Finally, A Machine To Organize Resistors!

September 6, 2023 by Jenny List 37 Comments

Perhaps it’s a side-effect of getting older, but it seems like reading the color bands on blue metal-film resistors is harder than it was on the old brown carbon ones. So often the multimeter has to come out to check, but it’s annoying. Thus we rather like [Mike]’s Resistorganizer, which automates the process of keeping track of the components.

At its heart is a fairly simple concept, with the microcontroller reading the value of a resistor by measuring the voltage from a potential divider. The Resistorganizer extends this using an array of analogue multiplexer chips, and is designed to plug into one side of a breadboard with the idea being that each line can have a resistor connected to earth through it. Of course it’s not quite as simple as that, because to maintain a readable range a set of resistors must be switched in and out to form the other half of the divider for different ranges. Thus another multiplexer chip performs that task.

Finally a set of digital multiplexers handles an LED to see which of the many resistors is currently selected through a pair of buttons, and a dot-matrix LCD display delivers the value. We want one already!

Fiery Torch Build Is Remarkably Stylish

September 4, 2023 by Lewin Day 7 Comments

Hollywood movies, RPGs, and Dungeons and Dragons campaigns are all full of flaming torches. They’re a typical source of light in scenarios where electrical solutions simply aren’t available. [Wesley Treat] decided to build a rather attractive ceremonial torch of his own design, showing off his impressive crafting skills in the process.

The torch ignited a pretty rad sculpture.

The build starts with a foam simulacra that helps [Wesley] rough out the general shape of the torch. It’s a little shorter and stubbier than an Olympic torch might be, for reference. The main body of the torch is then hewn out of stout wooden blocks with the aid of a bandsaw with a nifty angle-adjustable cutting bed. A torch was then used to heat and bend steel strip to make an attractive and heat-resistant flame shroud to sit on top. A wad of fuel-soaked material installed inside the shroud serves as the actual flaming compoment.

[Wesley] built the torch for the Maker Burn at Maker Camp in upstate New York. It did a plenty good job of helping burn down the giant scrap wood jackalope sculpture built for the event. We do love the fire and the flames around these parts. Video after the break.

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Hackaday Prize 2023: 10 KW Electronic Load

September 1, 2023 by Dave Rowntree 22 Comments

[tinfever] needed a high-power benchtop electronic load for an upcoming project, and by their own admission decided foolishly to build their own. And we’re glad they did. The thing is, whilst this isn’t exactly a super-cheap project to build, buying a commercial offering with a capability of 10 kW and up to 30 kW pulsed, is going to cost an absolute fortune.

Built inside a cubic frame using what appears to be standard 2020 aluminum rails and fixturing, the modular construction is nice and clean, with plenty of space around the load boards to allow the cooling air to circulate.

The operating principle is very simple; custom PCBs act in parallel to provide any load needed, by switching in the on-board load resistor. Each load board handles all the details of switching and dumping the power due to the inductance in the system wiring and the wire-wound resistors themselves.

Whilst we know that wire-wound resistors are reverse-wound to minimize inductance, there will still be some, and each load board will contribute a little more when the whole system is scaled up. Also, each load PCB handles its own temperature sensing, and current measurement passing these data off to the control PCB. A front-end connector PCB provides a variety of connection options to interface to the DUT (Device Under Test.) The system controller is based around an STM32 processor which deals with quite a lot more than you might think is needed on a first look.

The sense currents from each load need to be sensed, scaled, and summed to keep the overall load accuracy within the 1% spec. Also, it is on duty for PWM control of the cooling fans, handling the user interface, and any other remote connectivity. There are a lot of details on the project page, as we’re only skimming the surface here. If you’re interested in building an active load, this is a project you really should be digging into.

We shall watch with interest for when [tinfever] scales up this eight-slot prototype to the full specification of 52 stages! When working with power applications, there comes a point when you really need an electronic load, and to that end, here’s one with a very specific use case to get you started.

There is also the option of buying something cheap from the usual sources and hacking on some custom firmware to adapt it a little to your needs.

Making An Injection Mold For Yourself

August 28, 2023 by Jenny List 29 Comments

Injection molding is the obvious onward step from 3D printing when the making of a few plastic parts becomes their series manufacture. The problem with injection molding is though, that making a mold can be prohibitively expensive. Has the advent of affordable CNC machining changed that? [Teaching Tech] takes a look, and machines a mold for part of a bicycle bracket.

