Shred The Gnar Without Paddling For Waves

January 28, 2019 by Bryan Cockfield 10 Comments

[Ben Gravy] isn’t your average pro surfer. For one thing, he lives in New Jersey instead of someplace like Hawaii or Australia, and for another he became famous not for riding the largest waves but rather for riding the weirdest ones. He’s a novelty wave hunter, but some days even the obscure surf spots aren’t breaking. For that, he decided to build a surfboard that doesn’t need waves. (Video, embedded below the break.)

The surfboard that [Ben] used for this project isn’t typical either. It’s made out of foam without any fiberglass, which makes the board less expensive than a traditional surfboard. The propulsion was handled by an electric trolling motor and was hooked up to a deep cycle battery mounted in the center of the board in a waterproof box. The first prototype ended up sinking though, as most surfboards can’t support the weight of a single person on their own without waves even without all the equipment that he bolted to it.

After some reworking, [Ben] was able to realize his dream of riding a surfboard without any waves. It’s not fast, but the amount of excitement that he had proves that it works and could fool most of us. This hack has everything, too: a first prototype that didn’t work exactly right and was fixed with duct tape, electricity used in a semi-dangerous way, and solving a problem we didn’t know we had. We hope he builds a second, faster one as well.

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A Quartet Of Drills Put The Spurs To This Electric Utility Vehicle

January 6, 2019 by Dan Maloney 2 Comments

Low-slung body style. Four-wheel drive. All electric drivetrain. Turns on a dime. Neck-snapping acceleration. Leather seating surface. Is it the latest offering from Tesla? Nope; it’s a drill-powered electric utility vehicle, and it looks like a blast to drive.

Surprisingly, this isn’t a just-for-kicks kind of build. There’s actually a practical reason for the low form factor and long range of [Axel Borg]’s little vehicle. We’ll leave the back story to the second video below, but suffice it to say that this will be a smaller version of the crawler NASA used to roll rockets out to the launch pad, used instead to transport his insanely dangerous looking manned-multicopter. The running gear on this vehicle is the interesting bit: four hefty electric drills, one for each of the mobility cart wheels. The drills are powered by a large series-connected battery pack putting out 260V at full charge. The universal motors of the drills are fine with DC, and the speed of each is controlled via the PWM signals from a pair of cordless drills. The first video below shows [Axel] putting it through its paces; he didn’t hold back at all, but the vehicle kept coming back for more.

We know this cart is in service to another project, but we’d have a hard time concentrating on anything if we had the potential for that much fun sitting in the shop. Still, we hope that multirotor gets a good test flight soon, and that all goes well with it.

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Brushless Motor Thrust Stand Provides Useful Data

December 16, 2018 by Lewin Day 16 Comments

When designing model aircraft of any shape or size, it’s useful to know the performance you can expect from the components chosen. For motors and propellers, this can be difficult. It’s always best to test them in combination. However, with the numbers of propeller and motor combinations possible, such data can be tough to come by. [Nikus] decided it would be easier to just do the testing in-house, and built a rig to do so.

The key component in this build is the strain gauge, which comes already laced up with an Arduino-compatible analog-digital converter module. Sourced for under $10 from Banggood, we can’t help but think that we’ve got it easy in 2018. A sturdy frame secures motor and propeller combination to the strain gauge assembly. An ATMEGA328 handles sending commands to the motor controller, reading the strain gauge results, and spitting out data to the LCD.

It’s a cheap and effective build that solves a tricky problem and would be a useful addition to the workshop for any serious modeler. We’ve seen other approaches in this area too, for those eager to graph their motor performance data. Video after the break.

[Thanks to Baldpower for the tip!]

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Adorable Desktop Disc Sander Warms Our Hearts And Our Parts

December 4, 2018 by Kerry Scharfglass 17 Comments

Casually browsing YouTube for “shop improvements” yields a veritable river of project ideas, objects for cat amusement, and 12 INCREDIBLE SHOP HACKS YOU WON’T BELIEVE, though some of these are of predictably dubious value. So you might imagine that when we found [Henrique]’s adorable disc sander we dismissed it out of hand, how useful could such a tiny tool be? But then we remembered the jumbo tub o’ motors on the shelf and reconsidered, maybe a palm sized sander has a place in the tiny shop.

