A 7 GHz Signal Analyser Teardown And A Trivial Repair

[Shahriar] of The Signal Path is back with another fascinating video teardown and analysis for your viewing pleasure. (Embedded below.) This time the target is an Agilent E5052A 7 GHz signal Source/Analyser which is an expensive piece of kit not many of us are fortunate enough to have on the bench. This particular unit is reported as faulty, with a signal power measurement that is completely off-the-rails wrong, which leads one to not trust anything the instrument reports.

After digging into the service manual of the related E5052B unit, [Shahriar] notes that the phase noise measurement part of the instrument is totally separate from the power measurement, only connected via some internal resistive power splitters, and this simplifies debugging a lot. But first, a short segue into that first measurement subsystem, because it’s really neat.

Cross-correlating time-gated FFT (TG-FFT) subsystem at the top, dodgy power detector at the bottom

A traditional swept-mode instrument works by mixing the input signal with a locally-sourced low-noise oscillator, which when low-pass filtered, is fed into a power meter or digitizer. This simply put, down-converts the signal to something easy to measure. It then presents power or noise as a function of the local oscillator (LO) frequency, giving us the spectral view we require. All good, but this scheme has a big flaw. The noise of the LO is essentially added to that of the signal, producing a spectral noise floor below which signals cannot be resolved.

The E5052 instrument uses a cunning cross-correlation technique enabling it to measure phase noise levels below that of its own internal signal source. The instrument houses an Oven-Compensated Crystal Oscillator (OCXO) for high stability, in fact, two from two different vendors, one for each LO, and mounted perpendicular to each other. The technique splits the input signal in half with a power splitter, then feeds both halves into identical (apart from the LOs) down-converters, the outputs of which are fed into a DSP via a pair of ADCs. Having identical input signals, but different LOs (with different phase noise spectra) turns the two signals from a correlated pair to an uncorrelated pair, with the effects of chassis vibration and gravity effects also rolled in.

The DSP subtracts the uncorrelated signal from the correlated signal, therefore removing the effect of the individual LO’s effect on the phase noise spectrum. This clever technique results in a phase noise spectrum below that of the LOs themselves, and a good representation of the input signal being measured.

This is what a DC-7GHz resistive power divider looks like. Notice the inductive matching section before each resistor branch.

Handily for [Shahriar] this complex subsystem is totally separate from the dodgy power measurement. This second system is much simpler, being fed with another copy of the input signal, via the main resistive power splitter. This second feed is then split again with a custom power divider, which upon visual inspection of the input SMA connector was clearly defective. It should not wobble. The root cause of the issue was a cold solder joint of a single SMA footprint, which worked loose over time. A little reflow and reassembly and the unit was fit for recalibration, and back into service.

We’ve seen phase noise measurements a few times on these pages, like debugging this STM32 PLL issue.

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Tactical Build Makes Machining Splined Shaft A Snap

Quick, what’s 360 divided by 23? It’s easy enough to get the answer, of course, but if you need to machine a feature every 15.652 degrees around a shaft, how exactly would you accomplish that? There are a number of ways, but they all involve some degree of machining wizardry. Or, you can just make the problem go away with a little automation.

The story behind [Tony Goacher]’s Rotary Table Buddy begins with some ATV tracks he got off AliExpress. His idea is to build a specialty electric vehicle for next year’s EMF Camp. The tracks require a splined shaft to drive them, which would need to be custom-made on a milling machine. A rotary table with a dividing plate — not as fancy as this one, of course –is usually the answer, but [Tony] was a little worried about getting everything set up correctly, so he embarked on a tactical automation solution to the problem.

An RP2040 provided the brains of the project, while a NEMA 23 stepper provides the brawn. [Tony] whipped up a quick PCB and 3D printed a case for the microcontroller, a stepper driver, an LCD display, and a few buttons. He 3D printed an adapter and a shaft coupler to mount the stepper motor to a rotary table. From there it was just a matter of coming up with a bit of code to run everything.

There’s a brief video in [Tony]’s blog post that shows Rotary Table Buddy in action, indexing to the next position after cutting one of the 23 splines. He says it took about ten minutes to cut each spline using this setup, which probably makes to total cutting time far less than the amount of time invested in the tool. But that’s hardly the point, and besides, now he’s set up for all kinds of machining operations in the future.

And we sure hope we hear about the EMF Camp build, too.

Exploring Woodworking Mysteries With Strain Gauges And Raspberry Pi

If you’re not a woodworker, you might not have heard of the “45-degree rule.” It goes like this: a clamp exerts a force that radiates out across a triangular region of the wood that forms a right angle — 45 degrees on each side of the clamp’s point of contact. So, to ensure that force is applied as evenly as possible across the entire glue joint, clamps should be spaced so that these force triangles overlap. It’s a handy rule, especially for the woodworker looking to justify the purchase of more clamps; you can never have too many clamps. But is it valid?

Myth busted?

