Mechanical Seven-Segment Display Mixes Art With Hacking

November 11, 2019 by Dan Maloney 28 Comments

We’re not sure what to call this one. Is it a circuit sculpture? Sort of, but it moves, so perhaps it’s a kinetic circuit sculpture. Creator [Tomohiro Tsuchita] calls it “something beautiful but totally useless,” which we find a tad harsh. But whatever you call it, we think this mechanical seven-segment display is really, really cool.

Before anyone gets to thinking that this is something like the other mechanical seven-segment displays we’ve seen lately, think again. This one is not addressable; it simply goes through the ten digits in order. So you won’t be building a clock from it, although we suppose the mechanism could be modified to allow that. Then again, looking at that drive train of laser-cut acrylic cams, maybe not. Each segment has its own cam with lobes or valleys for each segment. A cam follower lowers and raises the segments as the cams rotate on a common shaft. A full-rotation servo powers the display under the control of a Micro:bit; the microcontroller is overkill for now but will be used in version two, which will allow the speed to change in response to sensors.

Watching this display change at its stately pace is strangely soothing. We love the look of this, but then again, we’re partial to objets d’art-circuit. After all, we ran a circuit sculpture contest earlier in the year, and just wrapped up a Hack Chat dedicated to the subject.

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A Useless Tomb Of Eternal Doom

October 1, 2019 by Kristina Panos 10 Comments

It’s officially October, and that means we can start unleashing the Halloween hacks. Take for example this restless skeleton that master automaton maker [Greg Zumwalt] has doomed to spend eternity inside of a useless box. If that wasn’t enough to wake the dead, every time some joker pushes the button, these blinky lights come on. Hey, at least there’s no opera music.

The ironic thing about useless machines is that there are a ton of ways to make them. This spooktacular Halloween-themed do-nothing box doesn’t use a microcontroller, or even a 555 — it’s purely electromechanical. When the button is pressed, two AAAs power a small gear motor that simultaneously lifts the lid, raises the dead, and twists him a quarter turn so he can close the lid and put himself back to eternal rest.

The intricately-printed skeleton doesn’t really push the button — he’s far too dead and frail for that. The gear motor also turns a dual-lobe cam that activates a pair of roller switches that handle the candles and lower Mr. Bones back into his crypt. Clear as blood? Skitter past the break for a closer look at the mechanism.

Halloween or not, we love a good useless machine around these parts. Here’s one that incorporates a real candle and who could forget this octo-switched beast?

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Stepper-Controlled Chop Saw Automates A Tedious Job

August 10, 2019 by Dan Maloney 23 Comments

We’re not going to question why [Absorber Of Light] needs to cut a bazillion little fragments of aluminum stock. We assume his reasoning is sound, so all we’re interested in is the automated chop saw he built to make the job less tedious, and potentially less finger-choppy.

There are probably many ways to go about this job, but [Absorber] leaves few clues as to why he chose this particular setup. Whatever the reason, the build looks like fun, with a long, stepper-driven threaded rod pushing a follower down a track to a standard chop saw. The aluminum stock rides in the track and gets pushed out a set amount before being lopped off cleanly as the running saw is lowered by a linear actuator. The cycle then repeats until the stock is gone.

An Arduino controls the stock-advance stepper in the usual way, but the control method for the linear actuator is somewhat unconventional. A second stepper motor has two cams offset by 180° on the shaft. The cams actuate four microswitches which are set up in an H-bridge configuration. The stepper swivels back and forth to run the linear actuator first in one direction then the other, with a neutral position in between. It’s an interesting approach using mechanical rather than the typical optical isolation. Check it out in action in the video below.

We’ll admit to some curiosity as to the use of the coupons this rig produces, so maybe we’ll get lucky with some details from [Absorber Of Light] in the comment section. After all, we knew exactly what the brass tubes being cut by the similar “Auto Mega Cut-O-Matic” were being used for.

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EasyEDA Hack Chat With Dillon He

June 17, 2019 by Dan Maloney 7 Comments

Join us Wednesday at 5:00 PM Pacific time for the Easy EDA Hack Chat with Dillon He!

Note the different time than our usual Hack Chat slot! Dillon will be joining us from China.

Since the birth of electronic design automation in the 1980s, the universe of products to choose from has grown tremendously. Features from schematic editing to circuit simulation to PCB design and autorouting can be found in every permutation imaginable, and you’re sure to find something that fits your needs, suits your budget, and works on your platform.

Dillon He started EasyEDA back in 2010 with Eric Cui, and since then the cloud-based EDA tool has become a popular choice. From working across teams to its “run anywhere” capabilities, EasyEDA has become the go-to tool for hundred of thousands of designers. Dillon will drop by the Hack Chat to answer all your questions about EasyEDA — how it started, where it is now, and what we can expect in the future.

