automation

171 Articles

fastener counter

Fastener Fusion: Automating The Art Of Counting

July 6, 2025 by 7 Comments

Counting objects is an ideal task for automation, and when focusing on a single type of object, there are many effective solutions. But what if you need to count hundreds of different objects? That’s the challenge [Christopher] tackled with his latest addition to his impressive automation projects. (Video, embedded below.)

[Christopher] has released a series of videos showcasing a containerized counting system for various fasteners, available on his YouTube channel. Previously, he built remarkable devices to count and sort fastener hardware for automated packaging, but those systems were designed for a single fastener type. He effectively highlights the vast complexity of the fastener ecosystem, where each diameter has dozens of lengths, multiple finishes, various head shapes, and more.

To address this, he developed a machine that accepts standardized containers of fastener hardware. These uniform boxes can hold anything from a small M2 countersunk screw to a large M8 cap head bolt and everything in between. To identify the loaded box and determine the appropriate operations, the machine features an RFID reader that scans each box’s unique tag.

Once a box is loaded, the machine tilts it to begin counting fasteners using a clever combination of moving platforms, an optical sensor, and gravity. A shelf first pushes a random number of fasteners onto an adjustable ledge. A second moving platform then sweeps excess fasteners off, leaving only those properly aligned. It’s no surprise this system has nine degrees of freedom. The ledge then moves into view of a sensor from a flatbed scanner, which detects object locations with an impressive 0.04 mm resolution across its length—remarkable for such an affordable sensor. At this point, the system knows how many fasteners are on the ledge. If the count exceeds the desired number, a sloped opening allows the ledge to lift just high enough to release the correct amount, ensuring precision.

The ingenuity continues after the initial count. A secondary counting method uses weight, with a load cell connected to the bin where fasteners drop. A clever over-center mechanism decouples the tilting system from the load cell to ensure accurate readings. We love automation projects, and this one incorporates so many ingenious design elements that it’s sure to inspire others for their future endeavors.

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A clear acrylic cylinder is shown, inside of which plants are visible. There is mist inside the tube, and LEDs light it from above. A black plastic cap to the tube is visible.

Preserve Your Plants With An Automated Terrarium

June 30, 2025 by 1 Comment

For those of us who aren’t blessed with a green thumb and who are perhaps a bit forgetful, plants can be surprisingly difficult to keep alive. In those cases, some kind of automation, such as [Justin Buchanan]’s Oasis smart terrarium, is a good way to keep our plants from suffering too much.

The Oasis has an ultrasonic mister to water the plants from a built-in tank, LED grow lights, fans to control airflow, and a temperature and humidity sensor. It connects to the local WiFi network and can set up recurring watering and lighting schedules based on network time. Most of the terrarium is 3D-printed, with a section of acrylic tubing providing the clear walls. Before installing the electronics, it’s a good idea to waterproof the printed parts with low-viscosity epoxy, particularly since the water tank is located at the top of the terrarium, where a leak would drip directly onto the control electronics.

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Rise Of The Robots: How Robots Are Changing Dairy Farms

April 17, 2025 by 20 Comments

Running a dairy farm used to be a rather hands-on experience, with the farmer required to be around every few hours to milk the cows, feed them, do all the veterinarian tasks that the farmer can do themselves, and so on. The introduction of milking machines in the early 20th century however began a trend of increased automation whereby a single farmer could handle a hundred cows by the end of the century instead of only a couple. In a recent article in IEEE Spectrum covers the continued progress here is covered, including cows milking themselves, on-demand style as shown in the top image.

The article focuses primarily on Dutch company Lely’s recent robots, which range from said self-milking robots to a manure cleaning robot that looks like an oversized Roomba. With how labor-intensive (and low-margin) a dairy farm is, any level of automation that can improve matters will be welcomed, with so far Lely’s robots receiving a mostly positive response. Since cows are pretty smart, they will happily guide themselves to a self-milking robot when they feel that their udders are full enough, which can save the farmer a few hours of work each day, as this robot handles every task, including the cleaning of the udders prior to milking and sanitizing itself prior to inviting the next cow into its loving embrace.

As for the other tasks, speaking as a genuine Dutch dairy farm girl who was born & raised around cattle (and sheep), the idea of e.g. mucking out stables being taken over by robots is something that raises a lot more skepticism. After all, a farmer’s children have to earn their pocket money somehow, which includes mucking, herding, farm maintenance and so on. Unless those robots get really cheap and low maintenance, the idea of fully automated dairy farms may still be a long while off, but reducing the workload and making cows happier are definitely lofty goals.

Top image: The milking robot that can automatically milk a cow without human assistance. (Credit: Lely)

“Unnecessary” Automation Of A DIY Star Lamp Build

March 23, 2025 by 10 Comments

It all started with a gift idea: a star-field lamp in the form of a concrete sphere with lightpipes poking out where the stars are, lit up from the inside by LEDs. When you’re making one of these, maybe-just-maybe you’d be willing to drill a thousand holes and fit a thousand little plastic rods, but by the time you’re making a second, it’s time to build a machine to do the work for you.

