Tool Hacks

2963 Articles

Measuring SMD Parts With A Home Brew Version Of Smart Tweezers

November 7, 2012 by 22 Comments

SMD parts are great; they allow you to pack more parts on a board, do away with drilling dozens of PCBs, and when done correctly can produce a factory-quality board made in a home lab. There’s one problem with SMD parts; troubleshooting and measuring them. The ideal solution would be something akin to the Smart Tweezers we’ve seen before, but this fabulous tool costs three hundred bones. [Kai] came up with a much cheaper solution: home brew smart tweezers that can be built for a tenth of the cost as the professional model.

What [Kai] built is an LCR meter, basically a tool that measures inductance, capacitance, and resistance in a very, very small form factor. The technique of measuring a part’s properties involves feeding a set frequency into the device and measuring the phase, voltage and current coming out. It’s all wonderfully explained by [Dave] over at EEVblog in one of his earlier videos.

The hardware [Kai] is using includes an LCD display from a Nokia phone, an MSP430-based microcontroller, a very tiny opamp near the tip of one of the points of the tweezer, and a programmable gain amplifier used to measure the components. In testing, [Kai] can measure very low-value components with a +/- 2% accuracy, and larger, more realistic components with +/- 0.25% accuracy. An awesome accomplishment, and much better than the common Chinese meters that can’t measure in the nH/pF/mΩ range.

[Kai] hasn’t gotten his pair of smart tweezers working yet – he still needs to get the circuit up and running and write some software. We’ll keep our readers apprised of [Kai]’s progress, though, and gently convince him to work with Seeed Studio or someone similar to get his version of Smart Tweezers onto maker’s workbenches the world over.

Do Not Look Into 12 Watt UV Lamp With Remaining Eye

November 7, 2012 by 33 Comments

We’ve seen a couple of UV lamp builds for exposing photosensitive PCBs and erasing EPROMs, but [John] over at pcboard.ca decided if it’s worth doing, it’s worth overdoing. They designed a UV exposure board using twelve 1 Watt UV LEDs, an impressive amount ultraviolet light that you probably shouldn’t look at for too long.

We’ve seen UV exposure boxes before, usually made with a bunch of 5mm UV LEDs soldered to a piece of protoboard. These projects do their job, but the exposure time is on the order of minutes. The PCboard.ca UV lamp can expose a PCB in just 20 seconds.

The build began with four pieces of aluminum bar, 1 inch wide and 1/8″ thick. The 12 star LEDs were glued down to this bar with thermal adhesive and serve their purpose as a rather large heat sink.

[John] performed a little test to determine how long it would take this monstrous UV source to expose a PCB. By copying a PCB mask four times and placing it over an unexposed board, [John] made a PCB with exposure times of 60, 45, 30, and 15 seconds. After developing and etching, all but the 15-second exposure was fully etched, an amazing result that will probably lead to some very, very rapid prototyping.

All the more impressive is the fact that only four 1-watt LED drivers were used for this build. That’s right, this UV lamp is actually operating at about a quarter of its maximum rating, or about 285mA per LED. We’d hate to see this thing operate at full power, protective eyewear or not.

Upverter 2.0 Launches

November 6, 2012 by 41 Comments

Disclosure: I currently work at Upverter

We’ve featured Upverter here in the past. At that time, the EDA tool was capable of collaborative schematic capture. Today, Upverter is launching version 2.0 of their tool which includes many new features allowing for end-to-end electronics design.

Upverter now has a PCB editor, allowing you to manufacture your designs. They are working with PCB manufacturers to make it easy to choose a fab and submit design files. Other new features include a Spice based simulation engine allowing in-browser simulation, and product lifecycle management features to help manage your project’s bill of materials.

When we last looked at Upverter, it was just a tool for creating and sharing schematics. With today’s launch, the tool can be used for designing electronics from start to finish. Since Upverter is free for open source projects, it will be interesting to see how hackers use it.

You can check out a tour of the new features. Any thoughts on using a cloud based EDA tool? Let us know in the comments.

