Autofeeding CNC Lathe Cranks Out Parts All By Itself

The trouble with building a business around selling low-margin widgets is that you have to find a way to make a lot of them to make it worth your while. And if the widget in question is labor-intensive to make, you’ve got to find ways to reduce your inputs. That sounds like a job for industrial automation, a solution that’s often out of reach of small shops, for all the obvious reasons. Not if you’re clever about things, though, as this fully automated CNC lathe work cell shows.

This build comes to us from the woodshop of [Maher Lagha], where he’s making wooden honey dippers. Wooden dowel blanks are dispensed from an infeed rack and chucked between centers on the headstock and pneumatic tailstock. A two-axis stage in front of the workpiece moves a tool against the spinning stock, carving out the honey dipper in just a few minutes. When the lathe work is done, the spindle stops, the tailstock pulls the honey dipper back off the headstock, and a pneumatic piston unceremoniously whacks the almost-finished part — it looks like it still needs a little manual post-processing — into a bin. Lather, rinse, repeat, profit.

[Maher] doesn’t provide many details, but just looking at the work cell shows a veritable feast of industrial automation equipment. The spindle and tailstock of the lathe sit on a bed made from a massive slab of aluminum extrusion, and the X- and Y-axes use linear rails and ballscrews. And mindful of the effects of wood chips on delicate mechanisms, [Maher] did a good job of containing the mess with a host of acrylic guards.

As we said when we saw [Maher]’s wooden coaster work cell a while back, the wood widget business must be pretty good to justify automation like this. What’s nice with both these rigs is that they look like they could be quickly reprogrammed and retooled to create other products. Pretty impressive.

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Humble Arduino As PLC

On the surface, a programmable logic controller (PLC) might seem like nothing more than a generic microcontroller, perhaps outfitted to operate in industrial settings with things like high temperatures or harsh vibrations. While this is true to some extent, PLCs also have an international standard for their architecture and programming languages. This standard is maintained by the International Electrotechnical Commission, making it so that any device built under these specifications will be recognizable to control engineers and maintenance personnel worldwide. And, if you use this standard when working with certain Arduinos, this common platform can become a standard-compliant PLC as well.

The IDE itself supports programming ladder diagrams, functional block diagrams, and other programming systems covered under the IEC 61131-3 standard. Not only that, it allows the combination of these types of PLC programming with Arduino sketches. The system offers many of the perks of PLC programming alongside the familiar Arduino platform, and supports a number of protocols as well including CANOpen, Modbus RTU, and Modbus TCP. It can also be used for monitoring a PLC system, essentially adding IoT capabilities to existing systems, enabling continuous monitoring, debugging, and program updates.

While not every Arduino is a great platform to build a PLC around, there are a few available for those looking for a system a little less proprietary and a little more user-friendly than typical PLC systems tend to be. There’s a reason that PLCs are built around an international standard and generally have certain hardware in mind to run it, though, and this comparison of a Raspberry Pi with an off-the-shelf PLC goes into detail about why certain components aren’t good choices for PLCs.

Industrial Robot Gets Open-Source Upgrade

Industrial robots are shockingly expensive when new, typically only affordable for those running factories of some sort. Once they’ve gone through their life cycle building widgets, they can be purchased for little more than scrap value, which is essentially free compared to their original sticker price. [Excessive Overkill] explains all of this in a video where he purchased one at this stage to try to revive, but it also shows us how to get some more life out of these robots if you can spend some time hunting for spare parts, installing open-source firmware, and also have the space for a robot that weighs well over a thousand kilograms.

This specific robot is a Fanuc R2000ia with six degrees of freedom and a reach of over two meters. Originally the plan was to patch together a system that could send modern gcode to the Fanuc controller, but this was eventually scrapped when [Excessive Overkill] realized the controller that shipped with this robot was for an entirely different machine and would never work. Attempts to find upgraded firmware were frustrated, and after a few other false starts a solution was found to get the robot working again using LinuxCNC and Mesa FPGA cards, which have built-in support for Fanuc devices like this.

