Custom Parts Feeder Aims To Keep Pace With Pick And Place

February 9, 2018 by Dan Maloney 6 Comments

When your widgets have proven so successful that building them gets to be a grind, it might be time to consider a little mechanical help in the form of a pick and place machine (PnP). If you’re going to roll your own though, there’s a lot to think about, not the least of which is how to feed your beast with parts.

Managing the appetite of a PnP is the idea behind this custom modular parts feeder, but the interesting part of [Hans Jørgen Grimstad]’s work-in-progress project has more to do with the design process. The feeders are to support a custom PnP being built in parallel, and so the needs of one dictate the specs of the other. Chief among the specs are the usual big three: cheap, fast, and reliable. But size is an issue too insofar that the PnP could be working with dozens of component reels at once. Flexibility was another design criteria, so that reels of varied width can be accommodated.

With all that in mind, [Hans] and company came up with a pretty slick design. The frame of the feeder is made out of the PCBs that house the motors for handling the tape, and the ATmega168 that controls everything. Tapes are driven by a laser-cut sprocket driven by 3D-printed worm gears. The boards have fingers that mate up to the aluminum extrusion that the PnP will be built from, and at only a few millimeters wider than the tape, lots of feeders can be nestled together. The video below shows the feeder undergoing some tests.

Alas, this build isn’t quite done, so you’ll have to check back for the final schematics and PCB files if you want to build one for yourself. While you’re waiting, you might want to build your own pick and place.

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This Tiny Motor Is Built Into A PCB

January 24, 2018 by Dan Maloney 53 Comments

Mounting a motor on a PCB is nothing new, right? But how about making the PCB itself part of the motor? That’s what [Carl Bugeja] has done with his brushless DC motor in a PCB project, and we think it’s pretty cool.

Details on [Carl]’s Hackaday.io page are a bit sparse at this point, but we’ve been in contact with him and he filled us in a little. The PCB contains the stator of the BLDC and acts as a mechanical support for the rotor’s bearing. There are six spiral coils etched into the PCB, each with about 40 turns. The coils are distributed around the axis; connected in a wye configuration, they drive a 3D-printed rotor that has four magnets pressed into it. You can see a brief test in the video below; it seems to suffer from a little axial wobble due to the single bearing, but that could be handled with a hat board supporting an upper bearing.

We see a lot of potential in this design. [Carl] mentions that the lack of cores in the coil limit it to low-torque applications, but it seems feasible to bore out the center of the coils and press-fit a ferrite slug. Adding SMD Hall sensors to the board for feedback would be feasible, too — in fact, an entire ESC and motor on one PCB could be possible as well. [Carl] has promised to keep the project page updated, and we’re looking forward to more on this one.

For a more traditional approach to printed motors, check out this giant 3D-printed BLDC.

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PCB Production On The Sienci Mill One

January 6, 2018 by Tom Nardi 10 Comments

A complete start to finish electronics prototyping workshop is nirvana for many of us: being able to go from design on the computer to real hardware without having to get up from your rolling chair. The falling prices of 3D printers have helped make at least part of this a reality: $200 USD is enough to get you a printer that can churn out decent looking enclosures. But there’s more to producing your own hardware than creating slick looking project boxes; at some point you’ll need to put some electronics in there.

For [Chuck Hellebuyck] at least, the last piece of the puzzle has just fallen into place. He’s recently put up a YouTube video describing how he converted his $399 Sienci Mill One into a capable PCB mill. With a 3D printer and this new PCB mill, he’s happy to say he can now go from concept to production all on the same workbench.

The Sienci Mill One is a solid enough mill in its own right but did need some modification to attain the accuracy necessary for cutting at a depth of only .9 mm. First, a block of wood was cut to the same size as the original plastic bed of the Sienci, and then the mill itself was used to drill holes through the wood block and plastic bed. The wood was attached to the bed using a nut and bolt in each corner, being sure to torque it down enough that the head of the bolt is pulled down flush with the surface of the wood.

Pulling the head of the bolts flush wasn’t just to keep the surface free of any snags, [Chuck] uses them in conjunction with a probe in the mill’s chuck as a simple way of adjusting the Z height. With a continuity meter attached between the two, he could lower the probe down until they were touching just enough to make a circuit.

Click through the break for the rest of the story!

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Guide: Why Etch A PCB When You Can Mill?

