Tonewheels Warble In This Organ-Inspired Musical Instrument

February 10, 2021 by Dan Maloney 9 Comments

Younger readers may not recall the days when every mall had a music store — not the kind where tapes and LPs were sold, but the kind where you could buy instruments. These places inevitably had an employee belting out mall-music to all and sundry on an electric organ. And more often than not, the organist was playing a Hammond organ, with the distinct sound of these instruments generated by something similar to this tonewheel organ robot.

Tonewheels are toothed ferromagnetic wheels that are rotated near a pickup coil. This induces a current that can be amplified; alter the tooth profile or change the speed of rotation, and you’ve got control over the sounds produced. While a Hammond organ uses this technique to produce a wide range of sounds, [The Mixed Signal]’s effort is considerably more modest but nonetheless interesting. A stepper motor and a 1:8 ratio 3D-printed gearbox power a pair of shafts which each carry three different tonewheels. The tonewheels themselves are laser-cut from mild steel and range from what look like spur gears to wheels with but a few large lobes. This is a step up from the previous version of this instrument, which used tonewheels 3D-printed from magnetic filament.

Each tonewheel has its own pickup, wound using a coil winder that [TheMixed Signal] previously built. Each coil has a soft iron core, allowing for the addition of one or more neodymium bias magnets, which dramatically alters the tone. The video below shows the build and a demo; skip ahead to 16:10 or so if you just want to hear the instrument play. It’s — interesting. But it’s clearly a work in progress, and we’re eager to see where it goes. Continue reading “Tonewheels Warble In This Organ-Inspired Musical Instrument” →

Simple Sensor Makes Filament Measurements A Snap

February 7, 2021 by Dan Maloney 29 Comments

Just how tight are the manufacturing tolerances of modern FDM printer filament. Inquiring minds want to know, and when such minds are attached to handy fellows like [Thomas Sanladerer], you end up with something like this home-brew filament measurement rig to gather the data you seek.

The heart of this build is not, as one might assume, some exotic laser device to measure the diameter of filament optically. Those exist, but they are expensive bits of kit that are best left to the manufacturers, who use them on their production lines to make sure filament meets their specs. Rather, [Thomas] used a very clever homemade device, which relies on a Hall effect sensor and a magnet on a lever to do the job. The lever is attached to a roller bearing that rides on the filament as it spools through the sensor; variations in diameter are amplified by the lever arm, which wiggles a magnet over the Hall sensor, resulting in a signal proportional to filament diameter.

The full test rig has a motor-driven feed and takeup spools, and three sensors measuring across the filament in three different spots around the radius; the measurements are averaged together to account for any small-scale irregularities. [Thomas] ran several different spools representing different manufacturers and materials through the machine; we won’t spoil the results in the video below, but suffice it to say you probably have little to worry about if you buy from a reputable vendor.

When we see a filament sensor, it’s generally more of the “there/not there” variety to prevent a printer from blindly carrying on once the reel is spent. We’ve seen a few of those before, but this is a neat twist on that concept.

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Let KiCad And Python Make Your Coils

October 19, 2020 by Al Williams 16 Comments

We like to pretend that our circuits are as perfect as our schematics. But in truth, PCB traces have unwanted resistance, capacitance, and inductance. On the other hand, that means you can use those traces to build components. For example, it isn’t uncommon to see a very small value current sense resistor be nothing more than a long PC board trace. Using PC layers for decoupling capacitance and creating precise transmission lines are other examples. [IndoorGeek] takes us through his process of creating coils on the PCB using KiCad. To help, he used a Python script that works out the circles, something KiCAD has trouble with.

The idea is simple. A coil of wire has inductance even if it is a flat copper trace on a PCB. In this case, the coils are more for the electromagnetic properties, but the same idea applies if you wanted to build tuned circuits. The project took inspiration from FlexAR, an open-source flexible PCB magnet.

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Building This Mechanical Digital Clock Took Balls

October 13, 2020 by Dan Maloney 26 Comments

In the neverending quest for unique ways to display the time, hackers will try just about anything. We’ve seen it all, or at least we thought we had, and then up popped this purely mechanical digital clock that uses nothing but steel balls to display the time. And we absolutely love it!

Click to embiggen (you’ll be glad you did)

One glimpse at the still images or the brief video below shows you exactly how [Eric Nguyen] managed to pull this off. Each segment of the display is made up of four 0.25″ (6.35 mm) steel balls, picked up and held in place by magnets behind the plain wood face of the clock. But the electromechanical complexity needed to accomplish that is the impressive part of the build. Each segment requires two servos, for a whopping 28 units plus one for the colon. Add to that the two heavy-duty servos needed to tilt the head and the four needed to lift the tray holding the steel balls, and the level of complexity is way up there. And yet, [Eric] still managed to make the interior, which is packed with a laser-cut acrylic skeleton, neat and presentable, as well he might since watching the insides work is pretty satisfying.

