High Voltage Turns Welder Into Plasma Cutter

October 24, 2023 by Bryan Cockfield 29 Comments

For doing basic steel welding, most of us will reach for a MIG welder. It might not be the best tool for every welding job, but it’s definitely the most accessible since they tend to use only basic parts, easy-to-find gas, and can run from a standard electrical outlet. A plasma cutter isn’t as common, and while they’re certainly useful, [Rulof] wanted to forgo the expense of buying one off the shelf. Instead, he used parts of an old welder and a few other odds and ends to build his own plasma cutter.

The welder he’s working from in this project uses low-voltage alternating current to drive the welding process, but since a plasma cutter ionizes gas it needs high-voltage direct current. A 200 A bridge rectifier with some heat sinks from a Mac and an old stereo get this job done, but that’s not the only step in the process. A driver board and flyback transformer is used to generate the high voltage needed for the cutting head. There are some DIY circuit protection and safety features built in as well, including a spark gap using two nails, galvanic isolation from a transformer built from copper pipe, and some filtering coils made from old copper wire and iron bars.

With everything connected to the old welding machine and some pressurized air inside to push out the plasma, [Rulof] has a functional plasma cutter that can make short work out of a variety of metals at a fraction of the cost of a commercial tool. With the cutting tool finished, we’d recommend mounting it to a home-built CNC machine next.

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Arduino-Controlled Coil Winder

October 21, 2023 by Lewin Day 13 Comments

Coil winders are a popular project because doing the deed manually can be an incredibly tedious and time consuming task. After building one such rig, [Pisces Printing] wanted to find even further time savings, and thus designed an improved, faster version.

At it’s heart, it’s a straightforward design, using a linear rail and a leadscrew driven by a stepper motor. Control is via an Arduino Nano, with a few push buttons and a 16 x 2 LCD display for user feedback.

Often, completing a first build will reveal all manner of limitations and drawbacks of a design. In this case, the original winder was improved upon with faster stepper motors to cut the time it took to wind a coil. A redesigned PCB also specified a better buck converter power supply to avoid overheating issues of the initial design. A three-jaw lathe-style chuck was also 3D printed for the build to allow easy fixing of a coil bobbin.

Designing custom tools can be highly satisfying in and of itself, beyond the productivity gains they offer. Video after the break.

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Simple Circuit Keeps Process Control Loops In Tune

October 19, 2023 by Dan Maloney 7 Comments

Spare a moment’s pity for the process engineer, whose job it is to keep industrial automation running no matter what. These poor souls seem to be forever on call, fielding panicked requests to come to the factory floor whenever the line goes down. Day or night, weekends, vacations, whatever — when it breaks, the process engineer jumps.

The pressures of such a gig can be enormous, and seem to have weighed on [Tom Goff] enough that he spent a weekend building a junk bin analog signal generator to replace a loop calibrator that he misplaced. Two process control signaling schemes were to be supported — the 0 to 10 VDC analog signal, and the venerable 4-20 mA current loop. All that’s needed for both outputs is an Arduino and an LM358 dual op-amp, plus a few support components. The 0-10 V signal starts as a PWM output from the Arduino, with its 0-5 V average amplified by one of the op-amps set up as a non-inverting amp with a gain of 2. With a little filtering, the voltage output is pretty stable, and swings nicely through the desired range — see the video below for that.

The current loop output is only slightly more complicated. An identical circuit on a separate Arduino output generates the same 10 V max output, but a code change limits the low end of the range to 1 V. This output of the op-amp is fed through a 500-Ω trimmer pot, and the magic of Ohm’s Law results in a 4-20 mA current. The circuit lives on a piece of perf board in a small enclosure and does the job it was built for — nothing fancy needed.

And spoiler alert: [Tom] found the missing loop calibrator — after he built this, of course. Isn’t that always the way?

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Vector Network Analyzer Demo And Teardown

October 18, 2023 by Donald Papp 10 Comments

[Kerry Wong], ever interested in trying out and tearing down electrical devices, demonstrates and examines the SV 6301a Handheld Vector Network Analyzer. He puts the machine through its paces, noting that the 7 inch touchscreen is a pretty nice feature for those whose eyesight isn’t quite what it used to be.

The internals are similar to the nanoVNA-F V3, but not identical.

What’s a Vector Network Analyzer (VNA)? It’s not for testing Ethernet or WiFi. It’s aimed at a more classical type of “network”. The VNA tests and evaluates characteristics of electrical networks, especially as related to RF and microwave.

