Sigzig Data Loggers Ditch The Noise While Pimping The Case

January 21, 2015 by Mike Szczys 25 Comments

We ran into [Paul Allen] at CES. He was showing off Sigzig, a super-low noise data logger which his company is just rolling out.

A couple of years ago he worked on a standalone chemical sensor and had a few extra boards sitting around after the project was done. As any resourceful hacker will do, he reached for them as the closest and easiest solution when needing to log data as a quick test. It wasn’t for quite some time that he went back to try out commercially available loggers and found a problem in doing so.

The performance of off-the-shelf data loggers wasn’t doing it for [Paul’s] team. They kept having issues with the noise level found in the samples. Since he had been patching into the chemical sensor PCBs and getting better results, the impetus for a new product appeared.

The flagship 24-bit 8-channel Sigzig samples 0-5v with less than 1uV of noise. A less expensive 4-channel differential unit offers 18-bit with 10-12 uV of noise. They are targeting $199 and $399 price points for the two units. We asked about the sample rate in the video below. The smaller version shown here captures up to 240 samples per second. The big guy has the hardware potential to sample 30,000 times per second but ~~since the data is continuously streaming over USB~~ that rate is currently limited to much less.

Update: It has been pointed out in the comments that USB may not be the choke point for sample rate.

Circuit Plotting With An HP Plotter

January 18, 2015 by Brian Benchoff 13 Comments

Over the last few years we’ve seen a few commercial products that aim to put an entire PCB fab line on a desktop. As audacious as that sounds, there were a few booths showing off just that at CES last week, with one getting a $50k check from some blog. [Connor] and [Feiran] decided to do the hacker version of a PCB printer: an old HP plotter converted to modern hardware with a web interface with a conductive ink pen.

The plotter in question is a 1983 HP HIPLOT DMP-29 that was, like all old HP gear, a masterpiece of science and engineering. These electronics were discarded (preserved may be a better word) and replaced with modern hardware. The old servo motors ran at about 1.5A each, and a standard H-Bridge chip and beefy lab power supply these motors were the only part of the original plotter that were reused. For accurate positioning, a few 10-turn pots were duct taped to the motor shafts and fed into the ATMega1284p used for controlling the whole thing.

One of the more interesting aspects of the build is the web interface. This is a small JavaScript app that is capable of drawing lines on the X and Y axes and sends the resulting coordinates from a server to the printer. It’s very cool, but not as cool as the [Connor] and [Feiran]’s end goal: using existing Gerber files to draw some traces. They’re successfully parsing Gerber files, throwing out all the superfluous commands (drills, etc), and plotting them in conductive ink.

The final iteration of hardware wasn’t exactly what [Connor] and [Feiran] had in mind, but that’s mostly an issue with the terrible conductivity of the conductive ink. They’ve tried to fix this by running the pen over each line five times, but that introduces some backlash. This is the final project for an electrical engineering class, so we’re going to say that’s alright.

Video below.

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Cheap DIY Microscope Sees Individual Atoms

January 13, 2015 by Matt Freund 144 Comments

This is not an artist’s rendering, nor a physics simulation. This device held together with hardware-store MDF and eyebolts and connected to a breadboard, is taking pictures of actual atomic structures using actual measurements. All via an 80¢ piezo buzzer? Madness.

This apparent wizardry is called a scanning tunneling microscope which takes advantage of quantum tunneling. The device brings a needle atomically close to the object to be measured (by hand), applying a small voltage (+-15V), and stopping when it starts to conduct. Depending on the distance between the tip and the target, the voltage varies and does so precisely enough to identify whether an atom is underneath or not, and by how much.

The “pictures” are not photographs like a camera might take from a standard optical microscope, however they are neither guesses nor averages. They are representations of real physical measurements of specific individual atoms as they exist on the infinitesimal area being probed. It “sees” by measuring small voltage changes. Another difference lies in the “scanning.” The probe examines atoms the way one would draw ASCII images – single pixels at a time until an entire atom was drawn. Note that the resolution – as shown in the pictures – is sub-atomic. Sizes of atoms are apparent as are the distances between them. In this they are closer related to the far more expensive Scanning Electron Microscope technology, but are 10-100x zoomier; resolving 0.00000000001m, or 0.00000000039″.

HAD - STM4 — Scan Head – Piezo cut into quadrants

One would presume that dealing with actual atoms requires precision machining vast orders of magnitude beyond the home hobbyist but, no. Any one of us could make this at home or in our hackerspaces, for nearly free. Apparently even sharpening a tip to a single atom is, as [Dan] says “not as hard to achieve as you might think!” You take some tungsten wire and pull on it as you cut so that it shatters diagonally. There are better ways he suggests, but that method is good enough.

The ordinary piezo buzzer that is key to the measurement is chopped into quadrants with an ordinary X-Acto knife by hand. Carefully, because it is fragile, but, nothing more to it than that. There are two better and common methods but they cost hundreds of dollars, not 80 cents. It should be carefully glued since soldering heat will damage it, but, [Dan] soldered his anyway because it was easier. Continue reading “Cheap DIY Microscope Sees Individual Atoms” →

DIY Parts Tumbler Cleans Your Parts Good

January 11, 2015 by Rich Bremer 27 Comments

Part tumbling is a method of deburring and cleaning relatively small objects. This is done by capturing the parts and media inside a rotating container. The agitation continually moves the media around all surfaces and corners of the part, smoothing them out resulting in a uniform finish. The media can be anything from specialty ceramic shapes to ball bearings to even sand. This process can be done in either a wet or dry condition. Think about the beach, the rocks there are smooth. This is due to the waves repetitively rubbing together the sand and stones which result in smooth round shapes.