The short answer that [ari kardasis] comes up with in the video below is… sort of. With the help of a wonderfully complex array of strain gauges and a Raspberry Pi, he found that the story isn’t so simple. Each strain gauge lives in a 3D printed bracket that spaces the sensors evenly along the wood under test, with a lot of work going into making the test setup as stiff as possible with steel reinforcement. There were some problems with a few strain gauges, but once he sorted that out, the test setup went into action.

[ari] tested clamping force transmission through pieces of wood of various widths, using both hardwoods and softwoods. In general, he found that the force pattern is much broader than the 45-degree rule suggests — he got over 60 degrees in some cases. Softwoods seemed to have a somewhat more acute pattern than hardwoods, but still greater than the rulebook says. At the end of the day, it seems like clamp spacing of two board widths will suffice for hardwoods, while 1.5 or so will do for softwoods. Either way, that means fewer clamps are needed.

A lot of woodworking is seat-of-the-pants stuff, so it’s nice to see a more rigorous analysis like this. It reminds us a lot of some of the experiments [Matthia Wandel] has done, like load testing various types of woods and glues.

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Kerfmeter Measures Laser Cutter Kerf Allowances On The Fly

Nothing beats a laser cutter and a sheet of Baltic birch plywood or MDF when it comes to making quick, attractive enclosures. Burning out all the pieces and fitting them together with finger joints is super satisfying — right up until you realize that you didn’t quite get the kerf allowance right, and your pieces don’t fit together very nicely. If only there was a way to automate kerf measurement.

There is, in the form of Kerfmeter. It comes to us by way of the lab of [Patrick Baudisch] at the University of Potsdam, where they’ve come up with a clever way to measure the kerf of a laser cutter right during the cutting session. With the Kerfmeter mounted directly to the laser cutter head, a small test artifact based on an Archimedean spiral is cut into a corner of the workpiece. Pins on a small motor engage with the object and turn it until it jams in its hole; the wider the kerf, the greater the angle. Once the kerf is calculated, the rest of the design can be dilated by the proper amount to achieve a perfect fit. The video below shows it better than words can explain it.

What we like about this is its simplicity — all it involves is a motor and a microcontroller, plus a little software. It seems much faster than using a traditional kerf gauge, not to mention more precise. And while it does use up a little bit of material, the test pattern is really pretty small, all things considered. Seems like a reasonable trade-off to us. Still, if you want to figure out your kerfs the old-fashioned way, we’ve got you covered.

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Embed Hardware Into 3D Prints, But Not In The Way You’re Thinking

[Christopher Helmke] is doing fantastic work in DIY systems for handling small hardware like fasteners, and that includes robotic placement of hardware into 3D prints. Usually this means dropping nuts into parts in mid-print so that the hardware is captive, but that’s not really the story here.

The really inventive part we want to highlight is the concept of reducing packaging and labor. Instead of including a zip-lock bag of a few bolts, how about embedding the bolts into a void in the 3D print, covered with a little snip-out retainer? Skip ahead to 1:54 in the video to see exactly what we mean. It’s a pretty compelling concept that we hope sparks a few ideas in others.

As clever as that concept is, the rest of the video is also worth a watch because [Christopher] shows off a DIY system that sits on top of his 3D printer and takes care of robotically placing the hardware in mid-print. He talks all about the challenges of such a system. It’s not perfect (yet), but seeing it in action is very cool.

We’ve recently seen a lot of fascinating stuff when it comes to [Christopher Helmke]’s automated handling of fasteners and similar hardware. His system makes rapid and accurate dispensing of bolts look easy, and his work on using compressed air to zip pieces around seems effective.

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Soldering Station Designed Around Batteries

Companies now are looking to secure revenue streams by sneakily locking customers into as many recurring services as possible. Subscription software, OS ecosystems, music streaming, and even food delivery companies all want to lock consumers in to these types of services. Battery-operated power tools are no different as there’s often a cycle of buying tools that fit one’s existing batteries, then buying replacement batteries, ad infinitum. As consumers we might prefer a more open standard but since this is not likely to happen any time soon, at least we can build our own tools that work with our power tool brand of choice like this battery-powered soldering station. Continue reading “Soldering Station Designed Around Batteries”

Auto Tape Wrapping Machine Is Amazing For Cable Management

If you’ve dived under the hood of any car built in the last 40 years, you’ve likely noticed the bundles of neatly-wrapped cables making up the car’s wiring loom. [The Q] has built a tool for handling jobs like this yourself.

The build starts with a pair of sprockets linked up with bicycle chain, and mounted to a wooden frame. A motor drives the smaller sprocket, which turns the larger sprocket in turn. The larger sprocket itself is mounted on a series of internal rollers, while it mounts a carrier for a roll of tape. As the larger sprocket turns, it will happily wrap whatever you feed through the central hole in tape in a neat and tidy manner.

For those working with automotive looms, large robot cable runs, or PC builds, a tool like this can be of great utility. [The Q} even demonstrates it put to oddball tasks, like wrapping bicycle handlebars or pipe threads. We’ve seen similar builds before, too. Video after the break.

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