Optical Sensor Keeps Eye On Wandering Saw Blade

May 24, 2021 by Tom Nardi 17 Comments

Over the last year or so, we’ve been checking in on the progress [Andrew Consroe] has been making with his incredible CNC scroll saw project. While we were already impressed with his first prototype version, he somehow manages to keep pushing the envelope forward with each new upgrade, and we’re always excited when one of his progress reports hits the inbox.

Recently he’s been struggling with the fact that the considerable flexing of the scroll saw’s ultra-thin blade introduces positional errors while cutting. To combat this, he’s developed an ingenious sensor that can track the movement of the blade in two dimensions without actually touching it. Utilizing the Raspberry Pi HQ camera, a 3D printed framework, and some precisely placed mirrors, [Andrew] says his optical sensor is able to determine the blade’s position to within 10 microns.

In the video below [Andrew] goes over how his “Split Vision Periscope” works, complete with some ray traced simulations of what the Pi camera actually sees when it looks through the device. After experimenting with different lighting setups, the final optical configuration presents the camera with two different perspectives of the saw blade set on a black background. That makes it relatively easy to pick out the blade using computer vision, and turn that into positional information.

The periscope arrangement is particularly advantageous here as it allows the camera and lens to be placed under the work surface and well away from the actual cutting, though we’re interested in seeing how it fares against the dust and debris that will inevitably be produced as the saw cuts. While he hit all of his design goals, [Andrew] does note that his mirrors do leave some room for improvement; but considering he hand cut them out of old hard drive platters we think the results are more than acceptable.

An incredible amount of progress has been made since the first time we saw the CNC scroll saw, and we’re eager to see this new sensor fully integrated into the next version of [Andrew]’s impressive long-term project.

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Portable Drill Press

May 22, 2021 by Al Williams 31 Comments

We aren’t sure that [John Heisz’s] build is really what we think of as a drill press, but it is a very portable way to convert a regular drill into something like a drill press. Your drill will probably be different, but you can follow along with his build in the video below.

On the face of it, it doesn’t seem like this would be very hard, but there are a few tricks. Finding the exact center of the drill axis on the back of the drill takes a bit of effort.

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DIY Insulating Nuts And Bolts

May 22, 2021 by Chris Lott 12 Comments

[Rudi Schoenmackers] has devised a clever set of custom 3D-printed jigs that makes it easy to build your own wooden hex nuts and bolts. Well, easy if you have access to a woodworking shop with a router, bandsaw and belt sander.

You won’t be using these to mount your PCBs, however. They are pretty big — UNC 1½-6 threads (the closest metric thread would probably be M36-4). [Rudi] points out that these jigs can be readily adapted to generate different sizes and pitches of threads, even left-handed ones, but we suspect making a #4-40 or M3-0.5 is out of the question. There are commercial jigs for making threads, but as [Rudi] points out, those are quite expensive. The price of [Rudi]’s jigs is quite low, assuming you have a 3D printer.

We’re not sure how to best take advantage of these nuts and bolts in ordinary hacking projects, but [Rudi] enjoys giving them away as cool toys or making large clamps and vises out of them. Let us know if you have any applications where wooden threaded fasteners could come in handy. If wooden threads interest you, then check out this project we covered a few years ago on making simple taps.

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Simple Probe Sniffs Out EMI

May 21, 2021 by Tom Nardi 19 Comments

Unable to account for the strange glitches he was seeing on his DIY CNC router, [Daniël Van Den Berg] wondered if his electronics might be suffering from some form of electromagnetic interference (EMI). So he did what any good hacker would do, and rummaged through the parts bin to build an impromptu EMI detector.

[Daniël] is quick to point out that he’s not an electrical engineer, and makes no guarantees about the accuracy of his tossed together gadget. But it does seem to work well enough in his testing that he’s able to identify particularly “noisy” electronic components, so it’s probably worth putting one together just to hear what your hardware is pumping into the environment.

The hardware here is very simple, [Daniël] just attached a coil of solid copper wire to one of the analog pins on an Arduino Nano with a resistor, and hung a speaker off of one of the digital pins. From there, it just took a few lines of code to read the voltage in the coil and convert that into a tone for the speaker. The basic idea is that a strong alternating magnetic field will set up voltage fluctuations in the coil large enough for the Arduino’s ADC to read.

If you’re looking for a bit more insight into what kind of interference your electronic creations might be putting out, [Alex Whittimore] gave a fantastic presentation during the 2020 Hackaday Remoticon about performing RF debugging using a cheap RTL-SDR dongle.

Reading Floppies With An Oscilloscope

May 20, 2021 by Al Williams 6 Comments

There’s a lot of data on magnetic media that will soon be lost forever, as floppies weren’t really made to sit in attics and basements for decades and still work. [Chris Evans] and [Phil Pemberton] needed to read some disks that reportedly contained source code for several BBC Micro games, including Repton 3. They turned to Greaseweazle, an interface board that can dump just about any kind of floppy disk if it is attached to the right drive. The problem is that Greaseweazle couldn’t read the disks due to CRC errors. Time to break out the oscilloscope and read the disk manually, which is what they did.

Greaseweazle provides a nice display of read sectors and shows timing coming from the floppy read head. The disk in question looked good with reasonably clean timing clocks except in the area of one sector. At that point, the clocks degenerated into noise. Looking on the disk, it was easy to see why. The actual media had a small dent in it.

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Repurpose A Monitor Arm As Microscope Mount

May 16, 2021 by Chris Lott 12 Comments

Being a bit shocked at the prices of articulating arm microscope mounts, not to mention the shipping fees to the UK, [CapTec] realized they looked substantially similar to your typical computer monitor arm mount. Thinking he could adapt a monitor arm for much less money, he fired up FreeCAD and started designing.

[CapTec] is using this to support his Amscope / Eakins camera-equipped trinocular microscope, but notes that the same mechanical bracket / focus rack interface is found on binocular ‘scopes as well. He observes that the mount is no more stable than your desk or lab bench, so keep that in mind.

Ultimately the monitor arm set him back less than $40, and all told he reckons the whole thing was under $55. Based on prices he’s been researching online, this represents a savings of well over $200. In his calculations, the shipping fee comprised quite a hefty percentage of the total cost. We wonder if they are artificially high due to coronavirus — if so, the make / buy price comparison might yield different results in the future.

This type of project is a perfect use-case for a home 3D printer — making your own parts when the normal supply channels are unavailable or overpriced. Are articulating arms that are purpose-built for microscopes significantly different than those designed for big computer monitors? If you know, please comment down below.

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Tape Cutter Makes Short Work Of Through-Hole Resistor Reels

May 16, 2021 by Jenny List 9 Comments

As the world of electronics makes its inexorable movement from through-hole parts to surface-mount, it’s easy to forget about the humble wire-ended resistor. But a stack of them is still a very useful resource for any experimenter, and most of us probably have a bunch of them with their accompanying twin strips of tape. We’re entranced by [Sandeep]’s automated resistor tape cutting machine, which uses a fearsome looking pair of motorized knives to slice the tape into predetermined lengths.

At its heart is an Arduino and a set of stepper drivers, and it uses a PCB that he’s designed as a multipurpose board for motor-based projects. One motor advances the reel of resistors, while the other two operate those knives that simultaneously slice the two tapes. The whole is held in a wooden frame with 3D-printed parts, and control is through a touch screen. This feels more like an industrial machine than a maker project, and as can be seen in the video below, it makes short work of those tapes. Full details can be found on his website, including code.

We’ve not had so many through hole tape cutters, but we’ve seen at least one SMD cutter.

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