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.
Continue reading “Stepper Motor Mods Improve CNC Flat Coil Winder”
A fully stocked freezer can be a blessing, but it’s also a disaster waiting to happen. Depending on your tastes, there could be hundreds of dollars worth of food in there, and the only thing between it and the landfill is an uninterrupted supply of electricity. Keep the freezer in an out-of-the-way spot and your food is at even greater risk.
Mitigating that risk is the job of this junkbox power failure alarm. [Derek]’s freezer is in the garage, where GFCI outlets are mandated by code. We’ve covered circuit protection before, including GFCIs, and while they can save a life, they can also trip accidentally and cost you your steaks. [Derek] whipped up a simple alarm based on current flow to the freezer. A home-brew current transformer made from a split ferrite core and some magnet wire is the sensor, and a couple of op-amps and a 555 timer make up the detection and alarm part. And it’s all junk bin stuff — get a load of that Mallory Sonalert from 1983!
Granted, loss of power on a branch circuit is probably one of the less likely failure modes for a freezer, but the principles are generally applicable and worth knowing. And hats off to [Derek] for eschewing the microcontroller and rolling this old school. Not that there’s anything wrong with IoT fridge and freezer alarms.
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Few hackers have trouble understanding basic electric motors. We’ve all taken apart something that has a permanent magnet DC motor in it and hooked up its two leads to a battery to make it spin. Reverse the polarity, reverse the spin; remove the power, stop the spin. Stepper motors (and their close cousins, brushless DC motors) are a little tougher to grok, though, especially for the beginner. But with a giant 3D printed stepper motor, [Proto G] has made getting your head around electronically commutated motors a little easier.
While we’ve seen 3D printed stepper motors before, the size and simple layout of this one really lends to understanding the theory. With a 3D-printed frame, coils wound on nails, and rare-earth magnets glued to a rotor, this is an approachable build that lays the internals of a stepper motor out for all to see and understand. You can easily watch how the rotor lines up as the various coils are energized in a circular pattern, although it might be more revealing to include bi-color LEDs to indicate which coils are energized and what the polarity is. Those would be especially helpful demonstrating the concept of half-stepping. We’d also like to see more detail on the controller electronics, although admittedly all the video-worthy action is in the motor itself.
Continue reading “Giant Stepper Motor Gets You Up to Speed on Theory”
[Martin] seems to have a knack for locating lightly damaged second-hand audio gear. Over the years he’s collected various types of gear and made various repairs. His most recent project involved fixing two broken tweeter speakers.
He first he needed to test the tweeters. He had to remove them from the speaker cabinet in order to gain easier access to them. The multimeter showed them as an open-circuit, indicating that they had likely been burned. This is an issue he’s seen in the past with this brand of speaker. When too much power is pumped through the speaker, the tiny magnet wire inside over heats and burns out similar to a fuse.
The voice coil itself was bathing in an oily fluid. The idea is to help keep the coil cool so it doesn’t burn out. With that in mind, the thin wire would have likely burned somewhere outside of the cooling fluid. It turned out that it had become damaged just barely outside of the coil. [Martin] used a sharp blade to sever the connection to the coil. He then made a simple repair by soldering the magnet wire back in place using a very thin iron. We’ve seen similar work before with headphone cables.
He repeated this process on the second tweeter and put everything back together. It worked good as new. This may have ultimately been a very simple fix, but considering the amount of money [Martin] saved on these speakers, it was well worth the minimal effort.
[Johannes Agricola] recently held a workshop at the Peace Mission in Goettingen, Germany where he shared his RGB LED flowers. The small round PCB hosts an ATmega88 microcontroller which is running the V-USB stack so that the unit can be controlled by a computer. Each flower blossom is an RGB LED connected with four enameled wires which, when twisted together, make up the stem of the flower. [Johannes] took tons of pictures during the assembly while offering soldering advice along side the illustrations. The PCB is single-sided helping make this a great project for someone trying out surface mount component soldering for the first time. Or if you want something a little more free-formed try out this lemon-juice powered LED flower.
[W1VLF] is on a quest to communicate over long distances with a 9 kilohertz transmitter. He built this giant coil with that in mind. A round concrete form was used as a base and wound with magnet wire by hand. We’d recommend building an automated winding device, but this method seems to have worked. Operating at 50 Watts on the air-core coil at 8.97 KHz he was able to pick up the signal at a distance of 5 kilometers. It’s not breaking any overall distance or portability records, but on a project like this the quest is where the fun is at.