16-Bobbin Rope Braiding Machine Inspired By Surplus Store Find

July 29, 2014 by Mike Szczys 34 Comments

When the Red Bull Creation build days were past, [David] pulled us aside and asked if we wanted to see the mechanical hack he’s been working on. He built this rope braiding machine, which uses 16 bobbins, with help from his brother [Jed].

Ideas for projects always come from funny places. [David] came up with this one after finding a rope braiding machine at Ax-man Surplus. This outlet, located in the Twin Cities (Minneapolis/St. Paul, Minnesota) has been the origin for innumerable hacks. Just one that comes to mind is this electric scooter project from the ’90s.

[David] wanted to understand how the mechanism, which divides the bobbins up into groups of orbiting spools, actually works. It’s both mesmerizing and quite tough to visualize how it works without really getting in there and looking at the gearing. Thankfully you can do just that if he follows through with his plan to turn this into a kit.

In case you don’t recognize him, [David] was on the 1.21 Jigawatt’s team during this year’s Creation. We’ve also seen a couple of hacks from him in the past like this half-tone drum printer, and this bicycle frame welding jig.

Assembling the prototypes

Outfeed used to help with even braids

Testing prototypes

Turn the crank and 16 bobbins dance around one another

Machine being demonstrated

Cloning Tektronix Application Modules

July 28, 2014 by Brian Benchoff 169 Comments

Tektronix’s MSO2000 line of oscilloscopes are great tools, and with the addition of a few ‘application modules’, can do some pretty interesting tasks: decoding serial protocols, embedded protocols like I2C and SPI, and automotive protocols like CAN and LIN. While testing out his MSO2012B, [jm] really liked the (limited time) demo of the I2C decoder, but figured it wasn’t worth the $500 price the application module sells for. No matter, because it’s just some data on a cheap 24c08 EEPROM, and with a little bit of PCB design <<removed because of DMCA takedown>>

The application module Tektronix are selling is simply just a small EEPROM loaded up with an <<removed because of DMCA takedown>>. By writing this value to a $0.25 EEPROM, [jm] can enable two applications. The only problem was getting his scope to read the EEPROM: a problem easily solved with a custom board.

The board [jm] designed <<removed because of DMCA takedown>>, with the only additional components needed being an EEPROM, a set of contacts for reading a SIM card, and a little bit of plastic glued onto the back of the board for proper spacing.

UPDATE: Learn about the DMCA Takedown Notice that prompted this post to be altered: http://hackaday.com/2014/08/05/hardware-security-and-a-dmca-takedown-notice/

Spot Welder; Don’t Buy It, Build It

July 21, 2014 by James Hobson 84 Comments

Spot welders are super handy for making sheet metal enclosures for your projects. The problem is, commercial ones are rather expensive… The good news is, they’re actually really easy to make! This is [Caio Paulucci’s] first submission to Hack a Day, and it was a weekend project him and his father just finished.

A spot welder works by dissipating large amounts of heat in between two electrodes in the material you are bonding. It makes use of a transformer that converts mains voltage to a very low voltage, but high current energy source. The cool thing with this type of welder is it’s perfectly safe to hold onto the electrodes as the voltage is so low, you won’t get electrocuted. By running a super high current (generally >1000A @ ~1-2V) through a small surface area, you can super heat most materials hot enough to weld them together.

They can be made using the transformer from a microwave, some heavy duty welding wire (generally 2/0 or thicker), and a few other odds and ends such as wood, electrodes, and maybe a few nuts and bolts. At the most basic level, you are basically re-wrapping the transformer’s secondary coils to change the ratio to produce a low voltage, high current transformer.

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CERN Shows Off New KiCad Module Editor

July 14, 2014 by Eric Evenchick 38 Comments

CERN, the people that run a rather large particle collider, have just announced their most recent contributions to the KiCad project. This work focused on adding new features to the module editor, which is used to create footprints for parts.

The update includes support for DXF files, which will make it easy to import part drawings, or use external tools for more complex designs. New distribute tools make it easy to space out pads evenly. The copy and paste function now allows you to set a reference point, making it easy to align blocks. Finally, the pad enumeration tool lets you quickly set pin numbers.

CERN has already implemented a new graphics engine for KiCad, and demonstrated a new push and shove routing tool. The work plan for CERN’s KiCad contributions shows their long term goals. If you’re interested in what CERN is doing with KiCad, you can check out the CERN KiCad Developers Team on Launchpad.

After the break, watch a quick run through of the new features.

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Proper Debugging For Energia Sketches

July 13, 2014 by Eric Evenchick 10 Comments

Energia is a tool that brings the Arduino and Wiring framework to Texas Instruments’ MSP430 microcontrollers and the MSP430 Launchpad development board. This allows for easy development in an Arduino-like environment while targeting a different microcontroller family.

One problem with Energia and Arduino is the difficulty of debugging. Usually, we’re stuck putting a Serial.println(); and watching the serial port to trace what our program is doing. Other options include blinking LEDs, or using external displays.

Code Composer Studio, TI’s official development tool, allows for line-by-line debugging of applications. You can set breakpoints, watch the value of variables, and step through an application one instruction at a time.

The good news is that the latest version of Code Composer Studio supports importing Energia sketches. Once imported, you can step through the code and easily debug your application. This is a huge help to people developing more complex software using Energia, such as libraries.

TI gives us an overview of the new feature in a video after the break.

[Thanks to Adrian for the tip!]

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Piles Of Foam With A Hot Wire Slicer

July 6, 2014 by Brian Benchoff 23 Comments

foam

There are a million things you can do with foam, from some very impressive RC airplanes, all the way up to full-scale planes you can fly off into the wild blue yonder. Cutting foam, though, that’s a problem, and your best option is usually a hot wire foam cutter. [Darcy] put up some plans for a very nice bow cutter, but there’s also some experimentation for a foam slicer – a hot wire machine that takes a foam part and slices it like a smokehouse ham.

The bow-style cutter features laser cut parts, a pair of 1/4-20 bolts, a power supply, and about a foot of nichrome wire. It’s the bare minimum for cutting foam, but it seems to work really, really well.

The hot wire foam slicer is a much more interesting contraption, capable of making multiple thin sheets out of foam. Basically, it’s a laser cut tray with a bolt hole pattern running along the sides. Put two bolts along the side, loop some nichrome wire around the screw flights, and you have a way to cut foam in thicknesses of about 1/20th of an inch. Great if you’re trying to skin a model in very thin depron, or you just can’t find the right thickness of foam for your project.

Solderdoodle Is An Open Source, USB Rechargable Soldering Iron

July 4, 2014 by Rick Osgood 44 Comments

solderdoodle

Battery powered soldering irons are nothing new, but what about a soldering iron that can recharge via USB? [Solarcycle] realized that it might be handy to be able to recharge a portable soldering iron using such a ubiquitous connector and power source, so he developed the Solderdoodle.

The core component of the Solderdoodle is a Weller BP645 Soldering Iron. The heating element is removed from the Weller and placed into a custom case. The case is designed to be 3d printed. The STL files for the case are available if you want to make your own.

The Solderdoodle does away with large, disposable batteries and replaces them with a lithium ion battery pack. The battery contains no built-in protection circuitry in order to save space. Instead, this circuit is added later. [Solarcycle] appears to be using a circuit of his own design. The schematic and Gerber’s are available on his website.

The Instructable walks through all of the steps to build one of these yourself if you are so inclined. If you don’t have the spare time, you can fund the project’s Kickstarter and pre-order a production model. It’s always great to see a new commercial product with an open design.

[via Reddit]