Digi-Key Hacks UV Into Conveyor Line To Protect Warehouse Staff

July 4, 2020 by Orlando Hoilett 21 Comments

No doubt that every hacker has already heard of Digi-Key, the electronic component distributor that makes it just as possible to order one of something as it is to order a thousand of it. As an essential business, Digi-Key has been open during the duration of the lockdown since they support critical manufacturing services for virtually every industry on the planet including the medical industry.

Ensuring their workforce stays healthy is key to remaining open and as part of their efforts they hacked together a nice addition to their sanitation regime. They use around 8,000 plastic totes to transport components around the distribution center and devised a way to sanitize tote coming in from the receiving area using a UV light tunnel. From their sanitation plan we can see this is in addition to the fogging system (likely a vaporized hydrogen peroxide system) used to regularly sanitize the totes passing throughout the warehouse.

They developed a UV light tunnel that wraps around the conveyor rollers. The design includes a sensor and a timer to control when and how long the UV lights are on. The totes are a frequent touch point for employees, and running incoming shipments through the UV light tunnel helps decrease the chance of exposure.

Thinking of using UV as a sanitation tool? Make sure you do your research on the wavelengths you need and vet the source of critical components. [Voja] ran into UV lamps that were anything but germicidal.

The Hackaday Prize: Field Ready Is Changing The Face Of Humanitarian Relief

June 9, 2020 by Dan Maloney 11 Comments

It’s one of the enduring images of a humanitarian aid mobilization: military transport planes lined up on runways, ready to receive pallets of every conceivable supply. The cardboard boxes on those shrink-wrapped pallets are filled with everything from baby formula to drinking water, and will join crates filled with the tools and materials needed to shelter, clothe, feed, and heal people in places where civilization has suddenly come into short supply thanks to a disaster, sometimes natural, but often man-made.

What if it didn’t need to be that way? What if, instead of flight after flight of supplies sent in to help rebuild, perhaps just one flight was needed, one stuffed with the tools of our trade: 3D-printers, Arduinos, electronic components, machine tools, and the experts to use them. It certainly wouldn’t make up for the short-term need for food and water, but importing the ability to manufacture the items needed locally would go a long way to repairing infrastructure in the disaster area.

Rethinking disaster response is the core mission of Field Ready, one of the groups we’ve partnered with for the 2020 Hackaday Prize. By way of introduction to this non-profit with a potentially world-changing mission, and to help those who are participating in the 2020 Hackaday Prize challenges, here’s a little bit about Field Ready — what they do, how they see digital manufacturing fitting into their mission, and where they’re going in the future.

Continue reading “The Hackaday Prize: Field Ready Is Changing The Face Of Humanitarian Relief” →

Electric Vehicles Continue The Same Wasteful Mistakes That Limit Longevity

May 15, 2020 by Jenny List 372 Comments

A while back, I sat in the newish electric car that was the pride and joy of a friend of mine, and had what was at the time an odd experience. Instead of getting in, turning the key, and driving off, the car instead had to boot up.

The feeling was of a piece of software rather than a piece of hardware, and there was a tangible wait before the start button could be pressed. It was a miracle of technology that could travel smoothly and quietly for all but the longest journeys I could possibly throw at it on relative pennies-worth of electricity, but I hated it. As a technologist and car enthusiast, I should be all over these types of motor vehicles. I live for new technology and I lust after its latest incarnations in many fields including automobiles.

I want my next car to have an electric motor, I want it to push the boundaries of what is capable with a battery and I want it to be an automotive tour de force. The switch to electric cars represents an opportunity like no other to deliver a new type of car that doesn’t carry the baggage of what has gone before, but in that car I saw a future in which they were going badly astray.

I don’t want my next vehicle to be a car like my friend’s one, and to understand why that is the case it’s worth going back a few decades to the cars my parents drove back when when jumpers were goalposts, and the home computer was just a gleam in the eye of a few long-haired outsiders in California.

Continue reading “Electric Vehicles Continue The Same Wasteful Mistakes That Limit Longevity” →

Gain An Understanding Of Injection Molding’s Design Gotchas

April 19, 2020 by Donald Papp 11 Comments

When it comes to manufacturing, sheet metal and injection molding make the world go ’round. As a manufacturing method, injection molding has its own range of unique design issues and gotchas that are better to be aware of than not. To help with this awareness, [studiored] has a series of blog posts describing injection molding design issues, presented from the perspective of how to avoid and address them.

Design of screw bosses demonstrating conflict between molder’s guidelines and vendor’s recommendations. Compromising between both is a science and an art.

Because injection molding involves heat, warp is one issue to be aware of and its principles will probably be familiar to anyone with nitty-gritty experience in 3D printing. Sink marks are also an issue that comes down to differential cooling causing problems, and can ruin a smooth and glossy finish. Both of these play a role in how best to design bosses.

