DIY Comparatron Helps Trace Tiny, Complex Objects

December 11, 2022 by Donald Papp 21 Comments

Hackers frequently find themselves reverse-engineering or interfacing to existing hardware and devices, and when that interface needs to be a physical one, it really pays to be able to take accurate measurements.

This is easy to do when an object is big enough to fit inside calipers, or at least straight enough to be laid against a ruler. But what does one do when things are complex shapes, or especially small? That’s where [Cameron]’s DIY digital optical comparator comes in, and unlike commercial units it’s entirely within the reach (and budget) of a clever hacker.

The Comparatron is based off a CNC pen plotter, but instead of a pen, it has a USB microscope attached with the help of a 3D-printed fixture. Serving as a background is an LED-illuminated panel, the kind useful for tracing. The physical build instructions are here, but the image should give most mechanically-minded folks a pretty clear idea of how it fits together.

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A Wheatstone Bridge Matches Your Pots

December 7, 2022 by Jenny List 15 Comments

Sometimes the simplest hacks can be the most useful or ingenious, and such is the case with [Keri Szafir]’s method of ensuring that potentiometers used in audio devices are matched. If you consider a typical stereo amplifier for a moment, you’ll see two amplifiers in one box with a single volume control. Two channels, one knob? Volume knobs are ganged stereo potentiometers.

All potentiometers are not created equal, and particularly in the cheaper devices they may not have a consistently matched resistance across both pots and across their travel. This messes up the stereo balance, so naturally it’s worth selecting a part with good matching. [Keri] selects them not with his golden ears, but by wiring both pots together as a Wheatstone bridge. A meter between the two wipers would detect any current due to a mismatch.

A Wheatstone bridge is one of those handy circuits that has plenty of uses in both AC and DC measurements. We probably see them most often in a strain gauge.

Dosimetry: Measuring Radiation

November 7, 2022 by Dan Maloney 21 Comments

Thanks to stints as an X-ray technician in my early 20s followed by work in various biology labs into my early 40s, I’ve been classified as an “occupationally exposed worker” with regard to ionizing radiation for a lot of my life. And while the jobs I’ve done under that umbrella have been vastly different, they’ve all had some common ground. One is the required annual radiation safety training classes. Since the physics never changed and the regulations rarely did, these sessions would inevitably bore everyone to tears, which was a pity because it always felt like something I should be paying very close attention to, like the safety briefings flight attendants give but everyone ignores.

The other thing in common was the need to keep track of how much radiation my colleagues and I were exposed to. Aside from the obvious health and safety implications for us personally, there were legal and regulatory considerations for the various institutions involved, which explained the ritual of finding your name on a printout and signing off on the dose measured by your dosimeter for the month.

Dosimetry has come a long way since I was actively considered occupationally exposed, and even further from the times when very little was known about the effects of radiation on living tissue. What the early pioneers of radiochemistry learned about the dangers of exposure was hard-won indeed, but gave us the insights needed to develop dosimetric methods and tools that make working with radiation far safer than it ever was.

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Better Scope Measurements

September 22, 2022 by Al Williams 6 Comments

There was a time when few hobbyists had an oscilloscope and the ones you did see were old military or industrial surplus that were past their prime. Today you can buy a fancy scope for about what those used scopes cost that would have once been the envy of every giant research lab. However, this new breed of instrument is typically digital and while they look like an old analog scope, the way they work leads to some odd gotchas that [Arthur Pini] covers in a recent post.

Some of his tips are common sense, but easy to forget about. For example, if you stack your four input channels so each uses up a quarter of the screen, it makes sense, right? But [Arthur] points out that you are dropping two bits of dynamic range, which can really jack up a sensitive measurement.

