electromagnet

64 Articles

Electromagnets Make Vertical CNC Cutter A Little Stickier

April 12, 2024 by 10 Comments

Workholding is generally not a problem on a big CNC plasma cutter.; gravity does a pretty good job of keeping heavy sheet steel in place on the bed. But what if your CNC table isn’t a table? The answer: magnets — lots of magnets.

The backstory on this is a bit involved, but the condensed version is that [Lucas] needed a CNC plasma cutter big enough to cut full-sized sheets of steel, but lacked the floor space in his shop for such a beast. His solution was to build a custom CNC machine that stands more or less vertically, allowing him to cut full sheets in a mere fraction of the floor space. It’s a fantastic idea, one that he put a lot of effort into, but it’s not without its problems. Chief among them is the tendency for the sheet metal to buckle and bulge during cutting since gravity isn’t working for him, along with the pesky problem of offcuts slipping away.

To help hold things in place, [Lucas] decided to magnetize the bed of his cutter. That required winding a bunch of magnets, which is covered in the video below. Mass production of magnets turns out not to be as easy as you’d think. Also unexpected was the need to turn off magnets when the cutting torch is nearby, lest the magnetic field bork the cutting plasma. [Lucas] grabbed some code from the LinuxCNC forum that streams the gantry coordinates over serial and used an Arduino to parse those messages. When the torch is getting close to one of the magnets, a relay board cuts power to just that magnet. You can see it in action in the video below; at around the 18:15 mark, you can see the sheet bulging up a bit when the torch comes by, and sucking back down when it moves on.

The amount of work [Lucas] put into this project is impressive, and the results are fantastic. This isn’t the first time he’s relied on the power of magnets to deal with sheet steel, and it probably won’t be the last.

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Vibratory Rock Tumbler Bounces On Printed Spring

April 4, 2024 by 26 Comments

If you’re reading Hackaday, there’s a good chance you had a rock tumbler in your younger days. Hell, we’d put odds on a few of you having one rumbling away in the background as you read this. They’re relatively simple contraptions, and a common enough DIY project. But even still, this largely 3D printed rock tumbler from [Fraens] is unique enough to stand out.

To make a basic rock tumbler, all you really need to do is rotate a cylindrical chamber and let physics do its thing. Such contraptions are known as, unsurprisingly, rotary rock tumblers. But what [Fraens] has put together here is a vibratory tumbler, which…well, it vibrates. If this was Rockaday we might go farther down this particular rabbit hole and explain the pros and cons of each machine, but the short version is that vibratory tumblers are more mechanically complex and are generally better suited to fine finish work than rotary tumblers which take a brute force approach that tends to round off the rocks.

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Sort Of Electromagnet Attracts Copper, Aluminum

March 27, 2024 by 10 Comments

It is a common grade school experiment to wind some wire around a screw, power it up, and watch it pick up paper clips or other ferrous materials. It is also grade school science to show that neither an electromagnet nor a permanent magnet will pick up nonferrous items like copper or aluminum. While technically not an electromagnet, it is possible to build a similar device that will weakly pull on copper and aluminum, and [Cylo] shows us how it works in a recent video you can see below.

The device sure looks like an electromagnet made with magnet wire and a steel core. But when he shows the ends of the core, you’ll see that the side that attracts aluminum has a copper ring embedded in it. The coil is fed with AC.

The magnetic field from the coil induces an opposite field in the copper ring that is out of phase with the exciting field. The two fields combine to produce a force on the metal it interacts with. This is often referred to as a shaded pole, and the same technique can help AC motors self-start as well as hold in relays driven by AC. If you want to see much more about aluminum floating on a magnetic field, check out the 1975 video from [Professor Laithwaite] in the second video below.

You probably have a shaded pole AC motor in your microwave oven. Or, maybe,your old 8-track player.

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Handle Sheet Metal With The Power Of Microwave Oven Electromagnets

May 23, 2023 by 17 Comments

For those of us who don’t do it every day, handling sheet metal can be a nerve-wracking affair. Sheet metal is thin, heavy, and sharp, and one wrong move while handling it can have much the same result as other such objects, like guillotine blades. If only there was a way to lessen the danger.

Perhaps something like this electromagnetic sheet metal handler by [Lucas] over at “Cranktown City” would be useful in keeping one’s fingers and toes attached. Like many interesting builds, this one starts with the dismemberment of a couple of old microwave ovens, to liberate their transformers. Further dissection resulted in open-frame electromagnets, which when energized with a battery from a Ryobi cordless tool do a fine job sticking to stuff.

