A person holds a bundle of white, black, and blue wires. The left hand side of the wires are wrapped with black tape. The wires are inside a wire wrapping machine with a grey plastic "C" which rotates inside seven small pulleys. A large pulley in the background drives three of the pulleys to rotate the "C" around and wrap the wires with tape from the spool attached to the "C."

DIY Tool Makes Wrapping Wiring Harnesses A Breeze

February 26, 2023 by Navarre Bartz 17 Comments

If you’re making a lot of wiring harnesses, wrapping them can become a bit of a drag. [Well Done Tips] wanted to make this process easier and built a wiring harness wrapping machine.

The “C” shape of this wrapping machine means that you can wrap wires that are still attached at one or both ends, as you don’t have to pull the wires all the way through the machine. The plastic “C” rotates inside a series of pulleys with three of them driven by a belt attached to an electric motor. A foot pedal actuates the motor and speed is controlled by a rotary dial on the motor controller board.

Since this is battery powered, you could wrap wires virtually anywhere without needing to be near a wall outlet. This little machine seems like it would be really great if you need to wrap a ton of wire and shouldn’t be too complicated to build. Those are some of our favorite hacks.

If you’re wanting more wire harness fun, try this simple online wiring harness tool or see how the automotive industry handles harnesses.

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Two pairs of steel parallel pliers sit on a rough wooden benchtop. The pair on the left is open and the pair on the right is closed, demonstrating the parallel nature of the pliers' jaws over their entire range of motion. There are three brass pins flush with the steel surface of the handles and you can just barely make out the brass and copper filler material between the steel outer surfaces of the handles.

Producing A Pair Of Parallel Pliers

February 24, 2023 by Navarre Bartz 10 Comments

A regular pair of pliers is fine most of the time, but for delicate work with squarish objects you can’t go wrong with a pair of parallel pliers. [Neil Paskin] decided to make his own pair from scratch. (YouTube)

The jaws were machined down from round stock in [Paskin]’s mill before heat treating and tempering. The steel portions of the handles were cut from 16 gauge plate steel and half of them were stamped on a fly press to make the bridging section around the pivot bolt. The filler for the handles is copper on one side and brass on the other as [Paskin] didn’t have enough brass of the correct size to do both.

The steel and filler were joined with epoxy and copper pins before beveling the edges and sanding to give a comfortable contour to the handles. The bolts for the pliers started as ordinary hex bolts before being machined down on the lathe to a more aesthetically-pleasing shape and size. The final touches included electrolytically etching a logo into the bridge and then spraying down the pliers with a combination lubricant and corrosion preventative spray. This is surely a pair of pliers worth handing down through the generations.

For more mesmerizing machining, checkout this pocket safe or this tiny adjustable wrench.

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Testing The Raspberry Pi Debug Probe

February 23, 2023 by Jenny List 14 Comments

We mentioned the Raspberry Pi Debug Probe when it was launched, a little RP2040-based board that provides both a USB-to-UART and an ARM SWD debug interface. [Jeff Geerling] was lucky enough to snag one, and he’s put it through its paces in a handy blog post.

The first question he poses is: why buy the Pi offering when cheaper boards can be found on AliExpress and the like? It’s easily answered by pointing to the ease of setting up, good documentation and support, as well as the device’s reasonable price compared to other commercial probes. It also answered a personal question here as he hooked it up to a Pico, why it has three jumpers and not the more usual multi-way header we’ve seen on other ARM platforms. We should have looked at a Pico more closely of course, because it matched neatly to the Pi product. On the Pico they’re at the edge, while on the Pico W they’re in the center.

No doubt if the latest addition to the Pi stable has any further revelations we’ll bring them to you. But it’s worth a quick look at this piece to see a real experience with their latest. Meanwhile, take a quick look at our launch coverage.

Tidy Breadboard Uses Banana Bread

February 20, 2023 by Chris Lott 21 Comments

Self-described passionate maker in the electronics and 3D printing world, [Jakob], aka [testudor], was getting frustrated trying to connect banana plugs to solderless breadboards. Project Banana Bread was born — small banana jack adaptors and a companion tray with pockets to hold up to six modules.