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A RPI HAT For Synchronized Measurements

September 15, 2022 by Dave Rowntree 17 Comments

A team from the Institute for Automation of Complex Power System (ACS) at RWTH Aachen University have been working for a while on the analysis of widely distributed power systems. In a drive to move away from highly specialised (and expensive) electronics platforms, they have produced some instrumentation designed to operate with the Raspberry Pi platform, and an open source software stack. They call the platform the SMU (Synchronised Measurement Unit.) The SMU consists of a HAT sitting on an RPi3, inside a 3D printed box that is intended to attach to a DIN rail. After all, this is supposed to be an industrial platform.

Hardware wise, the star of the show is the Texas Instruments ADS8588S which is a 16-bit 8-channel simultaneous sampling ADC. This is quite a nice device, with 200 kSPS throughput and a per-channel programmable front end, packaged in a hacker-friendly 64-pin QFP. What makes this project interesting however, is how they solved the problem of controlling the sampled data acquisition and synchronisation.

1-PPS and BUSY edges converted to levels, then OR’d to trigger the DMA

By programming the ADC into byte-parallel mode, then using the BCM2837 Secondary Memory Interface (SMI) block together with the DMA, samples are transferred into memory with minimal CPU overhead. An onboard U-Blox Max-M8 GNSS module provides a 1PPS (top of second pulse) signal, which is combined with the ADC busy signal in a very simple manner, enabling both sample rate control as well as synchronisation between multiple units spread out in an installation. They reckon they can get synchronisation to within 180 ns of top-of-second, which for measuring relatively slow-changing power systems, should be enough. The HAT PCB was created in KiCAD and can be found in the SMU GitHub hardware section, making it easy to modify to your needs, or at least adjust the design to match the parts you can actually get your hands on.

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Digital Measuring Wheel Is Exactly What It Sounds Like

July 23, 2022 by Lewin Day 11 Comments

You may have seen surveyors (or maths students) running around with measuring wheels, counting the clicks to measure distances. [AGBarber]’s digital measuring wheel works in much the same way, but with the convenience of a measurement you can read off a screen.

The design is simple, and relies on the outer wheel of the device turning a mouse encoder wheel. This is read by anArduino Pro Mini which runs the show and records the requisite measurements. It then drives an SSD1306 OLED display which shows the measurements to the user. It’s all wrapped up in a 3D printed housing that makes it easy to roll around the small handheld device.

The wheel’s maximum measuring length is 9999.99 cm, or just under 100 meters. Given the size of the device, that’s probably more than enough, but you could always build a bigger version if you wanted to measure longer distances.

Measuring wheels make it easy to measure along curves, and are just generally fun to play with as well. You could certainly use one to determine whether flat tyres are making your speedometer lie to you. Or, you could dive into this great talk on measurement from [Adam Savage].

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Pressure Gauge Built In A Vacuum

February 23, 2022 by Bryan Cockfield 6 Comments

Necessity might be the mother of all invention, but we often find that inventions around here are just as often driven by expensive off-the-shelf parts and a lack of willingness to spend top dollar for them. More often than not, we find people building their own tools or parts as if these high prices are a challenge instead of simply shrugging and ordering them from a supplier. The latest in those accepting the challenge of building their own parts is [Advanced Tinkering] who needed a specialty pressure gauge for a vacuum chamber.

In this specific case, the sensor itself is not too highly priced but the controller for it was the deal-breaker, so with a trusty Arduino in hand a custom gauge was fashioned once the sensor was acquired. This one uses an external analog-to-digital converter to interface with the sensor with 16-bit resolution, along with some circuitry to bring the ~8 V output of the sensor down to the 5 V required by the microcontroller. [Advanced Tinkering] wanted a custom live readout as well, so a 3D printed enclosure was built that includes both an LCD readout of the pressure and a screen with a graph of the pressure over time.

For anyone else making sensitive pressure measurements in a vacuum chamber, [Advanced Tinkering] made the project code available on a GitHub page. It’s a great solution to an otherwise overpriced part provided you have the time to build something custom. If you’re looking for something a little less delicate, though, take a look at this no-battery pressure sensor meant to ride along on a bicycle wheel.

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