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56 Articles

Automating 3D Printer Support Hardware

June 6, 2024 by 22 Comments

While 3D printers have evolved over the past two decades from novelties to powerful prototyping tools, the amount of support systems have advanced tremendously as well. From rudimentary software that required extensive manual input and offered limited design capabilities, there’s now user-friendly interfaces with more features than you could shake a stick at. Hardware support has become refined as well with plenty of options including lighting, ventilation, filament recycling, and tool changers. It’s possible to automate some of these subsystems as well like [Caelestis Workshop] has done with this relay control box.

This build specifically focuses on automating or remotely controlling the power, enclosure lighting, and the ventilation system of [Caelestis Workshop]’s 3D printer but was specifically designed to be scalable and support adding other features quickly. A large power supply is housed inside of a 3D printed enclosure along with a Raspberry Pi. The Pi controls four relays which are used to control these various pieces hardware along with the 3D printer. That’s not the only thing the Pi is responsible for, though. It’s also configured to run Octoprint, a piece of open-source software that adds web interfaces for 3D printers and allows their operation to be monitored and controlled remotely too.

With this setup properly configured, [Caelestis Workshop] can access their printer from essentially any PC, monitor their prints, and ensure that ventilation is running. Streamlining the print process is key to reducing the frustration of any 3D printer setup, and this build will go a long way to achieving a more stress-free environment. In case you missed it, we recently hosed a FLOSS Weekly episode talking about Octoprint itself which is worth a listen especially if you haven’t tried this piece of software out yet.

Streaming Deck Removes Need For Dedicated Hardware

February 25, 2024 by 11 Comments

Streaming content online has never been more popular than it is now, from YouTube to Twitch there are all kinds of creators around with interesting streams across a wide spectrum of interests. With that gold rush comes plenty of people selling figurative shovels as well, with audio mixing gear, high-quality web cams, and dedicated devices for controlling all of this technology. Often these devices take the form of a tablet-like device, but [Lenochxd] thinks that any tablet ought to be able to perform this task without needing dedicated, often proprietary, hardware.

The solution offered here is called WebDeck, an application written in Flask that turns essentially any device with a broswer into a stream control device. Of course it helps to have a touch screen as well, but an abundance of tablets and smartphones in the world makes this a non-issue. With the software running on the host computer, the streamer can control various aspects of that computer remotely by scanning a QR code which opens a browser window with all of the controls accessible from within. It has support for VLC, OBS Studio, and Spotify as well which covers the bases for plenty of streaming needs.

Currently the host software only runs on Windows, but [Lenochxd] hopes to have MacOS and Linux versions available soon. We’re always in favor of any device that uses existing technology and also avoids proprietary hardware and software. Hopefully that’s a recipe to avoid planned obsolescence and unnecessary production. If you prefer a version with a little bit of tactile feedback, though, we’ve seen other decks which add physical buttons for quick control of the stream.

A Deep Dive Into Quadcopter Controls

January 1, 2024 by 3 Comments

In the old days, building a quadcopter or drone required a lot of hacking together of various components from the motors to the batteries and even the control software. Not so much anymore, with quadcopters of all sizes ready to go literally out-of-the-box. While this has resulted in a number of knock-on effects such as FAA regulations for drone pilots, it’s also let us disconnect a little bit from the more interesting control systems these unique aircraft have. A group at Cornell wanted to take a closer look into the control systems for drones and built this one-dimensional quadcopter to experiment with.

The drone is only capable of flying in one dimension to allow the project to more easily fit into the four-week schedule of the class, so it’s restricted to travel along a vertical rod (which also improves the safety of the lab).  The drone knows its current position using an on-board IMU and can be commanded to move to a different position, but it first has to calculate the movements it needs to make as well as making use of a PID control system to make its movements as smooth as possible. The movements are translated into commands to the individual propellers which get their power from a circuit designed from scratch for this build.

All of the components of the project were built specifically for this drone, including the drone platform itself which was 3D printed to hold the microcontroller, motors, and accommodate the rod that allows it to travel up and down. There were some challenges such as having to move the microcontroller off of the platform and boosting the current-handling capacity of the power supply to the motors. Controlling quadcopters, even in just one dimension, is a complex topic when building everything from the ground up, but this guide goes some more of the details of PID controllers and how they help quadcopters maintain their position.

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Heat Pump Control That Works

September 4, 2023 by 33 Comments

Heat pumps are taking the world by storm, and for good reason. Not only are they many times more efficient than electric heaters, but they can also be used to provide cooling in the summer. Efficiency aside, though, they’re not perfectly designed devices, largely with respect to their climate control abilities especially for split-unit setups. Many of them don’t have remotely located thermostats to monitor temperature in an area, and rely on crude infrared remote controls as the only user interface. Looking to make some improvements to this setup, [Danilo] built a setup more reminiscent of a central HVAC system to control his.