With a diversion into home-made silicone seals for the injection molding machine, he proceeds to machine the mold itself from a block of aluminium. It’s a basic introduction to mold construction for those of us who’ve never ventured in this direction before, and it provides some interesting lessons. As we’d expect he does a rough machining pass before returning with a ball-end tool to smooth off those curves, but there’s a lesson in measuring rather than believing the paperwork. The tool he used was a bit smaller then the spec, so his path left some rough edges that had to be returned to. Otherwise the use of a removable pair of bolts to form holes in the finished part is we guess obvious after watching the video, but it’s something we learned as injection molding newbies.

This video follows on from a previous one we also covered, in which we’re introduced to the machine itself.

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PCB Toaster Oven Solders Your Boards

August 28, 2023 by Al Williams 15 Comments

Using a toaster oven to reflow PCBs isn’t anything new, but just using a toaster oven has some limitations. Making toast isn’t as complex as reflowing PCBs. [Nabil] decided to modify an oven to get better results. In fact, this was the second iteration and involved making a custom PCB to replace the one in the oven. You can see the unit in the video below.

Of course, unless you have the exact oven (a Breville BOV450XL), you won’t want to duplicate the board, but it might give you some good ideas. The new board has a 2.8-inch capacitive LCD, an ESP32, and a few sensors and actuators.

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QSPICE Picks Up Where LTSpice Left Us

August 25, 2023 by Dave Rowntree 23 Comments

[Mike Engelhardt] is a name that should be very familiar to the hardcore electronics nerd. [Mike] is the developer responsible for LTSpice, which is quite likely the most widely used spice-compatible simulator in the free software domain. When you move away from digital electronics and the comfort of software with its helpful IDEs and toolchains, and dip a wary toe into the murky grey waters of analog or power electronics, LTSpice is your best friend. And, like all best friends, it’s a bit quirky, but it always has your back. Sadly, LTSpice development seems to have stalled some years ago, but luckily for us [Mike] has been busy on the successor, QSpice, under the watchful eye of Qorvo.

It does look in its early stages, but from a useability point of view, it’s much improved over LTSpice. Performance is excellent (based on this scribe’s limited testing while mobile.) Gone (thankfully!) is the uncommon verb-noun usage paradigm — replaced with a more usual cut-n-paste flow. Visually it still kind of looks like LTspice in places, but nicer with a clear and uncluttered design that gets straight to the point. Internally, the simulation engine has improved in speed and accuracy, as well as adding native support for modern semiconductor types, such as wide bandgap materials like SiC. Noted is that this updated software has a particular emphasis on power integrity and noise analysis, which are sticky problems that have a big impact on modern high-power systems.

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Hackaday Prize 2023: Jumperless, The Jumperless Jumperboard

August 25, 2023 by Dave Rowntree 9 Comments

Jumperless is a jumperless breadboard with multicolored LED visualization of signals in real-time. Sounds like magic? This beautifully executed entry to the 2023 Hackaday Prize by [Kevin Santo Cappuccio] uses a boatload of CH446Q analog switch ICs to perform the interconnect between the Raspberry Pi Pico header and the jumper board (or breadboard if you prefer.)

This will add some significant resistance, but for low currents and digital logic levels, this should not be a major concern. Additionally, there are two DAC channels and four ADC channels to help break out of the digital world, which could make for some very interesting non-trivial applications.

The visualization of the Pico header signals is solved neatly with a tiny wishbone-shaped PCB that is reverse-mounted to the back of the main board to illuminate upwards. The masking of the labels is done by using copper to mask off the individual signals and solder mask to draw in the legends. This PCB-level hacking is simply wonderful to see. The PCBs are designed with KiCAD, the design files for which you can find here. It appears however that [Kevin] needed to have the spring clips for the jumper board custom-made, so you’d need to contact them if you needed to get some for a build.

On the software side of things, [Kevin] currently recommends using Wokwi, to run the Arduino stack applications and to perform the signal routing to the virtual jumper board. You can follow how it works internally here. A Python-based bridge application runs on the host computer, which takes care of programming the interconnects as they are constructed, which looking at the demo in the embedded video, appears to ‘just work.’

One word of caution though — the bridge app uses Python requests and Beautiful Soup to scrape the Wowki project page, which could potentially make it vulnerable to getting out-of-sync with updates, so hopefully [Kevin] will keep track of this and keep them in sync.

Need some breadboarding tips? We got you covered. Talking of bread, here’s an 8-bit TTL breadboard-based CPU in a breadbin.

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