Low-Budget Hydroformer Puts The Squeeze On Sheet Metal Parts

October 20, 2017 by Dan Maloney 22 Comments

Between manufacturing technologies like 3D-printing, CNC routers, lost-whatever metal casting, and laser and plasma cutters, professional quality parts are making their way into even the most modest of DIY projects. But stamping has largely eluded the home-gamer, what with the need for an enormous hydraulic press and massive machined dies. There’s more than one way to stamp parts, though, and the budget-conscious shop might want to check out this low-end hydroforming method for turning sheet metal into quality parts.

If hydroforming sounds familiar, it might be because we covered [Colin Furze]’s attempt, which used a cheap pressure washer to inflate sheet metal bubbles with high-pressure water. The video below shows a hydroformer that [Rainbow Aviation] uses (with considerably less screaming) to make stamped aluminum parts for home-brew aircraft. The kicker with this build is that there is no fluid — at least not until the 40,000-pound hydraulic press semi-liquifies the thick neoprene rubber pad placed over the sheet metal blank and die. The pressure squeezes the metal into and around the die, forming some pretty complex shapes in a single operation. We especially like the pro-tip of using Corian solid-surface countertop material offcuts to make the dies, since they’re available for a pittance from cabinet fabricators.

It’s always a treat to see hacks from the home-brew aviation world. They always seem to have plenty of tricks and tips to share, like this pressure-formed light cowling we saw a while back.

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Motion Activated Super-Squirter Stands Guard

October 18, 2017 by Steven Dufresne 14 Comments

Thieves beware. If you prowl around [Matthew Gaber]’s place, you get soaked by his motion activated super-squirter. Even if he’s not at home, he can aim and fire it remotely using an iPhone app. And for the record, a camera saves photos of your wetted-self to an SD card.

ESPino, ArduCAM UNO and voltage converter boards

The whole security system is handled by three subsystems for target acquisition, photo documentation, and communications. The first subsystem is centered around an ESPino which utilizes a PIR sensor to detect motion. It then turns on a windscreen washer pump and uses pan and tilt servos to squirt water in a pattern toward the victim.

The target acquisition hardware also sends a message to the second subsystem, an ArduCAM ESP8266 UNO board. It takes a burst of photos using an ArduCAM Mini Camera mounted beside the squirter outlet. The UNO can also serve up a webpage with a collection of the photos.

The final subsystem is an iPhone app which talks to both the ESPino and the UNO board. It can remotely control the squirter and provide a video feed of what the camera sees.

One detail of the build we really enjoyed is the vacuum relief valve he fabricated himself. It prevents siphoning through the pump when it’s not on. Don’t miss a demo of the squirter in action after the break.

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Not Your Typical ATX Bench PSU

October 14, 2017 by Dan Maloney 7 Comments

We know what you’re thinking — yet another scrap PC power supply turned into a bench PSU. But look a little closer and you’ll see a nicely designed linear bench supply that just fits inside a gutted ATX case.

A lot of the items on [Medzik]’s BOM for this build are straight from the scrap bin. The aforementioned ATX supply case is one, as is the power transformer donated by a friend. Modules such as the 30V/2A regulator, the digital volt/ammeter, and a thermostat module to control the fan at higher power settings were all sourced via the usual suspects. The PSU boasts two outputs — an adjustable 0-22 volt supply, and a fixed 12-volt output. An unusual design feature is a secondary input which uses the 22-VAC supply from a Weller soldering station to give the PSU a little more oomph. This boosts the maximum output to 30 volts; one wonders why [Medzik] didn’t just source a bigger transformer, but you work with what you have sometimes. There are some nice touches, too, like custom-printed vinyl overlays for the case.

It’s a good-looking and compact unit with a decent suite of features, and you could do a lot worse when building your next bench supply. If it’s not your cup of tea though, just take your pick — tiny and yellow, built to last, or ensconced in Ultrasuede.

A Raspberry Pi Rain Man In The Making

October 13, 2017 by Dan Maloney 11 Comments

We see a lot of Raspberry Pis used to play games, but this is something entirely different from the latest RetroPie build. This Raspberry Pi is learning how to read playing cards, with the goal of becoming the ultimate card counting blackjack player.

