Custom Cut Pinwheel Makes a Useful HVAC Duct Flow Meter

Everyone is familiar with pinwheels, and few of us haven’t crafted one from a square of paper, a stick, and a pin. Pinwheels are pretty optimized from a design standpoint, and are so cheap and easy to build that putting a pinwheel to work as an HVAC duct flow meter seems like a great idea.

Great in theory, perhaps, but as [ItMightBeWorse] found out, a homemade pinwheel is far from an ideal anemometer. His experiments in air duct flow measurements, which previously delved into ultrasonic flow measurement, led him to try mechanical means. That calls for some kind of turbine producing a signal proportional to air flow, but a first attempt at using a computer fan with brushless DC motor failed when a gentle airflow couldn’t overcome the drag introduced by the rotor magnets. But a simple pinwheel, custom cut from patterns scaled down from a toy, proved to be just the thing. A reflective optosensor counts revolutions as the turbine spins in an HVAC duct, and with a little calibration the rig produces good results. The limitations are obvious: duct turbulence, flimsy construction, and poor bearings. But for a quick and dirty measurement, it’s not bad.

Looking for an outdoor anemometer rather than an HVAC flow meter? We’ve got one made from an old electric motor, or a crazy-accurate ultrasonic unit.

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Old Motor Donates Rotor for Coaxial Wind Vane and Anemometer

Problem: build a combined anemometer and wind vane where the pivots for both sensors are coaxial. Solution: turn an old universal motor into a step-wise potentiometer for the wind vane, and then pull a few tricks to get the whole thing assembled.

commutatior-with-series-resistorsWe have to admit that when we first saw [Ajoy Raman]’s Instructables post, we figured that he used a universal motor to generate a voltage from the anemometer. But [Ajoy]’s solution to the coaxial shafts problem is far more interesting than that. A discarded universal motor donated its rotor and bearings. The windings were stripped off the assembly leaving nothing but the commutator. 1kΩ SMD resistors were soldered across adjacent commutator sections to form a series resistance of 22kΩ with taps every 1k, allowing 0 to 2.2V to be read to the ADC of a microcontroller depending on the angle of the vane.

As clever as that is, [Ajoy] still had to pull off the coaxial part, which he did by drilling out the old motor shaft from one end to the other using just a drill press. The anemometer shaft passes through the hole in the shaft and turns a small DC motor to sense wind speed.

There might have been other ways to accomplish this, but given the constraints and the low cost of this solution, our hats are off to [Ajoy]. We’re a little concerned with that motor used for the anemometer, though. It could result in drag when used as a generator. Maybe a better solution would be a Hall-effect sensor to count rotations of a hard drive rotor.

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Solar-powered Weather Station Has the Complete Suite of Sensors

There was a time when getting weather conditions was only as timely or as local as the six o’clock news from the nearest big-city TV station. Monitoring the weather now is much more granular thanks to the proliferation of personal weather stations. For the ultimate in personalized weather, though, you might want to build your own solar powered weather station.

It looks like [Brian Masney] went all out in designing his weather station. It supports a full stack of sensors – wind speed and direction, rain, temperature, pressure, and dew point. About the only other parameters not supported (yet) are solar radiation, UV, and soil moisture and temperature. The design looks friendly enough that adding those sensors should be a snap – if fact, the 3D models in his GitHub repo suggest that he’s already working on soil sensors. The wind and rain sensor boom is an off-the-shelf unit from Sparkfun, and the temperature and pressure sensors are housed in a very professional 3D printed screen enclosure. All the sensors talk to a Raspberry Pi living in a (hopefully) waterproof enclosure topped with a solar panel for charging the stations batteries. All in all it’s a comprehensive build; you can check out the conditions at [Brian]’s place on Weather Underground.

Weather stations are popular around these parts, as witnessed by this reverse-engineered sensor suite or even this squirrel-logic based station.

Better Sailing Computers With Wearable Electronics

Sailing – specifically small boats in regattas – is a hobby that requires a lot of skill. Like any hobby, there are devices and electronics to make the hobby easier. For sailing, its tactical sailing compasses and GPS units. Remember, you probably don’t want to sail in a straight line, and that means offloading decades of experience to electronics. Instead of spending hundreds of dollars on a sailing computer, [Brook] thought it would be a better idea to build his own robot sailor from a Raspberry Pi and a Pebble smartwatch.

