Hackaday Prize Entry: Mini DRO For A Lathe

A manual lathe has dial wheels to control the feed of the main carriage and the cross slide to help take cuts on the workpiece. These feed wheels always have some backlash and require frequent resetting of the “zero”. The usual process would be to take measurements on the workpiece with either a vernier caliper or a micrometer at intervals which requires stopping the machine, adding up to increased machine time. The addition of a digital readout not only simplifies the process, but also reduces machining time substantially. Since the DRO magnetic strips are directly attached to the cross slide, the effects of backlash are mitigated.

[Igor] has just such a manual lathe and built his own mini DRO unit from scratch a couple of years back. Most DRO’s have encoder strips and sensors attached to the cross slide with a larger display unit attached separately on a stalk, with wires running between the two. [Igor] kept things simple by building a unit that fit within the space constraints he had. His unit consists of just two sensor modules – each attached directly to the slide. The main unit houses a linear hall sensor, electronics, buttons, a small LCD and batteries. The second axis unit houses just the sensor with a cable connecting it to the main unit for data and power. At the heart of the system is a pair of NSE-5310 linear hall sensor encoder chips. These work in conjunction with multipole magnetic strips. The encoder provides a 12-bit output, and the magnetic strips have poles spaced 2 mm apart. This translates to a theoretical resolution of almost 0.5 microns, but of course, the machine mechanics limit the actual results. The encoder chips talk to an ATtiny2313 over the I2C bus. Three buttons and the power supply round-up the hardware. To run it off a single 1.5 V rechargeable battery, [Igor] used a boost converter to get 3.3 V. The 5 V needed for the LCD is obtained by a voltage doubler connected to a PWM output from the microcontroller and regulated by a Zener diode. The second sensor unit connects via a TRRS 3.5 mm socket.

He added a Bluetooth module as an after thought, but ran out of GPIO pins as well as program space and had to get creative to make it work. The plan was to transmit the data to an Android tablet which would work as a large, remote, wireless display. He never did use that feature though, being satisfied with the small LCD display. There’s several things that went wrong in the build, and if he were to replicate the project again, several changes and improvements would help. So if anyone plans on doing something similar, do check up [Igor]’s project logs first.

The ATtiny MIDI Plug Synth

MIDI was created over thirty years ago to connect electronic instruments, synths, sequencers, and computers together. Of course, this means MIDI was meant to be used with computers that are now thirty years old, and now even the tiniest microcontrollers have enough processing power to take a MIDI signal and create digital audio. [mitxela]’s polyphonic synth for the ATtiny 2313 does just that, using only two kilobytes of Flash and fitting inside a MIDI jack.

Putting a MIDI synth into a MIDI plug is something we’ve seen a few times before. In fact, [mitxela] did the same thing a few months ago with an ATtiny85, and [Jan Ostman]’s DSP-G1 does the same thing with a tiny ARM chip. Building one of these with an ATtiny2313 is really pushing the envelope, though. With only 2 kB of Flash memory and 128 bytes of RAM, there’s not a lot of space in this chip. Making a polyphonic synth plug is even harder.

The circuit for [mitxela]’s chip is extremely simple, with power and MIDI data provided by a MIDI keyboard, a 20 MHz crystal, and audio output provided eight digital pins summed with a bunch of resistors. Yes, this is only a square wave synth, and the polyphony is limited to eight channels. It works, as the video below spells out.

Is it a good synth? No, not really. By [mitxela]’s own assertion, it’s not a practical solution to anything, the dead bug construction takes an hour to put together, and the synth itself is limited to square waves with some ugly quantization, at that. It is a neat exercise in developing unique audio devices and especially hackey, making it a very cool build. And it doesn’t sound half bad.

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Disk Hack Creates Persistence of Vision

[Adam Antok] was compelled to create this repurposed hard drive persistence of vision hack after seeing a toy of the same nature.

hdd-display-schematicHe used the frame, disk and motor from a drive and added LEDs under the spinning disk as the light source. The disk has 8 small holes drilled equidistant around the disk, and spiraling slightly toward the center. As the holes pass by the LEDS they are flashed by the ATtiny2313 processor to create images. To determine the position of the platters a Hall effect sensor is monitored by the 2313 to detect a magnet on the underside of the disk. There is room to display ten characters at one time. Each cursor position can scroll through the character set by rotating an encoder. For all the precision needed to coordinate the LEDs with the spinning holes the electronics and software code are amazingly simple. That’s a really nice job, [Adam]!