We love the level of craftsmanship and creativity on this build, congratulations to [Eric] on making his first Arduino build so hard to top. We’ve seen other mechanical digital displays before, but this one is really a work of art.

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TMD-1 Makes Turing Machine Concepts Easy To Understand

August 27, 2020 by Dan Maloney 10 Comments

For something that has been around since the 1930s and is so foundational to computer science, you’d think that the Turing machine, an abstraction for mechanical computation, would be easily understood. Making the abstract concepts easy to understand is what this Turing machine demonstrator aims to do.

The TMD-1 is a project that’s something of a departure from [Michael Gardi]’s usual fare, which has mostly been carefully crafted recreations of artifacts from the early days of computer history, like the Minivac 601 trainer and the DEC H-500 computer lab. The TMD-1 is, rather, a device that makes the principles of a Turing machine more concrete. To represent the concept of the “tape”, [Mike] used eight servo-controlled flip tiles. The “head” of the machine conceptually moves along the tape, its current position indicated by a lighted arrow while reading the status of the cell above it by polling the position of the servo.

Below the tape and head panel is the finite state machine through which the TMD-1 is programmed. [Mike] limited the machine to three states and ~~four transitions~~ three symbols, each of which is programmed by placing 3D-printed tiles on a matrix. Magnets were inserted into cavities during printing; Hall Effect sensors in the PCB below the matrix read the pattern of magnets to determine which tiles are where. The video below shows the TMD-1 counting from 0 to 10, which is enough to demonstrate the basics of Turing machines.

It’s hard not to comment on the irony of a Turing machine being run by an Arduino, but given that [Mike]’s goal was to make abstract concepts easy to understand, it makes perfect sense to leverage the platform rather than try to do this with discrete logic. And you can’t argue with results — TMD-1 made Turing machines clear to us for the first time.

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Mechanical Seven-Segment Display Really Sticks Out From The Pack

July 27, 2020 by Dan Maloney 20 Comments

We’ve been displaying numbers using segmented displays for almost 120 years now, an invention that predates the LEDs that usually power the ubiquitous devices by a half-dozen decades or so. But LEDs are far from the only way to run a seven-segment display — check out this mechanical seven-segment display for proof of that.

We’ve been seeing a lot of mechanical seven-segment displays lately, and when we first spotted [indoorgeek]’s build, we thought it would be a variation on the common “flip-dot” mechanism. But this one is different; to form each numeral, the necessary segments protrude from the face of the display slightly. Everything is 3D-printed from white filament, yielding a clean look when the retracted but casting a sharp shadow when extended. Each segment carries a small magnet on the back which snuggles up against the steel core of a custom-wound electromagnet, which repels the magnet when energized and extends the segment. We thought for sure it would be loud, but the video below shows that it’s really quiet.

While we like the subtle contrast of the display, it might not be enough for some users, especially where side-lighting is impractical. In that case, they might want to look at this earlier similar display and try contrasting colors on the sides of each segment.

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Experimenting With Vibratory Wind Generators

June 30, 2020 by Tom Nardi 42 Comments

We’ve all got a pretty good mental image of the traditional wind-powered generator: essentially a big propeller on a stick. Some might also be familiar with vertical wind turbines, which can operate no matter which way the wind is blowing. In either case, they use some form of rotating structure to harness the wind’s energy.

But as demonstrated by [Robert Murray-Smith], it’s possible to generate electrical power from wind without any moving parts. With simple components, he shows how you can build a device capable of harnessing the wind with nothing more than vibrations. Alright, so we suppose that means the parts are technically moving, but you get the idea.

In the video after the break, [Robert] shows two different devices that operate under the same basic principle. For the first, he cuts the cone out of a standard speaker and glues a flat stick to the voice coil. As the stick moves back and forth in the wind, the coil inside of the magnet’s field and produces a measurable voltage. This proves the idea has merit and can be thrown together easily, but isn’t terribly elegant.

For the revised version, he glues a coil to a small piece of neoprene rubber, which in turn is glued to a slat taken from a Venetian blind. On the opposite side of the coil, he glues a magnet. When the blind slat starts vibrating in the wind, the oscillation of the magnet relative to the coil is enough to produce a current. It’s tiny, of course. But if you had hundreds or even thousands of these electric “blades of grass”, you could potentially build up quite a bit of energy.

If this all sounds a bit too theoretical for your tastes, you can always 3D print yourself a more traditional wind turbine. We’ve even seen them in vertical form, if you want to get fancy.

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