Our Hack Chats are live community events in the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Wednesday, June 19 at 5:00 PM Pacific time. If time zones have got you down, we have a handy time zone converter.

Click that speech bubble to the right, and you’ll be taken directly to the Hack Chat group on Hackaday.io. You don’t have to wait until Wednesday; join whenever you want and you can see what the community is talking about.

Flexible PCBs Hack Chat With OSH Park

May 20, 2019 by Dan Maloney No comments

Join us Thursday at noon Pacific time for the Flexible PCBs Hack Chat with Drew and Chris from OSH Park!
Note the different day from our usual Hack Chat schedule!
Printed circuit boards have been around for decades, and mass production of them has been an incalculable boon to the electronics industry. But turning the economics of PCB production around and making it accessible to small-scale producers and even home experimenters is a relatively recent development, and one which may have an even broader and deeper impact on the industry in the long run.

And now, as if professional PCBs at ridiculous prices weren’t enough, the home-gamer now has access to flexible PCBs. From wearables to sensor applications, flex PCBs have wide-ranging applications and stand to open up new frontiers to the hardware hacker. We’ve even partnered with OSH Park in the Flexible PCB Contest, specifically to stretch your flexible wings and get you thinking beyond flat, rigid PCBs.

Our Hack Chats are live community events in the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Thursday, May 23 at 12:00 PM Pacific time. If time zones have got you down, we have a handy time zone converter.

Click that speech bubble to the right, and you’ll be taken directly to the Hack Chat group on Hackaday.io. You don’t have to wait until Thursday; join whenever you want and you can see what the community is talking about.

Autodesk Fusion 360 Hack Chat

April 8, 2019 by Dan Maloney 20 Comments

Join us Wednesday at noon Pacific time for the Autodesk Fusion 360 Hack Chat!

Most of us have a collection of tools that we use for the various mechanical, electronic, and manufacturing tasks we face daily. But if you were asked to name one tool that stretches across all these spaces, Autodesk Fusion 360 would certainly spring to mind. Everyone from casual designers of 3D-printed widgets to commercial CNC machine shops use it as an end to end design solution, and anyone who has used it over the last year or so knows that the feature set in Fusion is expanding rapidly.

Matt, who goes by technolomaniac on Hackaday.io, is Director of Product Development for EAGLE, Tinkercad, and Fusion 360 at Autodesk. He’ll drop by the Hack Chat this week to discuss your questions about:

All the Autodesk design software components, from EAGLE to Fusion and beyond
Future plans for an EAGLE-Fusion integration
Support for manufacturing, including additive, CNC, and even mold making
Will there ever be “one design tool to rule them all?”

You are, of course, encouraged to add your own questions to the discussion. You can do that by leaving a comment on the Autodesk Fusion 360 Hack Chat page and we’ll put that in the queue for the Hack Chat discussion.

Our Hack Chats are live community events in the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Wednesday, April 10, at noon, Pacific time. If time zones have got you down, we have a handy time zone converter.

Delta Printer Morphs Into CNC Flat Coil Winder

June 16, 2018 by Dan Maloney 21 Comments

Anyone who has ever wound a coil by hand has probably idly wondered “How do they do this with a machine?” at some point in the tedious process. That’s about when your attention wanders and the wire does what physics wants it to do, with the rat’s nest and cursing as a predictable result.

There’s got to be a better way, and [Russ Gries] is on his way to finding it with this proof-of-concept CNC flat coil winder. The video below is a brief overview of what came out of an intensive rapid prototyping session. [Russ] originally thought that moving the coil would be the way to go, but a friend put him onto the idea of using his delta-style 3D-printer to dispense the wire. An attachment somewhat like a drag knife was built, but with a wire feed tube and a metal roller to press the wire down onto an adhesive surface. The wire feed assembly went through a few design iterations before he discovered that a silicone cover was needed for the roller for the wire to properly track, and that the wire spool needed to be fed with as little friction as possible. Fusion 360’s CAM features were used to design the tool paths that describe the coils. It seems quite effective, and watching it lay down neat lines of magnet wire is pretty mesmerizing.

We’ve seen a couple of cylindrical coil winding rigs before, but it looks like this is the first flat coil winder we’ve featured. We can’t help but wonder about the applications. Wireless power transfer comes to mind, as do antennas and coils for RF applications. We also wonder if there are ways to use this to make printed circuit boards. Continue reading “Delta Printer Morphs Into CNC Flat Coil Winder” →