geiger counters work.

Why the interest in radioactivity? Bluntly put, because he is radioactive, at least for the next week. You see, [Derek] was recently diagnosed with thyroid cancer, and one of the post-thyroidectomy therapeutic options to scavenge up any stray thyroid cells is drinking a cocktail of iodine-131, a radioisotope that accumulates in thyroid cells and kills them. Trouble is, this leaves the patient dangerously radioactive, necessitating isolation for a week or more. To pass the time away from family and friends, [Derek] did a teardown on a commercial Geiger counter, the classic Ludlum Model 2 with a pancake probe. The internals of the meter are surprisingly simple, and each stage of the circuit is easily identified. He follows that up with a DIY Geiger counter kit build, which is also very simple — just a high-voltage section made from a 555 timer along with a microcontroller. He tests both instruments using himself as a source; we have to say it’s pretty alarming to hear how hot he still is. Check it out in the video below.

Given the circumstances, we’re amazed that [Derek] is not only keeping his cool but exhibiting a good sense of humor. We wish him well in his recovery, and if doing teardowns like this or projects like this freezer alarm or a no-IC bipolar power supply helps him cope, then we all win.

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Op Amps Before Transistors: A 600V Vacuum Tube Monster

August 9, 2018 by Ben James 11 Comments

Op amps. Often the first thing that many learn about when beginning the journey into analog electronics, they’re used in countless ways in an overwhelmingly large array of circuits. When we think about op amps, images of DIPs and SOICs spring to mind, with an incredibly tiny price tag to boot. We take their abundance and convenience for granted nowadays, but they weren’t always so easy to come by.

[Mr Carlson] serves up another vintage offering, this time in the form of a tube op amp. The K2-W model he acquired enjoyed popularity when it was released as one of the first modular general purpose amplifiers, due to its ‘compact form’ and ‘low price’. It also came with large application manuals which helped it to gain users.

In order to power up the op amp and check its functionality, +300V and -300V supplies are needed. [Mr Carlson] is able to cobble something together, since it’s very apparent that he has an enviable stash of gear lying around. A 600V rail to rail supply is not something to be taken lightly, though it does give this particular model the ability to output 100V pk-pk without any distortion.

The op amp is set up as an inverting amplifier, and once powered on proves to work flawlessly. As always, the video is an entertaining watch, stuffed full of retro electronics trivia. We’re big fans of [Mr Carlson]’s work, and have previously written about his adventures with a colossal walk-in AM radio transmitter, as well as his restoration of a 1930s oscilloscope and subsequent transformer de-potting.

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Remote Controlled Electric Snowblower Sports FPV For Safety

August 7, 2018 by Dan Maloney 27 Comments

As summer scorches the northern hemisphere, here’s something to cool your thoughts: winter is only four months away. And with it will come the general misery and the proclamations that “It’ll never be warm again,” not to mention the white stuff and the shoveling. Or perhaps not, if you’re lucky enough to have a semi-autonomous electric snowblower in the garage.

The device [Dane Kouttron] describes is a strange beast indeed, and one that came to him under somewhat mysterious circumstances. It appears to be a standard Ariens two-stage blower, the kind normally driven by a fairly beefy internal combustion engine so as to have enough power to run the auger, the impeller, and the drive wheels. But a previous owner had removed the gas engine and attached a 4-kW brushless motor to run the auger and impeller. Realizing the potential of this machine and with a winter storm heading his way, [Dane] used the old engine mount to hold giant LiFePO₄ batteries from a cell tower backup battery, slapped a couple of electric wheelchair motors onto the drive wheels, mounted a motor to swivel the exhaust chute, and added control electronics from a retired battlebot. Setting such a machine loose in the wild would be bad, so an FPV system was added just in time for storm cleanup. Upgrades for version 2 include better weight distribution for improved stability and traction, and of course googly eyes. Check out the video below to see it flinging snow and moving around faster than any snowblower we’ve ever seen.

We’ll never get lucky enough to have such wonders gifted on us as [Dane] did, but we applaud him for picking up the torch where someone else obviously left off. And who knows; perhaps the previous maker took inspiration from this remote-controlled snowblower build?

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Spot Welding …Plastic?

August 5, 2018 by Ben James 12 Comments

Plastic milk bottles, when your project or prototype needs an urgent source of plastic, they are often the first thing to hand. Convenient and flexible, but strong at the same time and usually free, they’re the ultimate source of material in a pinch. However, when it comes to actually manipulating the HDPE plastic they’re made from, there’s often a challenge. It’s easy to cut, but not so easy to join. Conventional glues can have a hard time, making it difficult to bond.

Enter [zimitt], and a spot welding solution for joining HDPE with ease. Ok, so ‘spot welding’ might be a little optimistic given the speed of this process, but it’s useful nonetheless. To heat the plastic, a cheap soldering iron is recommended. A low wattage, straight-to-the-wall one does well, especially as they commonly have the washer-style end shown in the picture. To protect the plastic from burning, a BBQ mat is used – they’re temperature resistant and usually made with a PTFE surface.

First, place the two sheets of plastic face to face and sandwich top and bottom with the BBQ mat. Apply some heat to the mat with the soldering iron then, after a few seconds, remove the iron and provide pressure with a flat object to bond the plastic. [zimitt] used an espresso tamper for this which was ideal.

The results are impressive, and [zimitt] experiments with different plastics as well. Of course, you should exercise caution when attempting anything like this, given the health risks present when heating up different types of plastic.

HDPE is easy to recycle at home, and we’ve seen a lot of great uses: a plastic joiner’s mallet, plastic tiles, and even a filament extruder for 3D printing.

Hacked Vacuum Chamber Won’t Suck A Hole In Your Budget

August 4, 2018 by Dan Maloney 38 Comments

There’s nothing like a true hack, where something useful is concocted from bits of scrap and bargain store finds. Builds like these are much more than the sum of their parts, especially when they result in a useful tool, like this DIY vacuum chamber that’s good for all sorts of jobs.

Everything [Black Beard Projects] used to accomplish this build is readily available almost everywhere in the world, although we have to note that appliance recycling efforts and refrigerant recovery programs have made it somewhat harder to lay hands on things like the old fridge compressor used here. The big steel cooking pot is an easy thrift store find, though, and while [Black Beard] used high-quality stainless fittings and valves to plumb the chamber, pretty much any cheap fittings will do.

The one sketchy area of the build is the plexiglass sheet used for the chamber top, which seems a little on the thin side to us. You can see it flexing in the video below as vacuum is pulled; it survived, but we can see it failing catastrophically at some point. We stand ready to be reassured in the comments. Still, it’s a tidy build with a few nice details, like wiring a switch into the old start capacitor box and using car door edge protector as a gasket on the chamber.

Fridge compressor hacks are standard fare, of course, being used to make everything from air compressors to two-stroke engines. Sometimes they’re even used to keep things cool too.

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