DIY Table Saw Cuts Through Anything, Leaves No Room For Mistakes

July 7, 2011 by Mike Nathan 62 Comments

Students in the BASTLI lab at the Swiss Federal Institute of Technology Zurich had been stuck using underpowered and unreliable saws for quite some time. The saws often got stuck while cutting through PCBs and were generally a drag to use. When group member [Mario Mauerer] came across a big and powerful brushless motor in his basement, he decided it was time to upgrade the lab’s cutting tools.

Along with fellow student [Lukas Schrittwieser] he built a test rig to see how powerful the motor really was, and satisfied with the results, the pair set off to build their own table saw. The enclosure was wrapped up pretty quickly, leaving the pair to source a power supply. Rather than purchase one, they built a 700w monster switching PSU to power their saw.

As you can see in the video below the saw chews through most things with the greatest of ease, but the students added a “boost button” to the saw just in case they need to run it at full tilt.

While we can’t exactly overlook the lack of finger and eye protection in their demonstration, it does look like a great little tool to have around.

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CEE Is A Swiss Army Knife For Analog Electronics

July 4, 2011 by Brian Benchoff 28 Comments

The team at nonolith labs announced their CEE, a device for billed as, “an analog buspirate” that is meant to control, experiment, and explore the world of analog electronics. Nonolith labs started a kickstarter campaign for the CEE.

The CEE is capable of sub-millivolt and milliamp sampling at 44.1k samples/second, and sourcing 2 channels of 5V @ 2A with a little bit of soldering. This allows for precise control of motors and sensors with the web-based UI. We’re thinking this would be a great way to teach high schoolers the art of electronics, and would be great combined with a few lectures from Paul Horowitz.

The CEE ties into nonolith labs Pixelpulse, a pretty handy tool for visualizing analog and digital signals. You can check out a demo of Pixelpulse simulating a charging capacitor here.

We’re hoping this focus on education on analog electronics catches on – you can learn a lot more by building a 555-based mini Segway than you can slapping a microcontroller in every project. This would go under the same theory as, “any idiot can count to one.”

Check out the video of the CEE on the kickstarter campaign page.

Importing PCB Layout Into Google Sketchup

July 1, 2011 by Mike Szczys 16 Comments

If you’ve been spending hours with the digital calipers while designing enclosures for your circuit boards there may be a better way. [Phil] tipped us off about a new software package that will let you import PCB layout files into Google Sketchup. This way you can start working on the enclosure in CAD before you’ve populated your first board. Of course this adds to the pain of realizing there’s an error in your layout, but what are you going to do?

The free software was developed by RS Components, a European component distributor. It takes IDF files, which can be exported from most PCB design software, and converts them to a format compatible with Sketchup, Google’s 3D design software. For those who enjoy a very dry demonstration video you won’t want to skip seeing what we’ve embedded after the jump.

We’re kind of surprised that this hasn’t already been done. If it has, leave a link in the comments.

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A Doorbell Loud Enough To Wake The Dead

June 29, 2011 by Mike Nathan 43 Comments

really_loud_doorbell

[Ed Nauman] runs a machine shop, which we imagine can be quite loud at times. Sick of never hearing the doorbell when he was busy working on things, he decided that the solution to his problem was a new doorbell…an incredibly loud doorbell.

His Really Loud Doorbell (RLD for short) is actually a pretty simple device. We imagine he could have wired up an old alarm bell instead, but where’s the fun in that? The doorbell was built using a PIC16F876 uC, which is used to control the air flow through a pneumatic valve. When someone rings his doorbell, the pneumatic actuator pulses up and down, rapidly striking a piece of 1/4” thick steel pipe. As you can see in the video below, it is quite loud and likely to cut through any shop noise without much trouble.

We have seen some extremely loud doorbells before, but we figured that at least a handful of you work in similar environments – have you implemented any inventive ‘notification’ systems in your workspace? Let us know in the comments.

[via Adafruit Blog]

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Solder Paste Dispenser Hacked To Run Off Compressed Air Cans

June 27, 2011 by Mike Nathan 12 Comments

solder_paste_dispenser_air_can_hack

[John] got a shiny new solder paste dispenser for a steal, and before he hooked up the tool, he decided to take a look inside to make sure everything was on the up and up. Aside from a few questionable wiring practices he didn’t approve of, everything else looked to be in good working order.

The only thing that was bothering [John] is that he wasn’t too keen on keeping his noisy and large air compressor in his workshop, so he set off to find a different way to provide compressed air to the device. He settled on air dusters like those used for cleaning the crumbs out of your keyboard, but he needed to find a way to reliably get the air to his solder dispenser. He heated the air can’s nozzle until he was able to screw his dispenser’s hose barb into it, creating a tight seal. The modified nozzle was reattached to the can and placed in a simple jig that keeps the nozzle held down continuously.

[John] fired up his dispenser, and the 80 psi coming from the duster was plenty to get the solder paste flowing. Sure the rig might not be the most high tech solution, but we think it’s a pretty good means of getting quiet compressed air anywhere you need it.

DIY Battery Reconditioner Saves Old Rechargeable Batteries From The Landfill

June 26, 2011 by Mike Nathan 20 Comments

rechargeable_battery_reconditioner

Instructables user [msuzuki777] had amassed quite a collection of batteries over the years, but was finding that some of his rechargeable AA and AAA cells seemed to be at the end of their useful life. After reading some information at the Battery University regarding the restoration process for nickel-based batteries, he figured he might as well try building a battery reconditioner of his own.

He worked through several designs that either flat-out did not work, or had issues that limited the number of batteries he could simultaneously recondition. After reading about this rechargeable battery capacity tester we featured a few months back, he was ready to give the project one more try.

It seems that the third try was the charm, because his FET-based design worked quite well. He ended up wiring two FETs to each battery, which are connected via a relay. The batteries get discharged until the voltage drops down to 1V, at which point one FET is turned off, allowing the batteries reach their target voltage of 0.4V more slowly.

Despite the self-proclaimed messy layout of his circuit, [msuzuki777] is quite happy with the results. He has been able to recover several batteries, which is a fantastic alternative to letting them decay in a landfill.

Semi-automatic PCB Drill Press

June 25, 2011 by Mike Szczys 26 Comments

Kiss the days of breaking bits while drilling through-hole PCBs goodbye thanks to this semi-automatic drill press (translated). Now it’s not going to line up the bit with the exact location of the hole (that would make it a fully automatic drill press). This works by lining up the board manually, then stepping on a pedal to activate the plunging motion of the drill.

A linear motor is responsible for the smooth, accurate motion along the Z-axis. Many hobby setups use a Dremel drill press, or even rely on prayer-based systems such as doing it free-hand with a rotary tool or by using a piece of acrylic as a guide hole. The hobby drill press tends to have some play in it and free-handing with tiny bits that are as fragile as glass both result in far too many broken drill bits. In the video after the break you can see that the linear motion is perfectly plumb with the table of the device, preventing the movements that cause breakage. The addition of the pedal makes it easy to position the boards because you can use both hands.

Having a tool like this takes all of the frustration out of using through-hole parts.

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