Ikea Provides A Great UV Exposure Box

November 6, 2012 by 17 Comments

Making your own boards at home is among the heights of achievement for home tinkerers, and one fraught with frustration. The toner transfer process requires carefully peeling away layers of photo paper, and milling your own circuit boards is an exercise in complexity. One of the best options is using photosensitive copper boards, but this requires exposing the masked-off copper to fairly intense UV light. A UV exposure box is a wonderful project, then, and something [Carlo] just about has wrapped up.

The first portion of [Carlo]’s build involved placing 135 UV LEDs on a piece of protoboard. This UV source eats up a surprising amount of power; [Carlo] is using 12V for the supply, so an old industrial power supply is more than capable of dishing out the 1.5 Amps required for the build.

Next, [Carlo] needed a timer for his exposure box. He settled on a design based on an ATMega8 turning a high voltage transistor on and off with a character LCD for the user interface. A few buttons allow [Carlo] to set the countdown timer, after which the LEDs turn on for a set period of time.

All this was packaged into a small box [Carlo] picked up from Ikea. It’s a very useful build, and judging from the video after the break, extremely easy to use.

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DIY Spot Welder Makes Metalwork Easy

October 31, 2012 by 62 Comments

At Hackaday, we’ve seen enclosures built out of just about every material. From wood, glass, epoxy resin, plastic, and even paper, all these different types of enclosures provide some interesting properties. Sometimes, though, you need an enclosure made out of metal and welding together steel cases isn’t exactly easy or cheap. [manekinen] came up with a really great solution to the problem of welding together sheet metal. It’s a very easy to build spot welder perfect for fabbing steel cases.

The core of the build is a transformer pulled from a Technics stereo amplifier. [manekinen] removed the stock secondary winding and rewound the transformer four turns of 35mm ² wire (about 2 AWG). This made the transformer put out 2.6 Volts a 1 kA – more than enough to weld 22 ga sheet.

For the control mechanism, [manekinen] put a limit switch on the electrode arm and wired that to a timer. A knob on the front of the welder allows him to vary the time the welder is on from 0 seconds to 4 seconds.

The results are fantastic – trying to rip apart a weld only results in the metal itself tearing; exactly what you want to see in a welder. It’s a great build made even more fantastic by the welder building its own enclosure.

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Semi-professional Board Assembly For Your Workshop

October 29, 2012 by 10 Comments

[Zach Hoeken] has the answer to assembling multiple surface mount PCBs in the home workshop. It’s certainly not for everyone. But if you’ve ever thought of marketing your own small runs he has the equipment and methodology you need.

He had tried using hacked together equipment, but after encountering a range of issues he finds the investment in a few key items saves time and money in the long run. The first is a precision tooling fixture block; that metal plate with a grid of holes that makes up the background of the image above. It comes with machined pegs which fit the holes perfectly, and as you can see, his panel of 16 boards include tooling holes that line up with the fixture. Once in place, a steel solder stencil is aligned with the board using its own tooling holes. The alignment of the stencil and its uniformed thickness ensure that the perfect amount of solder paste is easy to apply with a squeegee. [Zach] hand places his components but he did invest in a proper reflow oven to make the soldering a set and forget process.

DIY Pick And Place Builds Boards, Is Awesome

October 29, 2012 by 12 Comments

In what can probably be attributed to the pains of placing a lot of SMD components, [gravelrash] built his own home-made pick and place machine.

Instead of being frustrated with tweezers, stereo microscopes, and having an inordinate amount of concentration, [gravelrash] built a pick and place machine from a Chinese CNC router. The build doesn’t use automated feeders for its reels of parts. Instead,[gravelrash] picked up five manual feeders from eBay, allowing his pick and place to hold 25 different reels of components.

There is, of course, a vacuum pump for sucking up SMD parts and a two-axis gantry capable of moving components from reel to board. The software is Mach3, a program normally used with spinning cutters to mill away wood, metal and plastic. [gravelrash] replaced this motor with a few vacuum controlled needles to pick up, move, and drop components onto the board.

While the build may not be as fast as some other pick and place machines we’ve seen, it’s almost as fast as hand-placing components with the added bonus of not tearing your hair out over very tiny parts.

Tip ‘o the hat to [Alexander] for sending this one in.

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