[imp22b] recently got into ammo reloading and needed a way to clean his used shell casings. The casings are brass and after a little research online, [imp22b] found that a wet tumbling process with stainless steel pins for media was a DIY proven method for this casing material. He then went on to find a commercially available tumbler to model his build after, in this case a Thumler Model B. There is certainly no need to re-invent the wheel here.

As you can see in the photo, aluminum extrusion was used as the frame. Mounted to the frame are 4 pillow block bearings with shafts between each pair. A motor drives one of the bearing-mounted rods which in turn rotates a container resting on the rods. [imp22b] started with a 1/15 hp motor that he had kicking around but that wasn’t powerful enough so he did have to step up to a 1/3 hp unit. The container is made from off the shelf PVC pipe pieces and holds the media and casings along with some water. A bit of Lemon Shine and Dawn detergents are also added and help clean the parts. After a few hours of tumbling, the casings look pretty darn good.

If you’re interested making your own simpler tumbler, check out this one that uses a hand drill or this one that uses a coffee can.

R/C Wheel Loader Clears Snow, Lifts People

January 10, 2015 by Adam Fabio 18 Comments

For some people, R/C cars just aren’t enough. [djMedic2008] has gotten his hands on a monstrous 1/5 scale wheel loader. The loader weighs in at 500lbs, and can lift up to 250 lbs. It was built several years ago as a prototype by [Richard] at Tiny Titan Earth Movers.

The design is based upon huge machines made by companies like Caterpillar and Komatsu. The 4WD system is driven a DC motor through a worm gear reduction. Bucket operation and steering are both operated by a hydraulic system driven by an electric pump. Just like the full-scale machines, the mini loader uses an articulated steering system. The front wheels are locked in place while the entire chassis bends at the middle pivot point. This allows for a much stronger solid front axle.

After several years of hard life, the loader came to [djMedic] in need of some TLC. The biggest issue was that the rear axle bevel gear had lost several teeth. This gear is under enormous loads when the loader is turning. A gear made of harder steel was the easy answer. Thankfully, you can order high carbon steel bevel gears from Amazon. The repair video gives us a look at the design of the loader. The main components of the machine are welded up from steel sheet and tube stock. This means that [djMedic] won’t have a hard time finding spare parts for his machine once he puts it to work clearing snow, dirt, or anything else that gets in its way!

Click past the break to see the loader in action!

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A New Handle For An Old Soldering Station

January 10, 2015 by Brian Benchoff 4 Comments

About 20 years ago, [Simon] spent a few week’s pay on a soldering station, a Micron W/2172. It served him well for the past few decades, but lately he hasn’t been able to find a supply of new tips for it. The Micron went into a cupboard and he upgraded to a newer Hakko soldering station.

The old Micron was still sitting in the cupboard when [Simon] realized both stations use a 24V supply for the heater, and you can buy replacement Hakko handle for a few bucks. Having two soldering stations would be handy, so [Simon] set out to convert the old Micron station to accept Hakko handles.

The only technical challenge for this modification was to figure out how the old circuit board in the Micron would read the thermistor in the new handle. The original circuit used a dual op-amp, with one side used to amplify the thermocouple and the other to compare it to the temperature set point. After measuring the set point and a bit of Excel, [Simon] had a small circuit board that would replace the old op-amp. After that it was only a matter of wiring the new handle into the old station, calibrating the temperature settings, and enjoying the utility of two soldering stations.

Measuring The Planck Constant With Lego

January 8, 2015 by Brian Benchoff 47 Comments

For nearly 130 years, the kilogram has been defined by a small platinum and iridium cylinder sitting in a vault outside Paris. Every other unit of measurement is defined by reproducible physical phenomenon; the second is a precise number of oscillations of a cesium atom, and a meter is the length light travels in 1/299792458th of a second. Only the kilogram is defined by an actual object, until NIST and the International Committee of Weights and Measures defines it as a function of the Planck constant. How do you measure the Planck constant? With a Watt balance. How do you build a Watt balance? With Lego, of course.

A Watt balance looks like a double-armed scale where one weight can be compared to another weight of known mass. Instead of using two arms, a Watt balance only has one arm, brought into balance by a current flowing through a coil. The mechanical power in the balance – brought about by whatever is on the balance plate – can then be compared to the electrical power, and eventually the Planck constant. This will soon be part of the formal definition of the kilogram, and yes, a machine to measure this can be made out of Lego.

The only major non-Lego parts in the Lego Watt balance are a few coils of wire wound around a PVC pipe and a few neodymium magnets. These are placed on both arms of the balance, and a pair of lasers are used to make sure both arms of the balance are level. Data are collected by measuring the coils through a few analog pins on a Labjack and a Phidget. Once the voltage and current induced in each coil is measured, the Wattage can be calculated, then the Planck constant, and finally how close the mass on the balance pan is to a real, idealized kilogram. Despite being made out of Lego, this system can measure a gram mass to 1% uncertainty.

The authors have included a list of Lego parts, most of which could be found in any giant tub of Lego in an 8-year-old’s closet. The only really expensive item on the BOM is a 16-bit USB DAQ; apart from that, it’s something anyone can build.

Thanks [Matt] for the tip.