Delta Robot Is Sorting Golf Balls And Taking Names

It’s a common situation faced by every hard-working American – you get home after a long day at the calcium mines, and find yourself stuck with a pile of colored golf balls that simply aren’t going to sort themselves. Finally, you can put away your sorting funnels and ball-handling gloves – [Anthony] has the solution.

That’s right – it’s a delta robot, tasked with the job of sorting golf balls by color. A Pixy2 object tracking camera is used to survey the table, with the delta arms twitching around to allow the camera to get an unobstructed view. Once the position of the balls is known, a bubble sort is run and the balls rearranged into their correct color order.

[Anthony] readily admits the bubble sort is very inefficient at this task; it was an intentional choice so it could be later compared with other sorting methods. [Anthony] also goes into detail, sharing the development process of the suction gripper as well as discussing damping methods to reduce noise.

Delta machines are always fun to watch, and are a good choice for sorting machines. We’ve seen some really tiny ones, too. Video after the break.

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Dainty Delta Is About As Small As A Robot Can Be

There’s something mesmerizing about delta robots. Whether they are used at a stately pace for a 3D-printer or going so fast you can barely see them move in a pick and place machine, the way that three rotary actuators can work together to produce motion in three axes is always a treat to watch. Especially with a delta robot as small as this one.

[KarelK16] says this is one of those “just because I can” projects with no real application. And he appears to have been working on it for a while; the video below is from eight years ago. Regardless, the post is new, and it’s pretty interesting stuff. The tiny ball joints used in the arms are made from jewelry parts; small copper crank arms connect the three upper arms to micro-servos. The manipulator [KarelK16] attached is very clever, too – rather than load down the end of the arms with something heavy, a fourth servo opens an closes a flexible plastic grasper through a Bowden cable. It’s surprisingly nimble, and grasps small objects firmly.

There are certainly bigger deltas – much bigger – and more useful ones, too, but we really like this build. And who knows – perhaps model robotics will join model railroading as a hobby someday. If it does, [KarelK16]’s diminutive delta might be the shape of things to come.

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Delta Bot Plucks Out Tunes on a Mandolin

Is there no occupation safe from the scourge of robotic replacement? First it was the automobile assemblers, then fast food workers, and now it’s the — mandolin players?

Probably not, unless [Clayton Darwin]’s mandolin playing pluck-bot has anything to say about it. The pick-wielding delta-ish robot can be seen in action in the video below, plucking out the iconic opening measures of that 70s prom-theme favorite, “Colour My World.” The robot consists of two stepper motors connected to a hinged wooden arm by two pushrods. We had to slow the video down to catch the motion, but it looks like [Clayton] has worked out the kinematics so that the pick can be positioned in front of any of the mandolin’s eight strings. A quick move of the lower stepper then flicks the pick across a string and plucks it. [Clayton] goes into some detail about how he built the motion-control part in an earlier video; he also proves that steppers are better musicians than we’ll ever be with a little “Axel F” break.

It’s only a beginning, of course, but the complexity of the kinematics just goes to show how simple playing an instrument isn’t. Unless, of course, you unleash an endless waterfall of marbles on the problem.

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Rewound and Rewired BLDC Makes a Half-Decent Generator

What’s the best way to turn a high-powered brushless DC motor optimized for hobby use into a decent low-RPM generator? Do you take a purely mechanical approach and slap a gearbox on the shaft? Or do you tackle the problem electrically?

The latter approach is what [GreatScott!] settled on with his BLDC rewinding and rewiring project. Having previously explored which motors have the best potential as generators, he knew the essential problem: in rough terms, hobby BLDCs are optimized for turning volts into RPMs, and not the other way around. He started with a teardown of a small motor, to understand the mechanical challenges involved, then moved onto a larger motor. The bigger motor was stubborn, but with some elbow grease, a lot of scratches, and some destroyed bearings, the motor was relieved of both its rotor and stator. The windings were stripped off and replaced with heavier magnet wire with more turns per pole than the original. The effect of this was to drive the Kv down and allow better performance at low RPMs. Things looked even better when the windings were rewired from delta to wye configuration.

The take-home lesson is probably to use a generator where you need a generator and let motors be motors. But we appreciate [GreatScott!]’s lesson on the innards of BLDCs nonetheless, and his other work in the “DIY or buy?” vein. Whether you want to make your own inverter, turn a hard drive motor into an encoder, or roll your own lithium battery pack, he’s done a lot of the dirty work already.

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Stepper Motor Mods Improve CNC Flat Coil Winder

Finding just the right off-the-shelf part to complete a project is a satisfying experience – buy it, bolt it on, get on with business. Things don’t always work out so easily, though, which often requires the even more satisfying experience of modifying an existing part to do the job. Modifying a stepper motor by drilling a hole down its shaft probably qualifies for the satisfying mod of the year award.

That’s what [Russ] did to make needed improvements to his CNC flat-coil winder, which uses a modified delta-style 3D-printer to roll fine magnet wire out onto adhesive paper to form beautiful coils of various sizes and shapes. [Russ] has been tweaking his design since we featured it and coming up with better and better coils. While experimenting, the passive roller at the business end proved to be a liability. The problem was that the contact point lagged behind the center axis of the delta, leading to problems with the G-code. [Russ] figured that a new tool with the contact point at the dead center would help. The downside would be having to actively swivel the tool in concert with the X- and Y-axis movements. The video below shows his mods, which include disassembling the NEMA-17 stepper and drilling out the shaft to pass the coil wire. [Russ] also spent some time reversing the rotor in the frame and provided a small preload spring to keep the coil roller in contact with the paper.

A real-time coil winding session starts at the 21:18 mark, and we’ve got to admit it’s oddly soothing to watch. We’re not sure exactly what [Russ] intends to do with these coils, and by his own admission, neither is he. But it’s still pretty cool to see, and the stepper motor mods are a neat trick to keep in mind.

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Open Source DIY Printers are Alive and Well: What We Saw At ERRF 18

If you follow the desktop 3D printer market, it probably won’t surprise you to hear that nearly every 3D printer on display at the inaugural East Coast RepRap Festival (ERRF) was made in China. Even Printrbot CEO Brook Drumm had to admit that this was the year his company may finally bite the bullet and begin selling a branded and customized printer built overseas.

When you can get a decent (but let’s be clear, not great) 3D printer for $200 USD, it’s no surprise that American and European manufacturers are having a hard time staying competitive. But not everyone is seduced by low-cost printers. They know they could buy a decent printer for a couple hundred bucks, but for them that’s not the point. Some hackers are just as (if not more) interested in designing and building the machines than they are churning out little plastic boats with the finished product.

Luckily for us, these are also the type of folks who document their builds and make all their collected information and design files available for others under an open source license. Such builders exemplify the true spirit of the RepRap movement, and we’re happy to report that in a sea of imported printers, there were several interesting home built open source printers.

Whether you want to build your own copy of one of these machines, or simply get inspired by some of the ideas their creators had, these machines are physical proof that just because you can order a cheap 3D printer on eBay right now doesn’t mean you have to.

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Delta Printer Morphs into CNC Flat Coil Winder

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”