The base in the photo is made from 5083 aluminum, machined on a homemade CNC router. But design files for a yet-to-be-tested 3D printer version are available as well. As can happen, he strayed from the original goal of solving the banana jack issue, and also cranked out a USB-serial port and a blank template module for any custom interfaces folks may want to implement.

If it is only power connections you are interested in, we covered the Open Power project back in 2019. And also don’t forget the mother of all breadboards, this 1960s behemoth we wrote about last year. What kinds of breadboard interface modules do you find most useful? Let us know in the comments below.

Tiny PCB Banishes Soldering Fumes, Automatically

February 19, 2023 by Donald Papp 28 Comments

A fan to remove fumes is a handy thing to have when soldering, even better is a fan furnished with a filter. Better still is a fan that activates only when the iron is in use, turning off when the iron is in its stand. Now that’s handy!

[Petteri Aimonen] made exactly such a device when he noticed his JBC BT-2BWA soldering station could detect when the iron is removed from its stand, and indicate its operating mode via status LEDs. Broadly speaking, when the iron is removed from its cradle the green “in use” LED is on. By turning the fan on whenever that LED is lit (and turning it off when it becomes unlit), fume extraction gets a little more elegant and efficient.

Instead of tapping directly into the soldering station’s hardware to detect the LED’s state, [Petteri] went for a completely noninvasive solution that made good use of a few spare parts and a small bit of copper-clad board. The PCB is nothing more than piece of copper-clad board with lands scratched out with a hobby knife.

This tiny board sits atop the soldering station, parking a photodiode directly above the “in use” LED. The circuit is a simple comparator whose output controls fan power via a MOSFET, and a top-facing LED provides as a duplicate “in use” indicator, since the original is hidden under the tiny board.

Even for one-off designs like this, creating a PCB layout in an EDA program like KiCad is still worth doing because one can use it to scratch out lands on a copper-clad board, a technique with similarities to Manhattan-style circuit construction.

Curve Tracer Design For Power Vacuum Tubes Testing

February 15, 2023 by Maya Posch 9 Comments

Regardless of the mythical qualities that are all too often attributed to vacuum tubes, they are still components that can be damaged and wear out over time. Much like with transistors and kin, they come with a stack of datasheets, containing various curves detailing their properties and performance. These curves will change as a part ages, and validating these curves can help with debugging a vacuum tube-based circuit. This is where one can either spend an enormous sum on a commercial curve tracer like the Tektronix 570, or build your own, as [Basin Street Design] has done.

A semi-retired electronics design engineer by trade, he has previously covered the development of the curve tracer on Instructables for the version 1 and version 1.1. What this device essentially allows you to do is sweep the connected tube through its input parameter ranges, while observing the resulting curves on an attached (external) oscilloscope. Here a storage oscilloscope (or DSO) is immensely helpful to capture the curves.

In the project pages, the in-depth theory and functioning of the circuitry is explained, along with the schematics and a number of builds. The project has been around since before the VBA tracer which we covered last year, both of which are infinitely more affordable than a genuine Tektronix 570.

Thanks to [Fernando] for the tip.

OpenSPICE: A Portable Python Circuit Simulator

February 14, 2023 by Dave Rowntree 22 Comments

[Roman Parise] and [Georgios Is. Detorakis] have created OpenSPICE a fork of the PySpice project, adding a new simulation engine written entirely in Python. This enables the same PySpice simulations to be executed on any platform that runs python (which we reckon is quite a few!) whilst leveraging the full power of the python infrastructure. Since it is a fork — for supported platforms — you can also run your simulations upon Ngspice as well as Xyce, giving options for scaling up to larger systems when required, but importantly without having to recreate your circuit from scratch.

The OpenSPICE simulator first converts the parsed netlist into a set of data structures that represent the equations describing the various parts of the system. These are then in turn passed along the scipy library “optimize.root” function which solves the system, generating a list of branch currents and node voltages. The output of the simulation is a numpy array, which can be further processed and visualized with the mathplotlib library. All pretty standard stuff in python circles. Since this is based upon PySpice, it’s also possible to use KiCAD netlists, so you have a nice way to enter those schematics. We’ve not dug into this much yet, but support for the vast libraries of spice models out there in circulation would be high up on our wish list if it already can’t handle this. This scribe will most definitely be checking this out, as LTSpice whilst good, is a bit of a pain to use and does lack the power of a Python backend!

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