The sensors required for a sailing computer are par for the course – a Ublox GPS unit, a magnetometer, an acceleratometer, and a gyro. Being used on a sailboat also means there’s an anemometer thrown into the mix. These parts are stuffed into a waterproof polycarbonate field box with a USB power bank battery and a Bluetooth USB dongle.

With the hardware in place, it was time to write the software. The UI for this device is a Pebble smartwatch, which means there was a lot of futzing around with C# and Mono. This device is also a sailing data recorder, meaning [Brook] can integrate this project with VisualSail, a desktop application he wrote a few years ago to create 3D replays of sailing races using GPS data.


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Another Use for Old Hard Drive Parts: Anemometer

So you’ve just taken apart a hard drive, and you’re looking at all the pieces on your desktop. You’re somehow compelled to use them all in different projects. Why not pull out that very high quality bearing that keeps the platters spinning at high RPMs and build this simple anemometer with it? That’s what [Sergei Bezrukov] did, and it looks like a perfect el cheapo project.

The build is fairly low-tech and entirely sufficient. The cups are made from plastic containers that used to contain pantyhose. A Hall-effect sensor and a magnet take care of measuring the rotations, feeding its signal into a PIC that calculates the wind speed from the revolution rate. The rest of the housing is PVC, with some other miscellaneous parts found at the hardware store.

To calibrate the device, [Sergei] made a second hand-held unit that he could (presumably) drive around in a car to get a baseline wind speed, and then note down the revolution rate. Once you’ve got a good reference, holding the portable unit up to the permanent one transfers the calibration.

But the star of the show, that lets the anemometer spin effortlessly, is the sweet bearing that used to spin a hard-drive platter. If you haven’t played with one of these bearings before, you absolutely should. We just ran a post on taking apart a hard drive for its spare-parts goodness so you have no excuse. If you’re feeling goofy, you can mount one onto a board, step on it with the ball of your foot, and spin. They’re quality bearings, and you’ll be surprised how quickly you can spin as you pull your arms in.

Thank [Matt] for the tip!

Old School Gauges Let You Know Which Way the Wind Blows

When your passion is a sport that depends on Mother Nature’s cooperation, you need to keep a close eye on weather conditions. With this in mind, and not one to let work distract him from an opportunity to play, [mechanicalsquid] decided to build a wind-monitoring gauge with an old-school look to let him know when the wind is right for kitesurfing.

old-school-meter-for-windBeing an aficionado of big engineering helped [mechanicalsquid] come up with a style for his gauge – big old dials and meters. We hesitate to apply the “steampunk” label to every project that retasks old technology, but it sure looks like a couple of the gauges he used could have been for steam, so the moniker probably fits here. Weather data for favorite kitesurfing and windsurfing locales is scraped from the web and applied to the gauges to indicates wind speed and direction. [mechanicalsquid] made a valiant effort to drive the voltmeter coil directly from the Raspberry Pi, but it was not to be. Servos proved inaccurate, so steppers do the job of moving the needles on both gauges. Check out the nicely detailed build log for this one, too.

For more weather station fun be sure to check out this meter-based weather station with a slightly more modern look. And for another build in the steampunk style, this vintage meter and Nixie power display is sure to impress.

Raspberry Pi Wind Measurement

A well organized approach to a project is a delight to see. [Pavel Gesyuk] takes just that approach with the experiments on his blog. Experiment 13 is a multi-part series using a Raspberry Pi as the heart of a weather station. [Pavel] is looking at wind speed and direction, and temperature measurement, plus solar power for the station. One of his videos, there are many, is after the break.

electrical_02_tThe anemometer and direction sensors are stock units wired to a Raspberry Pi A+ using an analog to digital daughter board. The data from the temperature sensor is acquired using I2C. During one part of the experiment he uses an EDIMAX WiFi adapter for collecting the data.

Python is [Pavel’s’ language of choice for development and freely shares his code for others to see. The code collects the data and displays it on a monitor connected to the Pi. The experiment also attempts to use solar power to charge batteries so the station is not dependent on mains power.

The mechanical assembly shows attention to detail commensurate with his project presentation and we respect how well organized the work is.

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