More after the break…

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The Mystery Of Automatic Lubricators Is Revealed

Industrial machines have all kinds of moving parts that require regular lubrication in order to prevent wear and damage. Historically, these would require regular visits from maintenance personnel to keep them greased up and slippery. Automatic lubricators eliminate that job by regularly dosing machines with fresh grease, and [Big Clive] decided to see what makes them tick.

The device can be set to deliver a full load of grease over a period of 1-12 months.

The simplest models merely use a spring to slowly force grease out over time. Changing the spring changes the rate at which grease is dispensed. Chemical versions exist too. A chemical pill is selected and inserted into a chamber with liquid, which releases gas over time. As gas is released, it creates pressure which forces a plunger down, dispensing grease over time.

Perhaps the fanciest versions are the electronic models, however, which have a dial on the back for selecting the rate of grease delivery. Turning the dial changes a resistance that is connected across two zinc-air cells which are sealed. Apparently, when current is forced through these cells and they’re excluded from oxygen, the cells liberate hydrogen gas, according to a patent [Big Clive] found. This then forces down the plunger, dispensing the grease. Turning the dial changes the resistance, changing the rate at which grease is dispensed.

The quest for labor saving in industry has produced multiple designs of automated lubricator, all of which are fantastically simple and optimised for purpose. It shows just how much can be achieved with a few components and some creative thinking, where one’s first impulse might be to reach for a timer or microcontroller to do the job.

Lubrication is incredibly important – don’t forget it when building your CNC machines! Video after the break.

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Scratch-Built Robot Arm Looks Like Something Off The Factory Floor

[Jeremy Fielding] is rightly impressed with the power and precision of industrial robot arms. The big arms that you see welding cars on assembly lines and the like are engineering feats in their own right, which is why his leap into scratch-building one in the home shop promises to be quite an adventure, and one we’re eager to follow.

From the look of the video below, [Jeremy]’s arm is already substantially complete, so it seems like he’ll be releasing videos that detail how he got to the point where this impressively large and powerful arm took over so much of his shop. He’s not fooling around here — this is a seven-axis articulated arm built from aluminum and powered by AC servos. [Jeremy] allows that some of the structural parts are still 3D-printed prototypes that he’s using to finalize the design before committing to cutting metal, a wise move as he notes that most of the metalworking skills he needs to complete the build are still fairly new to him. It still looks amazing, and we’re looking forward to the rest of the series to see how he got to this point.

We always appreciate [Jeremy]’s enthusiasm and presentation style, and we generally learn a lot from his videos. Whether it’s a CNC table saw, a homebrew dynamometer, or supersonically melting baseballs, his videos are always great to watch.

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Breathtaking Alarm Clock Looks Like It Came From A 1960 Fallout Shelter

All the hardcore geeks have alarm clocks where the bell striker is a hard disk read head… or at least they’ll be building them after seeing this. [Senile Data Systems] created an industrial voltage alarm clock out of decade counters that looks like it was unearthed from a fallout shelter (machine translation).

At first glace you might mistake this for a binary clock since it uses a column of LEDs to indicate each digit of 24-hour time. It’s not, as each row corresponds to a pin on the CD4017 decade counters that make up the timekeeping circuit inside.

Thumbscrew wheel switches at the top of the bulky handheld unit are how the alarm time is set, triggering a bell along the top edge. The clock is driven by the 50 Hz line voltage and [SDS] tried using that AC to drive a solenoid as the striker on the prototype unit but it performed poorly. The use of a hard disk read head turns out to be the perfect striker, as heard in the video after the break. As for triggering from the decade counters, here’s what [SDS] told us about the design:

The switches’ outputs gets ANDed with a 10 Hz signal (on a 60 Hz grid it will become 12 Hz). This drives a slightly beefy transistor which in turn drives an electromagnet to hammer a bell which broke off my bicycle. Yes. This is a digital analog alarm clock. The clock portion is digital but the bell is analog and sounds like Grampa’s old wind up alarm clock.