If [Taxi-guy] hasn’t named his project Rain Man, we humbly suggest that he does so. Because a Pi that can count into a six-deck shoe would be quite a thing, even though it would never be allowed anywhere near a casino. Hurdle number one in counting cards is reading them, and [Taxi-guy] has done a solid job of leveraging the power of OpenCV on a Pi 3 for the task. His description in the video below is very detailed, but the approach is simple: find the cards in a PiCam image of the playing field using a combination of thresholding and contouring. Then, with the cards isolated, compare the rank and suit in the upper left corner of the rotated card image to prototype images to identify the card. The Pi provides enough horsepower to quickly identify an arbitrary number of non-overlapping cards; we assume [Taxi-guy] will have to address overlapping cards and decks that use different fonts at some point.

We’re keen to see this Pi playing blackjack someday. As he’s coding that up, he may want to look at algorithmic approaches to blackjack strategies, and the real odds of beating the house.

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Nematoduino: A Roundworm Neural Model On An Arduino

October 13, 2017 by Dan Maloney 13 Comments

When it comes to building a neural network to simulate complex behavior, Arduino isn’t exactly the first platform that springs to mind. But when your goal is to model the behavior of an organism with only a handful of neurons, the constraints presented by an Arduino start to make sense.

It may be the most important non-segmented worm you’ve never heard of, but Caenorhabditis elegans, mercifully abbreviated C. elegans, is an important model organism for neurobiology, having had its entire nervous system mapped in 2012. [Nathan Griffith] used this “connectome” to simulate a subset of the diminutive nematode’s behaviors, specifically movements toward attractants and away from obstacles. Riding atop a small robot chassis, the Arduino sends signals to the motors when the model determines it’s time to fire the virtual worm’s muscles. An ultrasonic sensor stands in for the “nose touch” neurons of the real worm, and when the model is not busy avoiding a touch, it’s actively seeking something to eat using the “chemotaxis” behavior. The model is up on GitHub and [Nathan] hopes it provides an approachable platform for would-be neuroroboticists.

This isn’t the first time someone has modeled the nematode’s connectome in silico, but kudos to [Nathan] for accomplishing it within the constraints an Arduino presents.

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Propane-Powered Plasma Rifle

October 12, 2017 by Dan Maloney 34 Comments

It may not be a “phased plasma rifle in the 40-watt range,” and it doesn’t even use plasma in the strict definition, but it’s pretty cool nonetheless. It’s a propane-powered bottle-launching rifle, and it looks like a lot of fun.

[NighthawkInLight] sure likes things that go pop, like his watermelon-wasting air-powered cannon and cheesy-poof pop gun. This one has a little more oomph to it, powered as it is by a propane torch. The principle is simple: fill a soda bottle with propane, ignite the gas, fun ensues. The details are a little more subtle, though, and allowances need to be made to keep back pressure from preventing the projectile from filling with fuel. [NighthawkInLight] overcomes this with some clever machining of the barrel. The final production version in the video below is needlessly but delightfully complex, with a wooden stock and a ~~coil of clear vinyl tubing~~ helical plasma accumulator before the barrel; the last bit is just for show, and we have to admit that it looks pretty good.

Unless you count the pro tip on using CPVC pipe to make custom fittings, this one is nothing but fun. But we don’t have a problem with that.

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A Lesson On Zener Regulators

October 11, 2017 by Inderpreet Singh 40 Comments

For the longest time, Zener diode regulators have been one of those circuits that have been widely shared and highly misunderstood. First timers have tried to use it to power up their experiments and wondered why things did not go as planned. [James Lewis] has put up a worth tutorial on the subject titled, “Zener Diode makes for a Lousy Regulator” that clarifies the misconceptions behind using the device.

[James Lewis] does an experiment with a regulator circuit with an ESP8266 after a short introduction to Zener diodes themselves. For the uninitiated, the Zener diode can operate in the reverse bias safely and can do so at a particular voltage. This allows for the voltage across the device to be a fixed value.

This, however, depends on the current flowing through the circuit which in turn relies on the load. The circuit will work as expected for loads the draw a small amount of current. This makes it suitable for generating reference voltages for microcontrollers and such.

To make a Zener into a “proper” voltage regulator, you just need to buffer the output with an amplifier of some kind. A single transistor is the bare minimum, but actually can work pretty well. You might also add a capacitor in parallel with the Zener to smooth out some of its noise.

Zener diodes are wonderful little devices and write-ups like these are indispensable for beginners and should be shared more often like the Zener and Schottky Tutorial and Diodes as a Switch.