Based on an ESP32 from Adafruit with an integrated TFT display, the device is placed away from the heat pump to more accurately measure room temperature. A humidity sensor is also included, as well as an ambient light sensor to automatically reduce the brightness of the display at night. A large wheel makes it quick and easy to adjust the temperature settings up or down. Armed with an infrared emitter, the device is capable of sending commands to the heat pump to more accurately control the climate of the room than the built-in controls are able to do. It’s also capable of logging data and integrating with various home automation systems.

While the device is optimized for the Mitsubishi heat pumps that [Danilo] has, only a few lines of code need to be changed to get this to work with other brands. This is a welcome improvement for those frustrated with the inaccurate climate controls of their heat pumps, and since it integrates seamlessly into home automation systems could also function in tandem with other backup heat sources, used in cold climates when it’s too cold outside to efficiently run the heat pump. And, if you don’t have a heat pump yet, you can always try and build your own.

MOSFET Heater Is Its Own Thermostat

March 29, 2023 by 16 Comments

While we might all be quick to grab a microcontroller and an appropriate sensor to solve some problem, gather data about a system, or control another piece of technology, there are some downsides with this method. Software has a lot of failure modes, and relying on it without any backups or redundancy can lead to problems. Often, a much more reliable way to solve a simple problem is with hardware. This heating circuit, for example, uses a MOSFET as a heating element and as its own temperature control.

The function of the circuit relies on a parasitic diode formed within the transistor itself, inherent in its construction. This diode is found in most power MOSFETs and conducts from the source to the drain. The key is that it conducts at a rate proportional to its temperature, so if the circuit is fed with AC, during the negative half of the voltage cycle this diode can be probed and used as a thermostat. In this build, it is controlled by a set of resistors attached to a voltage regulator, which turn the heater on if it hasn’t reached its threshold temperature yet.

In theory, these resistors could be replaced with potentiometers to allow for adjustable heat for certain applications, with plastic cutting and welding, temperature control for small biological systems, or heating other circuits as target applications for this type of analog circuitry. For more analog circuit design inspiration, though, you’ll want to take a look at some classic pieces of electronics literature.

Clever Control Loop Makes This Spinning Drone Fault-Tolerant

November 9, 2022 by 18 Comments

Most multi-rotor aircraft are about as aerodynamic as a brick. Unless all its motors are turning and the control electronics are doing their thing, most UAVs are quickly destined to become UGVs, and generally in spectacular fashion. But by switching up things a bit, it’s possible to make a multi-rotor drone that keeps on flying even without two-thirds of its motors running.

We’ve been keeping a close eye on [Nick Rehm]’s cool spinning drone project, which basically eschews a rigid airframe for a set of three airfoils joined to a central hub. The collective pitch of the blades can be controlled via a servo in the hub, and the whole thing can be made to rotate and provide lift thanks to the thrust of tip-mounted motors and props. We’ve seen [Nick] manage to get this contraption airborne, and hovering is pretty straightforward. The video below covers the next step: getting pitch, roll, and yaw control over the spinning blades of doom.

The problem isn’t trivial. First off, [Nick] had to decide what the front of a spinning aircraft even means. Through the clever uses of LED strips mounted to the airfoils and some POV magic, he was able to visually indicate a reference axis. From there he was able to come up with a scheme to vary the power to each motor as it moves relative to the reference axis, modulating it in either a sine or cosine function to achieve roll and pitch control. This basically imitates the cyclic pitch control of a classic helicopter — a sort of virtual swashplate.

The results of all this are impressive, if a bit terrifying. [Nick] clearly has control of the aircraft even though it’s spinning at 250 RPM, but even cooler is the bit where he kills first one then two motors. It struggles, but it’s still controllable enough for a bumpy but safe landing.

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Mini Falcon 9 Uses NASA Software

July 26, 2022 by 17 Comments

[T-Zero Systems] has been working on his model Falcon 9 rocket for a while now. It’s an impressive model, complete with thrust vectoring, a microcontroller which follows a predetermined flight plan, a working launch pad, and even legs to attempt vertical landings. During his first tests of his model, though, there were some issues with the control system software that he wrote so he’s back with a new system that borrows software from the Space Shuttle.

The first problem to solve is gimbal lock, a problem that arises when two axes of rotation line up during flight, causing erratic motion. This is especially difficult because this model has no ability to control roll. Solving this using quaternion instead of Euler angles involves a lot of math, provided by libraries developed for use on the Space Shuttle, but with the extra efficiency improvements the new software runs at a much faster rate than it did previously. Unfortunately, the new software had a bug which prevented the parachute from opening, which wasn’t discovered until after launch.

There’s a lot going on in this build behind-the-scenes, too, like the test rocket motor used for testing the control system, which is actually two counter-rotating propellers that can be used to model the thrust of a motor without actually lighting anything on fire. There’s also a separate video describing a test method which validates new hardware with data from prior launches. And, if you want to take your model rocketry further in a different direction, it’s always possible to make your own fuel as well.

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