Electrically the build is a simple as can be. It’s just a brushed DC motor plugged into a wall wart with a barrel jack and a toggle switch. But what else does it need? This isn’t a precision machine tool, so applying the “make it out of whatever scrap” mindset seems like a much better fit than figuring out PWM control with a MOSFET and a microcontroller.

There are a couple of neat tricks in the build here. The most obvious is the classic laser-cut living hinge that we love so much. [Henrique] mentions that he buys MDF in 3 mm sheets for easy storage, so each section of the frame is built from layers that he laminates with glue himself. This trades precision and adds steps, but also give him a little flexibility. It’s certainly easier to add layers of thin stock together than it would be to carve out thicker pieces. Using the laser to precisely cut holes which are then match drilled through into the rest of the frame is a nice build acceleration too. The only improvement we can imagine would be using a shaft with a small finger chuck (like a Dremel) so it could use standard rotary tool bits to avoid making sanding disks by hand.

What could a tool like this be used for? There are lots of parts with small enough features to be cleaned up by such a small tool. Perhaps those nasty burrs after cutting off a bolt? Or trimming down mousebites on the edges of PCBs? (Though make sure to use proper respiration for cutting fiberglass!)

If you want to make one of these tools for your own desk, the files are here on Thingiverse. And check out the video overview after the break.

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3D Printed Brushed Motor Is Easy To Visualize

December 1, 2018 by Al Williams 5 Comments

A motor — or a generator — requires some normal magnets and some electromagnets. The usual arrangement is to have a brushed commutator that both powers the electromagnets and switches their polarity as the motor spins. Permanent magnets don’t rotate and attract or repel the electromagnets as they swing by. That can be a little hard to visualize, but if you 3D Print [Miller’s Planet’s] working model — or just watch the video below — you can see how it all works.

We imagine the hardest part of this is winding the large electromagnets. Getting the axle — a nail — centered is hard too, but from the video, it looks like it isn’t that critical. There was a problem with the link to the 3D model files, but it looks like this one works.

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Smooth Moves From Cheap Motors

November 16, 2018 by Bryan Cockfield 36 Comments

Building an electric motor isn’t hard or technically challenging, but these motors have very little in the way of control. A stepper motor is usually employed in applications that need precision, but adding this feature to a motor adds complexity and therefore cost. There is a small $3 stepper motor available, but the downside to this motor is that it’s not exactly the Cadillac of motors, nor was it intended to be. With some coaxing, though, [T-Kuhn] was able to get a lot out of this small, cheap motor.

To test out the motors, [T-Kuhn] built a small robotic arm. He began by programming his own pulse generating algorithm that mimics a sine wave in order to smooth out the movement of the motor. An Arduino isn’t fast enough to do these computations, though, so he upgraded to using the ESP32. He also was able to implement the inverse kinematics on his own. The result of all this work for a specific platform and motor type is a robotic arm that has a very low cost but delivers performance of much more expensive hardware.

The robot arm was built by [T-Kuhn] too, and all of the details on that build, as well as all the schematics and code, are available on the project site if you need a low-cost robot arm or a good stepper motor controller for a low cost. There are many other ways of getting the most out of other types of low-cost motors as well.

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Rewound And Rewired BLDC Makes A Half-Decent Generator

November 8, 2018 by Dan Maloney 18 Comments

What’s the best way to turn a high-powered brushless DC motor optimized for hobby use into a decent low-RPM generator? Do you take a purely mechanical approach and slap a gearbox on the shaft? Or do you tackle the problem electrically?

The latter approach is what [GreatScott!] settled on with his BLDC rewinding and rewiring project. Having previously explored which motors have the best potential as generators, he knew the essential problem: in rough terms, hobby BLDCs are optimized for turning volts into RPMs, and not the other way around. He started with a teardown of a small motor, to understand the mechanical challenges involved, then moved onto a larger motor. The bigger motor was stubborn, but with some elbow grease, a lot of scratches, and some destroyed bearings, the motor was relieved of both its rotor and stator. The windings were stripped off and replaced with heavier magnet wire with more turns per pole than the original. The effect of this was to drive the Kv down and allow better performance at low RPMs. Things looked even better when the windings were rewired from delta to wye configuration.

The take-home lesson is probably to use a generator where you need a generator and let motors be motors. But we appreciate [GreatScott!]’s lesson on the innards of BLDCs nonetheless, and his other work in the “DIY or buy?” vein. Whether you want to make your own inverter, turn a hard drive motor into an encoder, or roll your own lithium battery pack, he’s done a lot of the dirty work already.

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