Tool Hacks

2975 Articles

Cheap Function Generator Teardown And Improvement

August 28, 2015 by 18 Comments

In general, you get what you pay for, and when [Craig] picked up a cheap function generator off eBay, he didn’t expect much from it. But as he shows us in his blog post and a series of videos below, while the instrument lived down to his expectations, he was able to fix it up a bit.

Having spent only $100USD for the MHS-5200A, [Craig]’s adventure is a complete teardown and analysis of the function generator. While it sort of lives up to its specs, it’s pretty clear that some design decisions resulted in suboptimal performance. At higher frequencies and higher amplitudes, the sine wave output took on a markedly non-sinusoidal character, approaching more of a triangle waveform. The spectrum analyzer told the tale of multiple harmonics across the spectrum. With a reverse-engineered schematic in hand, he traced the signal generation and conditioning circuits and finally nailed the culprit – an AD812 op-amp used as the final amplifier. An in-depth discussion of slew rate follows in part 2, and part 3 covers replacement of the dodgy chip with a better selection that improves the output signal. We’re also treated to improvements to a low-pass filter that fixed a nasty overshoot and ringing problem with the unit’s square wave function.

If hacking the MHS-5200A seems a bit familiar to you, that’s because we covered another reverse-engineering exploit of it recently. That hack of the serial protocol of the instrument was by [WD5GNR], also known as Hackaday’s own [Al Williams]. Cheers to both [Craig] and [Al] for showing us what you can do with a hundred bucks and a little know-how.

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Modified Mower Hacks The Heavy Stuff

August 28, 2015 by 25 Comments

Clearing brush is no fun. Sure, swinging a machete on a hot, humid day sounds great, but when you’re sitting in an oatmeal bath the next day because you didn’t see the poison ivy, you’ll be looking for a better way. [RoboMonkey] did just that with a field-expedient brush trimmer that’s sure to help with his chores.

This is a hack in the true Junkyard Wars sense of the word. A cast-off electric push mower deck caught [RoboMonkey]’s eye, and a few spare brackets and bolts later his electric hedge trimmer was attached across the front of the mower. With a long extension cord trailing behind, he was able to complete in 10 minutes what would normally take him an hour to accomplish, without spending a dime on either a specialized brush cutter or a landscaping service. The video after the break reveals that it may not be the most powerful tool in the shed, and it won’t likely stand up to daily use, but for this twice a year chore, it’s more than sufficient. And since the hedge trimmer wasn’t modified, it’s still available for its original purpose. Reduce, reuse, recycle – and repurpose.

While we haven’t seen many brush cutters before, we seen plenty of mower mods. From LiPo electrics to a gas-powered RC unit, the common push-mower seems to be a great platform for all kinds of hacking.

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Data Logging In The Picoampere Range

August 26, 2015 by 17 Comments

You probably know that to transfer the most energy between a source and a load their impedance needs to match. That’s why a ham radio transmitter needs a 50 ohm antenna (at least, usually). The transmitter is 50 ohms and you want a match. Some test equipment matches impedance, but for multimeters, oscilloscopes and a lot of other gear, the instrument just presents a very large impedance. As long as it is much larger than the measured circuit’s impedance, the effect will be small.

With today’s MOSFET instrumentation amplifiers, it isn’t uncommon to see very high input impedances.  However, you sometimes run into something that has a low input Z and that can cause issues if you don’t account for them. On the other hand, where some people see issues, others see opportunities.

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VirtualBench Tear Down

August 25, 2015 by 9 Comments

What do you get when you cross a mixed-signal oscilloscope, a function generator, a multimeter, a power supply, and some programmable digital I/O in a box? Sounds like the set up to a very geeky joke, but it is actually National Instrument’s VirtualBench product. [Shahriar] has one and wanted to know what was inside, so he did a tear down.

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Breadboards Go To Pot

August 24, 2015 by 7 Comments

Solderless breadboards are great for ICs and discrete components like resistors, capacitors, and transistors (at least the through hole kind). They aren’t so good at holding big components like potentiometers. Sure, you can jam trimmers in maybe. You can also solder leads to a pot, but that’s not pretty and tend to pull out when handled. [PaulStoffregen] got tired of it, so he put together some good looking PC boards that mount a 6mm shaft pot securely to a breadboard.

[Paul] noticed that having delicate or knobless adjustments on a breadboard inhibited people from playing with demo circuits. The new set up invites people to make adjustments. The pictures and video show an early version with six pins, but [Paul] added two more pins on the recent batch to increase the grip of the breadboard.

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Hot-Wire CNC Foam Cutter From E Waste

August 24, 2015 by 3 Comments

A couple of old DVD ROM drives and a compact photo printer is fairly standard fare at the thrift store, but what do you do with them? Hack them up to make a CNC foam cutter of course!

[Jonah] started with a couple LITE-ON brand DVD RW drives, which use stepper motors instead of plain old DC motors. This is a huge score since steppers make accurate positioning possible. With the internal frames removed, threaded rod and nuts were used to hold the two units parallel to each other forming the Z axis.

The feed mechanism from a Canon compact photo printer was then bolted onto the bottom to form the Y axis. Add a bit of nichrome wire for the cutting element (this can be found in old hair dryers) onto where the laser assembly of the DVD rom once lived, and you have the mechanics done.

Control is handled by an Arduino and some easy-driver modules to interface with the steppers. G-Code is generated by CamBam, which handles various cad files, or has its own geometry editor.

This is a fantastic way to get your feet wet in several ways; Cracking things open to harvest parts, driving steppers with simple micocontrollers, modeling and generating g-code, etc. The one issue we see with this build is a chicken-or-egg problem since you need to have a cube of foam cut down to somewhat strict dimensions before it will fit in this cutter. But we suppose that is really just an iterative design problem.

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Building An Atomic Force Microscope On The Cheap!

August 22, 2015 by 13 Comments

LEGO2NANO, are building an open hardware AFM (Atomic Force Microscope).

AFMs are a kind of probe microscope. Unlike an optical microscope, a probe is used to “feel” the topology of a surface. An atomic force microscope uses a flexible cantilever with a nanometer scale tip on the end. As the tip scans across the surface it will be deflected by its interaction with the surface. A laser spot is usually reflected off the back of the cantilever, and captured by a photodiode array. The angle of the reflected beam, and therefore which photodiodes are excited lets you know how much the cantilever was deflected by the surface.

One of the challenges of building an AFM is developing an actuator that can move with nanoscale precision. We recently reported on [Dan Berard]s awesome capacitor actuator, and have previously reported on his STM build which uses a piezo buzzer. LEGO2NANO are experimenting with a number of different configurations, including using Piezo buzzers, but in a different configuration to [Dan]s system.

The LEGO2NANO project runs as a yearly summer school to encourage high school students to take part in the ambitious task of building an AFM for a few hundred dollars (commercial instruments cost about 100,000USD). While the project isn’t yet complete, whatever the outcome the students have clearly learned a lot, and gained an exciting insight into this cutting edge microscopy technique.