So maybe we quibble with the channel name “Unnecessary Automation,” but we won’t quibble with the results. It’s a machine that orients a sphere, drills the hole, inserts the plastic wire, glues it together with a UV-curing glue, and then trims the end off. And if you like crazy machines, it’s a beauty.

The video goes through all of the design thoughts in detail, but it’s when it comes time to build the machine that the extra-clever bits emerge. For instance, [UA] used a custom 3D-printed peristaltic pump to push the glue out. Taking the disadvantage of peristaltic pumps – that they pulse – as an advantage, a custom housing was designed that dispensed the right amount between the rollers. The rolling glue dispenser mechanism tips up and back to prevent drips.

There are tons of other project-specific hacks here, from the form on the inside of the sphere that simplifies optic bundling and routing to the clever use of a razor blade as a spring. Give it a watch if you find yourself designing your own wacky machines. We think Rube Goldberg would approve. Check out this video for a more software-orientated take on fiber-optic displays.

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Retrotechtacular: Yamming CRT Yokes

February 19, 2025 by 28 Comments

Those of us who worked in TV repair shops, back when there was such a thing, will likely remember the cardinal rule of TV repair: Never touch the yoke if you can help it. The complex arrangement of copper wire coils and ferrite beads wrapped around a plastic cone attached to the neck of the CRT was critical to picture quality, and it took very little effort to completely screw things up. Fixing it would be a time-consuming and frustrating battle with the cams, screws, and spacers that kept the coils in the right orientation, both between themselves and relative to the picture tube. It was best to leave it the way the factory set it and to look elsewhere for solutions to picture problems.

But how exactly did the factory set up a deflection yoke? We had no idea at the time, only learning just recently about the wonders of automated deflection yoke yamming. The video below was made by Thomson Consumer Electronics, once a major supplier of CRTs to the television and computer monitor industry, and appears directed to its customers as a way of showing off their automated processes. They never really define yamming, but from the context of the video, it seems to be an industry term for the initial alignment of a deflection yoke during manufacturing. The manual process would require a skilled technician to manipulate the yoke while watching a series of test patterns on the CRT, slowly tweaking the coils to bring everything into perfect alignment.

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Custom Fan Controller For Otherwise Fanless PCs

October 29, 2024 by 6 Comments

Most of us using desktop computers, and plenty of us on laptops, have some sort of fan or pump installed in our computer to remove heat and keep our machines running at the most optimum temperature. That’s generally a good thing for performance, but comes with a noise pollution cost. It’s possible to build fanless computers, though, which are passively cooled by using larger heat sinks with greater thermal mass, or by building more efficient computers, or both. But sometimes even fanless designs can benefit from some forced air, so [Sasa] built this system for cooling fanless systems with fans.

The main advantage of a system like this is that the fans on an otherwise fanless system remain off when not absolutely necessary, keeping ambient noise levels to a minimum. [Sasa] does have a few computers with fans, and this system helps there as well. Each fan module is WiFi-enabled, allowing for control of each fan on the system to be set up and controlled from a web page. It also can control 5V and 12V fans automatically with no user input, and can run from any USB power source, so it’s not necessary to find a USB-PD-compatible source just to run a small fan.

Like his previous project, this version is built to easily integrate with scripting and other third-party software, making it fairly straightforward to configure in a home automation setup or with any other system that is monitoring a temperature. It doesn’t have to be limited to a computer, either; [Sasa] runs one inside a server cabinet that monitors the ambient temperature in the cabinet, but it could be put to use anywhere else a fan is needed. Perhaps even a hydroponic setup.

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Keeping Tabs On An Undergraduate Projects Lab’s Door Status

October 24, 2024 by 18 Comments

Over at the University of Wisconsin’s Undergraduate Projects Lab (UPL) there’s been a way to check whether this room is open for general use by CS undergraduates and others practically for most of the decades that it has existed. Most recently [Andrew Moses] gave improving on the then latest, machine vision-based iteration a shot. Starting off with a historical retrospective, the 1990s version saw a $15 camera combined with a Mac IIcx running a video grabber, an FTP server and an HP workstation that’d try to fetch the latest FTP image.

As the accuracy of this system means the difference between standing all forlorn in front of a closed UPL door and happily waddling into the room to work on some projects, it’s obvious that any new system had to be as robust as possible. The machine vision based version that got installed previously seemed fancy: it used a Logitech C920 webcam, a YOLOv7 MV model to count humanoids and a tie into Discord to report the results. The problem here was that this would sometimes count items like chairs as people, and there was the slight issue that people in the room didn’t equate an open door, as the room may be used for a meeting.

Thus the solution was changed to keeping track of whether the door was open, using a sensor on the two doors into the room. Sadly, the captive-portal-and-login-based WiFi made the straightforward approach with a reed sensor, a magnet and an ESP32 too much of a liability. Instead the sensor would have to communicate with a device in the room that’d be easier to be updated, ergo a Zigbee-using door sensor, Raspberry Pi with Zigbee dongle and Home Assistant (HA) was used.

One last wrinkle was the need to use a Cloudflare-based tunnel add-on to expose the HA API from the outside, but now at long last the UPL door status can be checked with absolute certainty that it is correct. Probably.

Featured image: The machine vision-based room occupancy system at UoW’s UPL. (Credit: UPL, University of Wisconsin)