Minimizing and simplifying undercuts (similar to overhangs in 3D printer parlance) is a bit more in-depth, because even a single undercut means much more complex tooling for the mold. Finally, because injection molding depends on reliably molding, cooling, and ejecting parts, designing parts with draft (a slight angle to aid part removal) can be a fact of life.

[studiored] seems to have been working overtime on sharing tips for product design and manufacture on their blog, so it’s worth keeping an eye on it for more additions. We mentioned earlier that much of the manufacturing world revolves around injection molding and sheet metal, so to round out your knowledge we published a primer on everything you need to know about the art and science of bending sheet metal. With a working knowledge of the kinds of design issues that affect these two common manufacturing methods, you’ll have a solid foundation for any forays into either world.

Clever Suction For Robot Arm Automates Face Shield Production

April 12, 2020 by Mike Szczys 9 Comments

We’re certainly familiar with vacuum grabbers used in manufacturing to pick items up, but this is a bit different. [James Wigglesworth] sent in some renders and demo video (embedded after the break) of the Dexter robot arm and a laser cutter automatically producing face shields.

It’s a nice little bit of automation, where you can see a roll of plastic on the right side of the Glowforge laser cutter feeding into the machine. Once the laser does its thing, the the robot arm reaches in and grabs the newly cut face shield and stacks it in a box neatly for future assembly. There are a lot of interesting parts here, but the fact that the vacuum grabber is doing it’s job without a vacuum air supply is the one we have our eye on.

The vacuum comes from a corrugated sleeve that makes up the suction cup on the end of the robot arm. A rubber band holds a hinged piece over a valve on that sleeve that can be opened or closed by a servo motor. When the cuff is compressed against the face shield, the servo closes the valve, using the tape as a gasket, and the corrugated nature of the cuff creates a vacuum due to the weight of the item it is lifting. This means you don’t need a vacuum source plumbed into the robot, just a wire to power the servo.

The robot arm is of course the design that won the 2018 Hackaday Prize. I comes as no surprise to see the Haddington Dynamics crew setting up a manufacturing line like this one. As we discovered a few weeks ago, 3D printers, laser cutters, and robot arms are part of their microfactory setup and well suited to making PPE to help reduce the shortage during the COVID-19 outbreak.

Continue reading “Clever Suction For Robot Arm Automates Face Shield Production” →

Dexter Robot Arm Embraces New Manufacturing With First Micro-Factory

March 9, 2020 by Mike Szczys 32 Comments

Haddington Dynamics, the company behind the Dexter robot arm that won the 2018 Hackaday Prize, has opened its first microfactory to build robot arms for Australia and Southeast Asia.

You may remember that the combination of Dexter’s makeup and capabilities are what let it stand out among robotics projects. The fully-articulated robot arm can be motion trained; it records how you move the arm and can play back with high precision rather than needing to be taught with code. The high-precision is thanks to a clever encoder makeup that leverages the power of FPGAs to amplify the granularity of its optical encodes. And it embraces advanced manufacturing to combine 3D printed and glue-up parts with mass produced gears, belts, bearings, and motors.

It’s a versatile robot arm, for a fraction of the cost of what came before it, with immense potential for customization. And did I mention that it’s open source? Continue reading “Dexter Robot Arm Embraces New Manufacturing With First Micro-Factory” →

Ask Hackaday: What’s Your Coronavirus Supply Chain Exposure?

February 10, 2020 by Dan Maloney 128 Comments

In whichever hemisphere you dwell, winter is the time of year when viruses come into their own. Cold weather forces people indoors, crowding them together in buildings and creating a perfect breeding ground for all sorts of viruses. Everything from the common cold to influenza spread quickly during the cold months, spreading misery and debilitation far and wide.

In addition to the usual cocktail of bugs making their annual appearance, this year a new virus appeared. Novel coronavirus 2019, or 2019-nCoV, cropped up first in the city of Wuhan in east-central China. From a family of viruses known to cause everything from the common cold to severe acute respiratory syndrome (SARS) in humans, 2019-nCoV tends toward the more virulent side of the spectrum, causing 600 deaths out of 28,000 infections reported so far, according to official numbers at the time of this writing.

(For scale: the influenzas hit tens of millions of people, resulting in around four million severe illnesses and 500,000 deaths per season, worldwide.)

With China’s unique position in the global economy, 2019-nCoV has the potential to seriously disrupt manufacturing. It may seem crass to worry about something as trivial as this when people are suffering, and of course our hearts go out to the people who are directly affected by this virus and its aftermath. But just like businesses have plans for contingencies such as this, so too should the hacking community know what impact something like 2019-nCoV will have on supply chains that we’ve come to depend on.

Continue reading “Ask Hackaday: What’s Your Coronavirus Supply Chain Exposure?” →