January 4, 2018 by Adil Malik 83 Comments

I recall the point I started taking electronics seriously, although excited, a sense of dread followed upon the thought of facing the two main obstacles faced by hobbyists and even professionals: Fabricating you own PCB’s and fiddling with the ever decreasing surface mount footprints. Any resistance to the latter proves futile, expensive, and frankly a bit silly in retrospect. Cheap SMD tools have made it extremely easy to store, place, and solder all things SMD.

Once you’ve restricted all your hobbyist designs/experiments to SMD, how do you go about producing the PCBs needed for prototyping? Personally, I dread the thought of etching my own boards. The process is laborious and involves messy chemicals and specially sensitized PCB’s — none of which interest me. I’ve only ever done it a few times, and have promised myself never to do it again. Professional but cheap PCB manufacturing is more like it board pooling services such as OSH park have made this both easy and affordable — if you can wait for the turnaround.

So what are the alternatives? If you are really serious about swift prototyping from your own Lab, I put forth the case of milling your own PCB’s. Read on as I take you through the typical workflow from design to prototype and convince you to put up with the relatively high start up cost of purchasing a PCB mill.

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Exporting Eagle Libraries To FOSS Tools

December 21, 2017 by Brian Benchoff 39 Comments

Since Autodesk’s acquisition, Eagle has been making waves in the community. The de facto standard for Open Hardware PCB design is now getting push-and-shove routing, a button that flips the board over to the back (genius!), integration with Fusion360, automated 3D renderings of components, and a bunch of other neat tools. However, Eagle is not without its warts, and there is a desire to port those innumerable Eagle board layouts and libraries to other PCB design packages. This tool does just that.

The tool is an extension of pcb-rnd, a FOSS tool for circuit board editing, and this update massively extends support for Eagle boards and libraries. As an example, [VK5HSE] loaded up an Eagle .brd file of a transceiver, selected a pin header, and exported that component to a KiCad library. It worked the first time. For another experiment, the ever popular TV-B-Gone .brd file was exported directly to pcb-rnd. This is a mostly complete solution for Eagle to KiCad, Eagle to Autotrax, and Eagle to gEDA PCB, with a few minimal caveats relating to copper pours and silkscreen — nothing that can’t be dealt with if you’re not mindlessly using the tool.

While it must be noted that most Open Hardware projects fit inside a 80 cm² board area, and can therefore be opened and modified with the free-to-use version of Autodesk’s Eagle, this is a very capable tool to turn Eagle boards and libraries into designs that can be built with FOSS tools.

Thanks [Erich] for the tip.

Friday Hack Chat: Eagle One Year Later

December 14, 2017 by Brian Benchoff 103 Comments

Way back in June of 2016, Autodesk acquired Cadsoft, and with it EagleCAD, the popular PCB design software. There were plans for some features that should have been in Eagle two decades ago, and right now Autodesk is rolling out an impressive list of features that include UX improvements, integration with MCAD and Fusion360, and push and shove routing.

Six months into the new age of Eagle, Autodesk announced they would be changing their licensing models to a subscription service. Where you could pay less than $100 once and hold onto version 6.0 forever, now you’re required to pay $15 every month for your copy of Eagle. Yes, there’s still a free, educational version, but this change to a subscription model caused much consternation in the community when announced.

For this week’s Hack Chat, we’re going to be talking about Eagle, one year in. Our guest for this Hack Chat is Matt Berggren, director of Autodesk Circuits, hardware engineer, and technologist that has been working on bringing electronic design to everyone. We’ll be asking Matt all about Eagle, with questions including:

What new features are in the latest edition of Eagle?
What’s on the Eagle wishlist?
What technical challenges arise when designing new features?
Where can a beginner find resources for designing PCBs in Eagle?

Join the chat to hear about new features in Eagle, how things are holding up for Eagle under new ownership, and how exactly the new subscription model for Eagle is going. We’re looking for questions from the community, so if you have a question for Matt or the rest of the Eagle team, put it on the Hack Chat event page.

If you’re wondering about how Altium and KiCad are holding up, or have any questions about these PCB design tools, don’t worry: we’re going to have Hack Chats with these engineers in the new year.

Our Hack Chats are live community events on the Hackaday.io Hack Chat group messaging. This Hack Chat is going down on noon, PST, Friday, December 15th. Time Zones got you down? Here’s a handy count down timer!

Click that speech bubble to the left, and you’ll be taken directly to the Hack Chat group on Hackaday.io.

You don’t have to wait until Friday; join whenever you want and you can see what the community is talking about.