Persistence of vision hacks are to hackers like flames are to moths. One really nice thing about [Adam’s] project is that you can interact with it while it’s running. Check it out after the break.

For a novel take on POV, check out this slow swinging pendulum clock.

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In Which Robots Fight the Console Wars

Though the names have changed over the years, the console wars wage on. [moop] must have been feeling nostalgic for the NES vs. SEGA days when he started his current project, Foobot, which is a tabletop football (soccer) game played by robots that are controlled with classic NES and SEGA controllers.

Each team has two robots that tool around on laser-cut perspex wheels attached directly to 16,000RPM motors. An SN754410 controls the motors, and each robot has an ATtiny2313 brain. They all communicate with a single transmitter over their 433MHz 1402 radio receiver modules. To avoid collisions, [moop] used a packet system, wherein each robot has an ID. The messages all contain a robot ID, message payload, and checksum. The robots ignore messages addressed to others, and any message with an invalid checksum.

[moop] has made everything available on his github, including the PCB layouts and CAD files for the robot chassis and transmitter case. Watch them battle it out after the break. If the Foobots have riled you up about vintage gaming, check out these sweet arcade hacks.

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Infrared-controlled Light Switch

If you’re looking for your first electronics project, or a project to get someone else started in electronics, [Vadim] has you covered. Back when he was first starting out in electronics he built this infrared-controlled light switch that works with a standard TV remote control.

[Vadim]’s first few projects ended up as parts for other projects after they were built, so he wanted to build something useful that wouldn’t ultimately end up back in the parts drawer. The other requirements for the project were to use a microcontroller and to keep it simple. [Vadim] chose an ATtiny2313 to handle the RC-5 IR protocol and switch the light.

The circuit still has a switch to manually control the lights, preserving the original functionality of the light switch. The rest of the design includes a header for programming the board and another header for tying into the high voltage lines. This is a great project for anyone who knows what they’re doing with mains power but is just getting started with microcontrollers. If properly designed and implemented you’ll never stumble across a room to turn the lights out again!

Perhaps mixing high and low voltages on the same circuit board doesn’t spark your fancy or you can’t modify the light switch in your place of residence? Check out this mechanically-switched light switch.

 

An Improvised ATtiny2313 Logic Analyzer

2313logic

After banging his head against a wall trying to get a PS/2 interface to work, [Joonas] decided he needed a dedicated logic analyzer. He didn’t need anything fancy; writing bits to a serial port would do. He came up with a very, very simple ATtiny2313-based logic analyzer that can capture at 50+ kHz, more than enough for a PS/2 port.

The hardware for [Joonas’] build is a simple ATtiny2313 breadboard adapter, an FTDI Friend, and not much else. The 2313 has eight input ports on one side of the chip, making attaching the right logic line to the right port a cinch.

The highs and lows on each logic line are sent to a computer over the FTDI chip, converted into OLS format, and piped into Open Sniffer to make some fancy graphs.

[Joonas] was able to capture PS/2 signals with his logic sniffer, so we’ll call this project a success. However, there were a few problems that made this project a little more trouble than it was worth: there is no easy way to turn a serial dump into a binary file, Putty didn’t allow suppressing output to the terminal, and Mac serial ports twinkling above 115.2 kbps don’t work natively. Still, the project did its job, and we couldn’t ask for anything more.

[via Dangerous Prototypes]

An Open Source Hardware Modchip

OSHW XenoGC Clone

Many Hackaday readers might remember the days of buying modchips from somewhat questionable sources. These little devices connect to a gaming system to circumvent security measures, allowing you to run homebrew games (and pirated games, but lets not focus on that). [Guillermo] built an open source hardware Gamecube modchip based on the XenoGC.

The XenoGC was a popular modchip back in the Gamecube days, and its source was released in a forum post. A Wiki page explains how to build a clone of the device based on an ATtiny2313.  Most modchips were closed source, but this project lets you look at how they work. You can browse the XenoGC source on Google Code to learn more about the exploit itself. You’ll find the AVR code, which manipulates the DVD drive over a serial interface, in the XenoAT folder.

[Guillermo]’s hardware is available from OSHPark, so you can easily order boards. He’s also hosted the design files on Github. With one in hand, you can start building homebrew for the Gamecube, which can probably be picked up for around $25 nowadays.