Helix Turning Tool Born From Necessity

June 4, 2014 by Rich Bremer 16 Comments

helix turning tool

Sometimes while working on a project there comes a point where a specialized tool is needed. That necessary tool may or may not even exist. While [Fabien] was working on his DNA Lamp project he needed to bend a copper wire into a helical shape. Every one of us has wrapped a wire around a pencil and made a little springy thing at some point. While the diameter may have been constant, the turn spacing certainly was not. [Fabien] came up with a simple gizmo to solve that problem.

The tool utilizes an 8mm rod that will ensure the ID of the helix is indeed 8mm. We’ve already discussed that was the easy part. To make certain the turn spacing is not only consistent but also of the correct amount, a wooden frame is used. The frame has holes in it to allow the 8mm rod to pass through. Adjacent to those rod holes are much smaller holes just a bit larger than the copper wire that will become the helix. These holes are drilled at an angle to produce the correct turn spacing. [Fabien] figured out the correct angle by taking the desired turn spacing distance, helix diameter and wire diameter and plopping it in this formula:

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TIQ Probe Is More Logical Than Most

May 29, 2014 by Mike Szczys 11 Comments

[youtube=https://www.youtube.com/watch?v=XZz1W-LurlU&w=580]

We had [Mark] on our “dance card” for people to find at Maker Faire. But before we could track him down he bumped into us holding the TIQ Probe in one hand and a testing box in the other. TIQ is conceived in the form factor of a traditional logic probe but thanks to the Cypress PSoC 5LP inside it’s much, much smarter than the decades-old bench tools. Sure, it can tell you if that uC pin is a 1 or a 0, but it can also detect what type of signal it’s probing and has built-in protection for over-voltage.

The point of the tool is to bridge the gap between things which would be measured with a DMM and those measured with a proper Oscilloscope. We think he did a pretty good job of including the things that someone just starting out without expensive bench equipment might want. For instance, you can set it to trigger on common data protocols like i2c, and use the probe itself as a rudimentary pulse generator.

The bulk of the details on the probe can be found on its Kickstarter page (which has just a few days left). You may also be interested in his company page. We’re curious about the insides of the test rig he was hauling around. [Mark] is a regular reader so hopefully he’ll leave a comment below with the details of that black box.

Overkill Phone Charger, Because, Well, Why Not?

May 27, 2014 by Rich Bremer 26 Comments

ATX Phone Charger

There are times in a tinkerer’s existence where it is convenient to have the ability to plug in and power a lot of USB devices. Sure, you could use a USB hub but this may not be satisfactory if your devices require a lot of current. A computer may work but is not really a stand alone solution.

[Jeff] and the crew over at Make Lehigh Valley ran into this predicament. They were putting on an Adafruit Trinket class and needed a USB power supply to power all of the Trinkets that were going to be used. As any makerspace would do, they built their own USB Power Station, and the final product is certainly overkill for what they needed (that’s not a bad thing).

An old ATX computer power supply is a logical component to use for this type of project. These power supplies are usually available in abundance and will provide all the amperage any reasonable amount of 5v USB devices can ask for. The 5v output from the ATX power supply was wired to 8 USB jacks. Keeping up with the project’s resourcefulness, those USB jacks were scavenged from a couple of old PCI-slot USB hub panels. Not satisfied with only USB outputs, the guys also wired up some banana jacks so that 3.3, 5 and 12 volts were available for whatever project was being worked on. A 3D printed enclosure keeps everything neat and tidy.

This project used a bunch of recycled parts and solved a problem faced by the group. If you’re interested in using an ATX power supply to make a more bench-top style power supply then check out this build.

An Audio Based USB Oscilloscope And Signal Generator For $20

May 27, 2014 by Nick Conn 23 Comments

SoundScope

Are you interested in building a 20kHz 2-channel oscilloscope and a 2-channel signal generator for only $20 with minimal effort? Be sure to check out [Jana Marie’s] Instructable that goes over how to build this awesome tool from a cheap USB audio card.

