A Simple Guide To Cams

May 31, 2023 by Danie Conradie 10 Comments

With the availability of precision controllable actuators, it’s easy to overlook the simple but versatile mechanisms that got us here. In the video after the break, [Teaching Tech] explores the basics of cams and how to use them in your projects.

Cams are used to convert rotation into linear motion, and are probably best known for their use in engines and locking mechanisms. [Teaching Tech] first goes over the basic design and terminology in CAD, and demonstrates it’s use with a cam follower, locking mechanism, cam plate, and a knob that snaps to predefined positions. Of course a cam shape is not limited to a single lobe, but can have multiple lobes of various heights to create different motion patterns.

Cams are especially useful when you need to operate multiple mechanisms from a single input drive, as [Teaching Tech] demonstrates with the 3D printed automaton of a polar bear attempting to swipe a seal. We’ve also seen cams on a mechanical 7-segment display, and they were used to safely fire machine guns through aircraft propellers up to the 1950’s.

So next time you’re thinking adding another actuator to a project, take a moment to consider if a cheap and simple cam could do the job.

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The Wizard Of Semiconductors

May 22, 2023 by Al Williams 19 Comments

If you have three hours and you want to learn the fundamentals of semiconductors, [Tiny Tapeout] has something for you: An introduction to SiliWiz. You’ll also need the SiliWiz software (or use it online), which resembles the kind of tools that chip designers use but is meant for students to use as a learning tool

Using SiliWiz, you create layers on a virtual device, and you can use Spice to view the results. The tutorial is meant to be high-level and is suggested for students aged 14 or over (but we liked it and we are quite a bit older than that). Some more advanced material is also available at the same site.

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Op-Amp Challenge: MOSFETs Make This Discrete Op Amp Tick

May 20, 2023 by Dan Maloney 9 Comments

When it comes to our analog designs, op-amps tend to be just another jellybean part. We tend to spec whatever does the job, and don’t give much of a thought as to the internals. And while it doesn’t make much sense to roll your own op-amp out of discrete components, that doesn’t mean there isn’t plenty to be learned from doing just that.

While we’re more accustomed to seeing [Mitsuru Yamada]’s digital projects, he’s no stranger to the analog world. In fact, this project is a follow-on to his previous bipolar transistor op-amp, which we featured back in 2021. This design features MOSFETs rather than BJTs, but retains the same basic five-transistor topology as the previous work, with a differential pair input stage, a gain stage, and a buffer stage. Even the construction of the module is similar, using his trademark perfboard and ultra-tidy wiring.

Also new is a flexible evaluation unit for these discrete op-amp modules. This very sturdy-looking circuit provides an easy way to configure the op-amp for testing in inverting, non-inverting, and transimpedance mode, selecting from a range of feedback resistors, and even provides a photodiode input. The video below shows the eval unit in action with the CMOS module, as well as highlights the excellent construction [Mitsuru Yamada] is known for.

Looking for some digital goodness? Check out the PERSEUS-8, a 6502 machine we wish had been a real product back in the day.

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Big Tactile Button Is Silly But Cool

May 18, 2023 by Lewin Day 8 Comments

Every hacker is familiar with those teeny little tactile buttons that are so enjoyable to click over and over again. [ROBO HUB] has built a giant version as a tribute, and it works just like the real thing!

The giant button has been scaled up 20 times compared to the original. For simplicity’s sake, [ROBO HUB] designed this replica to use materials readily available around the home. Thanks to its cardboard construction, it’s easy to replicate with a minimum of tools. One need merely cut out the various sections before assembling them together with hot glue, with popsicle sticks serving as the legs. A juice bottle is used as the primary button itself, with aluminium foil serving as the contacts and rubber bands standing in for the spring.

It’s not the most useful button, given that it it’s quite fragile and has a weak spring return. However, it would be a great teaching tool to show students exactly what’s going on inside an actual button. As a bonus, it looks like it would be remarkably fun to pound on to activate some kind of massive air horn. Just an idea.

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The New Hotness

May 6, 2023 by Elliot Williams 35 Comments

If there’s one good thing to be said about the chip shortage of 2020-2023 (and counting!) it’s that a number of us were forced out of our ruts, and pushed to explore parts that we never would have otherwise. Or maybe it’s just me.