It provides detailed information about properties across a specified frequency range, making it an indispensable tool for advanced work. Tektronix has a resource page that goes into detail about exactly what kinds of things a VNA is good for.

[Kerry] shows off a few different features and sample tests before pulling the unit apart. In the end, he’s satisfied with the features and performance of the device, especially the large screen and sensible user interface.

After all, not every piece of test equipment does a great job at fulfilling its primary function, like the cheap oscilloscope that was a perhaps a little too cheap.

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STM32 Offers Performance Gains For DIY Oscilloscope

October 18, 2023 by Bryan Cockfield 23 Comments

There’s no shortage of cheap digital oscilloscopes available today from the usual online retailers, but that doesn’t mean the appeal of building your own has gone away — especially when we have access to powerful microcontrollers that make it easier than ever to spin up custom gear. [mircemk] is using one of those microcontrollers to build an improved, pocket-sized oscilloscope.

The microcontroller he’s chosen is the STM32F103C8T6, part of the 32-bit STM family which has tremendous performance compared to common 8-bit microcontrollers for only a marginally increased cost. Paired with a small 3-inch TFT color display, it has enough functions to cover plenty of use cases, capable of measuring both AC and DC signals, freezing a signal for analysis, and operating at an impressive 500 kHz at a cost of only around $15. The display also outputs a fairly comprehensive analysis of the incoming signal as well, with the small scope capable of measuring up to 6.6 V on its input.

This isn’t [mircemk]’s first oscilloscope, either. His previous versions have used Arduinos, generally only running around 50 kHz. With the STM32 microcontroller the sampling frequency is an order of magnitude higher at 500 kHz. While that’s not going to beat the latest four-channel scope from Tektronix or Rigol, it’s not bad for the form factor and cost and would be an effective scope in plenty of applications. If all you have on hand is an 8-bit microcontroller, though, we have seen some interesting scopes built with them in the past.

Badminton String Winder Gets The Tension Just Right

October 12, 2023 by Lewin Day No comments

If you want to keep your badminton game at its peak, you’ll need a good racket with a proper set of strings. When an injury kept [Antonie Colin] off the court for a few months, building a restringing machine helped pass the time.

The design is straightforward, using commonly-available motion components and 3D-printed parts. The round assembly at one end is used to hold the racket during the restringing process. A leadscrew mechanism driven by a stepper motor is used to apply tension to the strings, anywhere from 18 lbs to 34 lbs. Strings can also be prestretched if so desired. The stringing process is managed by an Arduino, which uses a loadcell to monitor tension placed on the strings. An LCD screen on the device provides feedback on the process and allows various functions to be selected. Flying clamps are used to hold strings in place during the process, either fitted from above or below the device as needed.

If you find yourself regularly restringing your badminton racket, or you simply don’t trust your local pro shop to do so, you might find this build useful. You might also like to build a shuttlecock launcher for training if your practice partners aren’t available on the regular. Our badminton department is looking rather bare at the moment, so don’t hesitate to send your own nifty hacks in to the tipsline!

Hackaday Prize 2023: AC Measurements Made Easy

October 12, 2023 by Bryan Cockfield 17 Comments

When working on simple DC systems, a small low-cost multimeter from the hardware store will get the job done well enough. Often they have the capability for measuring AC, but this is where cheap meters can get tripped up. Unless the waveform is a perfect sinusoid at a specific frequency, their simple algorithms won’t be able to give accurate readings like a high-quality meter will. [hesam.moshiri] took this as a design challenge, though, and built an AC multimeter to take into account some of the edge cases that come up when working with AC circuits, especially when dealing with inductive loads.

The small meter, an upgrade from a previous Arduino version that is now based on the ESP32, is capable of assessing root mean square (RMS) voltage, RMS current, active power, power factor, and energy consumption after first being calibrated using the included push buttons. Readings are given via a small OLED screen and have an accuracy rate of 0.5% or better. The board also includes modern design considerations such as galvanic isolation between the measurement side of the meter and the user interface side, each with its own isolated power supply. The schematics and bill-of-materials are also available for anyone looking to recreate or build on this design.

With the project built on an easily-accessible platform like the ESP32, it would be possible to use this as a base to measure other types of signals as well. Square and triangle waves, as well as signals with a large amount of harmonics or with varying frequencies, all need different measurement techniques in order to get accurate readings. Take a look at this classic multimeter to see what that entails.

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