[Lucas] then harvested the battery connector from the cheapest possible Ryobi tool — an electric fan — and built a prototype, which worked well enough to proceed to a more polished version two. This one had the same guts in a nicely designed case, 3D-printed from lime green filament for that OEM look. The video below shows the design and build, as well as field testing. We have to say this gave us a bit of pause, especially when the battery popped out of one of the handlers and sent the sheet on a near-miss of [Lucas]’ toes. Close call there.

If you’re thinking that you’ve seen MOTs repurposed as electromagnets before, you’re right. Whether climbing like [Spider-Man], lifting heavy steel beams, or walking upside down, microwave oven transformers are the key.

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Levitating Banana Is An Excellent Conversation Starter

February 3, 2023 by 6 Comments

“I really like your floating banana.” If that’s something you’ve always wanted your guests to say when visiting your living room, this levitating banana project from [ElectroBing] is for you.

The design is simple. It relies on a electromagnet to lift the banana into the air. As bananas aren’t usually ferromagnetic, a simple bar magnet is fitted to the banana to allow it to be attracted to the electromagnet. One could insert the magnets more stealthily inside the banana, though this would come with the risk that someone may accidentally consume them, which can be deadly.

Of course, typically, the magnet would either be too weak to lift the banana, or so strong that it simply attracted the banana until it made contact. To get the non-contact levitating effect, some circuitry is required. A hall effect sensor is installed directly under the electromagnet. As the banana’s magnet gets closer to the electromagnet, the hall effect sensor’s output voltage goes down. Once it drops below a certain threshold, a control circuit cuts power to the electromagnet. As the banana falls away, power is restored, pulling the banana back up. By carefully controlling the power to the electromagnet on a continuous basis, the banana can be made to float a short distance away in mid-air.

It’s a fun build, and one that teaches many useful lessons in both physics and electronics. Other levitation techniques exist, too, such as through the use of ultrasound. Video after the break.

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A row of electromagnetic coils fastened to a metal track

Propel Paper Planes, Bisect Sausages With Electromagnets

November 14, 2021 by 7 Comments

Are you still launching paper airplanes using your hands? That’s like a baby’s toy! [Tom Stanton] and his homebrew electromagnetic rail launcher are sure to bring your paper airplane game into the 21st century.

To be fair, these kinds of linear motors can be used for more than just launching paper airplanes, and can already be found in niche industrial applications, mass transportation systems and roller coasters. And, yes, the potential to leverage electromagnetism in the theater of war is also being vigorously explored by many of the world’s superpowers in the form of Gauss rifles and railguns. In the meantime, the video (after the break) proves that it’s entirely possible to build a rudimentary yet effective linear motor in your makerspace, using relatively basic components and fundamental physics.

In short, these launch systems use electromagnetism and well timed electronics to propel a mass of magnetic material down a straight (or sometimes curved) track. Multiple pairs of coils are placed along the track, with each pair subsequently energized by high current as the payload approaches. By using many coils in succession, the mass and its payload can be accelerated to high speed.

While a homemade rail launcher is unlikely to turn the tides of war, [Tom Stanton] explores their lethal potential with an experiment involving high-speed video and supermarket sausages, with gruesome results.

If you’re looking for more, why not check out our our previous coverage on electromagnetic weaponry?

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Is This 12-layer PCB Coil The Next Step In Ferrofluid Displays?

November 12, 2021 by 21 Comments

[Applied Procrastination] is in the business of vertical ferrofluid displays, but struggles somewhat with the electromagnets available off the shelf and the proliferation of wiring that results. [Carl Bugeja] is in the business of making PCB coils, both with rigid and flex PCB substrates, so when the opportunity for a collaboration arose, [AP] jumped at the opportunity.

As [Simen from AP] mentions in the video after the break, they had considered using a large PCB with embedded coils for Fetch their ferrofluid display unit, but the possible magnetic field was just too weak, and attempting to crank up the amps, just overheats them. Some improvements were made, first sticking the coil PCB to a small disk of ferrous metal, which doubled up as a handy heatsink. Next, he tried adding a permanent magnet, which added a bit of bias field. Alone this was not enough to hold the ferrofluid in place, but with the coil powered, it was starting to look encouraging.

Much more progress was made when [Carl] sent over a new design of his, a 12-layer PCB coil. This obviously had a much larger field, but still not enough without the extra boost from permanent magnet.

[Simen] currently doesn’t think the PCB approach is quite there yet, and is looking for help to source PCB-mounted electromagnets of the wired variety. We would imaging prototyping with such a large 12-layer PCB would be rather prohibitively expensive anyway.

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