The build came about when a cache of over 600 industrial LEDs (24 V – 48 V) fell into his lap. This makes the insides of the clock something to behold as point-to-point soldering connects the panel mount lights and all nine logic chips. Add in that transformer for getting the line voltage and we imagine this thing has quite a bit of heft to it.

If you’ve ever had an alarm with a wind-up bell you know there’s no better way to jolt yourself out of a peaceful slumber and into the chaos of the real world. If the gentle tinkle of the hard drive head isn’t enough for you, this fire bell alarm clock will certainly do the trick.

 

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Hackaday Links: April 26, 2020

Gosh, what a shame: it turns out that perhaps 2 billion phones won’t be capable of COVID-19 contact-tracing using the API that Google and Apple are jointly developing. The problem is that the scheme the two tech giants have concocted, which Elliot Williams expertly dissected recently, is based on Bluetooth LE. If a phone lacks a BLE chipset, then it won’t work with apps built on the contact-tracing API, which uses the limited range of BLE signals as a proxy for the physical proximity of any two people. If a user is reported to be COVID-19 positive, all the people whose BLE beacons were received by the infected user’s phone within a defined time period can be anonymously notified of their contact. As Elliot points out, numerous questions loom around this scheme, not least of which is privacy, but for now, something like a third of phones in mature smartphone markets won’t be able to participate, and perhaps two-thirds of the phones in developing markets are not compatible. For those who don’t like the privacy-threatening aspects of this scheme, pulling an old phone out and dusting it off might not be a bad idea.

We occasionally cover stories where engineers in industrial settings use an Arduino for a quick-and-dirty automation solution. This is uniformly met with much teeth-gnashing and hair-rending in the comments asserting that Arduinos are not appropriate for industrial use. Whether true or not, such comments miss the point that the Arduino solution is usually a stop-gap or proof-of-concept deal. But now the purists and pedants can relax, because Automation Direct is offering Arduino-compatible, industrial-grade programmable controllers. Their ProductivityOpen line is compatible with the Arduino IDE while having industrial certifications and hardening against harsh conditions, with a rich line of shields available to piece together complete automation controllers. For the home-gamer, an Arduino in an enclosure that can withstand harsh conditions and only cost $49 might fill a niche.

Speaking of Arduinos and Arduino accessories, better watch out if you’ve got any modules and you come under the scrutiny of an authoritarian regime, because you could be accused of being a bomb maker. Police in Hong Kong allegedly arrested a 20-year-old student and posted a picture of parts he used to manufacture a “remote detonated bomb”. The BOM for the bomb was strangely devoid of anything with wireless capabilities or, you know, actual explosives, and instead looks pretty much like the stuff found on any of our workbenches or junk bins. Pretty scary stuff.

If you’ve run through every binge-worthy series on Netflix and are looking for a bit of space-nerd entertainment, have we got one for you. Scott Manley has a new video that goes into detail on the four different computers used for each Apollo mission. We knew about the Apollo Guidance Computers that guided the Command Module and the Lunar Module, and the Launch Vehicle Digital Computer that got the whole stack into orbit and on the way to the Moon, but we’d never heard of the Abort Guidance System, a backup to the Lunar Module AGC intended to get the astronauts back into lunar orbit in the event of an emergency. And we’d also never heard that there wasn’t a common architecture for these machines, to the point where each had its own word length. The bit about infighting between MIT and IBM was entertaining too.

And finally, if you still find yourself with time on your hands, why not try your hand at pen-testing a military satellite in orbit? That’s the offer on the table to hackers from the US Air Force, proprietor of some of the tippy-toppest secret hardware in orbit. The Hack-A-Sat Space Security Challenge is aimed at exposing weaknesses that have been inadvertantly baked into space hardware during decades of closed development and secrecy, vulnerabilities that may pose risks to billions of dollars worth of irreplaceable assets. The qualification round requires teams to hack a grounded test satellite before moving on to attacking an orbiting platform during DEFCON in August, with prizes going to the winning teams. Get paid to hack government assets and not get arrested? Maybe 2020 isn’t so bad after all.