Back in the old times, I used to be a die-hard Atmel AVR fan for small projects, and an STM32 fan for anything larger. And I’ll freely admit, I got stuck in my ways. The incredible abundance of dev boards in the $2 range also helped keep me lazy. I had my thing, and I was fine sticking with it, admittedly due to the low price of those little blue pills.

And then came the drought, and like everyone else, my stockpile of microcontrollers started to dwindle. Replacements at $9 just weren’t an option, so I started looking around. And it’s with no small bit of shame that I’ll admit that I hadn’t been keeping up with the changes as much as I should have. Nowadays, it’s all ESP32s and RP2040s over here, and granted there’s a bit of a price bump, but the performance is there in abundance. But I can’t help feeling like I’m a few years back of the cutting edge.

So when I see work like what [CNLohr] and [Bitluni] are doing with the ultra-cheap CH32V003 microcontrollers, it makes me think that I need to start filling in gaps in my comfortable working-set of chips again. But how the heck am I supposed to keep up? And how do you? It took a global pandemic and silicon drought to force me out of my comfort zone last time. Can the simple allure of dirt-cheap chips get me out? We’ll see!

FET: Fun Endeavors Together

May 2, 2023 by Arya Voronova 42 Comments

Last time, we’ve looked over FET basics, details, nuances and caveats. Basics aren’t all there is to FETs, however – let’s go through real-world uses, in all their wonderful variety! I want to show you a bunch of cool circuits where a friendly FET, specifically a MOSFET, can help you – and, along the way, I’d also like to introduce you to a few FETs that I feel like you all could have a good long-term friendship with. If you don’t already know them, that is!

Driving Relays

Perhaps, that’s the single most popular use for an NPN transistor – driving coils, like relays or solenoids. We are quite used to driving relays with BJTs, typically an NPN – but it doesn’t have to be a BJT, FETs often will do the job just as fine! Here’s an N-FET, used in the exact same configuration as a typical BJT is, except instead of a base current limiting resistor, we have a gate-source resistor – you can’t quite solder the BJT out and solder the FET in after you have designed the board, but it’s a pretty seamless replacement otherwise. The freewheel (back EMF protection) diode is still needed for when you switch the relay and the coil produces wacky voltages in protest, but hey, can’t have every single aspect be superior.

The reason you can drive it the same way is quite simple: in the usual NPN circuit, the relay is driven by a 3.3 V or a 5 V logic level GPIO, and for small signal FETs, that is well within Vgs. However, if your MCU has 1.8 V GPIOs and your FET’s Vgs doesn’t quite cut it, an NPN transistor is a more advantageous solution, since that one will work as long as you can source the whatever little current and the measly 0.7 V needed.

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Hinges Live Inside 3D Prints

May 1, 2023 by Bryan Cockfield 5 Comments

Since desktop 3D printers have become more common, we’ve seen dramatic shifts in all kinds of areas such as rapid prototyping, antique restoration, mass production of consumer goods, or even household repairs that might not have been possible otherwise. There are a lot of unique manufacturing methods that can be explored in depth with a 3D printer as well, and [Slant 3D] demonstrates how one such method known as the living hinge can be created with this revolutionary new tool.

Living hinges, unlike a metal hinge you might pick up at a hardware store, are integrated into the design of the part and made of the same material. Typically found in plastic containers, they allow for flexibility while keeping parts count and cost low. The major downside is that they create stresses in the materials when used, so their lifespan is finite. But there are a number of ways to extend their life, albeit with a few trade-offs.

The first note is to make sure that you’re using the right kind of plastic, but after that’s taken care of [Slant 3D] builds a few flexible parts starting with longer circular-shaped living hinge which allows greater range of motion and distributes the forces across a wider area, at a cost of greater used space and increased complexity. A few other types of living hinges are shown to use less space in some areas, but make the hinges only suitable for use in other narrower applications.

One of the more interesting living hinges he demonstrates is one that’s more commonly seen in woodworking, known there as a kerf bend. By removing strips of material from a sheet, the entire sheet can be rotated around the cuts. In woodworking this is often done by subtracting material with a CNC machine or a laser cutter, but in 3D printing the voids can simply be designed into the part.

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