We have featured tons and tons of DIY oscilloscopes in the past, but this effort resulted in something very well put together while remaining very simple to understand and easy to build. You don’t even need to modify the USB audio card at all. One of the coolest parts of this build is that you can unplug your probe assembly from your USB audio card, and bring it wherever your hacking takes you. After the build, all you need is [Christian Zeitnitz’s] Soundcard Oscilloscope program and you are good to go. One of the major downsides that is often overlooked when using an audio based oscilloscope, is that it is “AC coupled”. This means you cannot measure low-frequencies (including DC signals) using a sound card. Be sure to heed [Jana’s] advice and do not use your built in audio card as an oscilloscope. With no protection circuitry, it is a sure fire way to fry your computer.

What analog projects have you built around an audio interface? We have seen such an interface used for many different applications, including a few fun medical related hacks (be sure to keep safety your first priority). Write in and let us know!

Achievement Unlocked: Drill A Square Hole With A Rotary Broach

May 26, 2014 by Kristina Panos 18 Comments

There are times in a man’s life when he needs to drill a square hole through an 8mm thick piece of steel. If that man doesn’t have one or two thousand dollars to spend on commercial tooling to do this, he might just shrug his shoulders and make do with round holes. But if that man is [Chris], he rolls up his sleeves and makes his own tool to drill square holes with a rotary broach.

This tool that [Chris] has named the Wobble Drive drills a square hole by applying force to each of the corners of a square bit one a time. How, you might ask, did he achieve this? With a two-part tool and the power of offset driving. He took a cylindrical chunk of steel and bored a little cup for a ball bearing to move around in. He didn’t have one rolling around his tool box, so he liberated one from a 2209 double row self-aligning cylindrical bore with a screwdriver. Then he hammered a square rod of steel into a hole in the other end and made the rod’s bottom a little bit concave on the grinding wheel. He also took a little off the sides to aid the weeble wobble action. A second steel cylinder with a ball bearing cup sits in the chuck of his Bridgeport mill and wobbles the tool bit through the power of a 1/4″ offset.

[Chris] tested it on the same sacrificial plate he used to demonstrate the awesome power of Lil’ Screwy, his 100-ton homebrew press. He drilled a 3/8″ round pilot hole and then went to work with the Wobble Drive. The tool bit side proved to be too long to provide the requisite stroke, so he cut it down by about half. Once the tool has chewed through the steel, the tool bit decouples at the ball bearing and [Chris] has himself a square hole and that much more hacking cred.

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Showing the tablet interface for the scope

Discovering A Wifi Enabled 10MHz Oscilloscope

May 23, 2014 by Mathieu Stephan 17 Comments

[youtube=https://www.youtube.com/watch?v=qEqWtKGJhFQ&w=580]

As most of our readers know, [Mike] was visiting Bay Area Maker Faire last weekend with a big Jolly Wrencher on his back. During his tour he encountered the neat oscilloscope shown in the video above, made by the Belgian company Velleman. Even though it only has a 10MS/s sampling rate and a 10MHz bandwidth, our guess is that it may still be useful for some hobbyists out there as it can communicate with any PC/smartphone/tablet using its Wifi interface.

Inside the black box is a 3.7V 1800mAh Li-ion battery with a USB port to recharge it or update the oscilloscope’s firmware. As seen in the video, the tablet’s touchscreens may enable more natural interaction with the user interface. The protocol used to export the acquired samples is open, which may allow users to create their own analysis program. The oscilloscope uses an 8 bit analog to digital converter and a 4K samples buffer.

Sealed-System Bucket Loader Cleans Messes In Dangerous Places

May 20, 2014 by Mike Szczys 23 Comments

[youtube=https://www.youtube.com/watch?v=XjHJ71SVop4&w=580]

Cleaning up after a disaster is hard and dangerous. But the ROEBL project is trying to make it substantially safer by removing the human operator from harm’s way. The Remote Operated Electric Bucket Loader had a big double-fenced, cement barrier play area set up at Maker Faire and [Justin Gray] walked us through the project which concluded with a demonstration of the hardware.

For now the operator does need to be on site to see what the loader is doing, but a first-person video setup is planned for the future. Still, removing the operator from the jarring experience of riding inside is an improvement. And the sealed nature of the electric and hydraulic systems mean that it can operate in areas inundated with liquids like water or oil.

The video above has a 90 second demonstration at the end (while we all laugh like children at what really was a giddy display of power being thrown about by a handheld controller). The ROEBL website has a gallery where you can see the conversion process that started with a standard diesel machine.