Vintage Headphones Bluetooth Conversion Goes The Extra Mile

July 9, 2018 by Ben James 2 Comments

[KaZjjW] wanted to retrofit a pair of nicely styled vintage headphones to be able to play wirelessly over Bluetooth. In principle this is an easy task: simply stick a Bluetooth audio receiver on the line-in, add a battery, and you’re all set. However, [KaZjjW] wanted to keep the aesthetic changes to the headphones at an absolute minimum, retaining the existing casing and volume control, whilst cramming the electronics entirely inside and out of sight.

With the inherent space constraints inside the cups of the headphones, this proved to be quite a challenge. The existing volume potentiometer which hung half outside the case was remounted on an ingenious hinge made of two PCBs, with the pot floating next to a surface mounted switch. This allowed it to not only control the volume, but also act as an on/off switch for the Bluetooth. The only other existing cuts in the casing were a circular hole for the audio cable, and a slit for the cable strain relief. These worked perfectly for an LED status indicator and micro-USB battery charging.

The main chip used for receiving audio over Bluetooth was the BM62 by Microchip. It’s a great all-in-one solution for this kind of project as it has built-in battery charging, an on-board DAC and audio amp, as well as a serial control interface. In part 2 of the project log, the process of programming the BM62 was documented, and it was painful – it’s a shame that the software support lets it down. But a hacker will always find a way, and we’ve seen some pretty neat hacks for reprogramming existing chips in off-the-shelf Bluetooth headphones.

Two PCBs for the pot button hinge, one for the LED and micro-USB connector, as well as one for the Bluetooth receiver and a PIC. That’s four PCBs in a pretty small space, enabled by some commendable design effort both electronically and mechanically. It certainly paid off, as the finished product looks very slick.

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Put The 3D Printer To Sleep So You Can Rest Easy

May 29, 2018 by Tom Nardi 34 Comments

At this point you’ve probably already heard the news: cheap Chinese 3D printers sometimes catch fire. Now we can’t say we’re shocked to find out that absolute bottom of the barrel gear wasn’t designed to the highest standards (gotta cut those corners someplace), but that doesn’t change the fact that there are thousands of hackers and makers out there who are in possession of one of these suspect machines. Just tossing them to the curb is hardly the hacker way, so we’ve got to find ways to make the best of the hand dealt to us.

After sleeping with one eye (and maybe one nostril) open during some overnight prints, Hackaday.io user [TheGrim] wanted a way to make sure his Alunar Anet A6 didn’t stay powered on any longer than necessary. So he came up with a way of using the printer’s own endstop switch to detect if the print has completed, and cut the power.

The idea is simple, but of course the real trick is in the implementation. By adding a “Home” command to his ending G-Code in Cura, [TheGrim] reasoned he could use the Y endstop switch to determine if the print had completed. It was just a matter of reading the state of the switch and acting on it.

In the most basic implementation, the switch could be used to control a relay on the AC side of the power supply. But [TheGrim] doesn’t trust relays, and he wanted to pack in a couple “smart” features so he ended up using a PIC microcontroller and two 12 amp TRIACs. There’s also a couple of LEDs and toggle switches to serve as the user interface, allowing you to enable and disable the automatic shutdown and get status information about the system.

Will cutting the juice to the PSU prevent another terrible fire? It’s debatable. But it certainly can’t hurt, and if it makes [TheGrim] feel more confident about running his machine, then so be it. We’d still advise anyone with a 3D printer at home to brush up on their fire safety knowledge.

Headlight Mod For An Audi A3

May 24, 2018 by Anool Mahidharia 24 Comments

If you have a car that is getting on in years, it may be missing some of the latest frills and features that the latest models sport. [Muris] has a slightly dated Audi A3 8P which did not have an AUTO setting for the headlights. In the newer models, this feature turns on the headlights when the ambient light falls below a threshold level (overcast conditions or when going through a tunnel), or when the windshield wipers are turned on. The light sensor is integrated behind the rear view mirror in a special mount, requiring an expensive windshield upgrade if he were to opt for the factory retrofit. Instead, he decided to build his own Automatic Headlights Sensor upgrade for his Audi A3.

His local regulations require the car headlights to be on all the time when the vehicle is in motion. So adding this feature may seem moot at first sight. But [Muris] programmed the headlights to be powered at 70% during daytime conditions and switch to 100% when his sensor detects low ambient light conditions. In the power save mode, all of the other non-essential lights (number plate, tail light) are also turned off to hopefully extend their life. He achieved this by using the VCDS (VAG-COM Diagnostic System) – a widely used aftermarket diagnostics tool for VW-Audi Group vehicles. His tiny circuit switches the lights between the two power settings.

His plan was to install the device without disturbing the original wiring or light switch assembly in any way. The low-powered device consists of a PIC micro-controller, an LDR (light dependent resistor) for light sensing and a low current relay which switches between the two modes. Setting the threshold at which the circuit switches the output is adjusted by a variable trimpot acting as a voltage divider with the LDR. [Muris] wired up a short custom harness which let him install this circuit between the default light switch and the car electronics. After switching on power, he has 15 seconds to enable or disable his unit by toggling the light switch five times, and that status gets stored in memory. The tiny board is assembled using SMD parts and is protected with a heatshrink sleeve. The circuit would work equally well with a lot of other cars, so If you’ve got one which could do with this feature upgrade, then [Muris] has the Eagle CAD files and code available for download on his blog.

Check out the video below where he runs a demo, describes his circuit in detail and then proceeds to assemble the PCB without using a vise or a third hand to hold the PCB. That’s a fancy watch he’s sporting at 00:50 s down the video.

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Rescue An Old Washing Machine With Modern Controls

January 2, 2018 by Lewin Day 25 Comments

The humble washing machine is an appliance that few of us are truly passionate about. They’re expected to come into our lives and serve faithfully, with a minimum of fuss. In the good old days, it was common for a washing machine to last for well over 20 years, and in doing so ingratiate itself with its masters. Sadly now while the simple mechanical parts may still be serviceable, the electronics behind the scenes can tend to fail. This is a Russian story (Google Translate link) about giving a new brain to an old friend.

The machine in question is known as an Oriole, and had served long and hard. Logic chips and entire controllers had been replaced, but were continuing to fail. Instead, a replacement was designed to keep the machine operational for some time yet. Rather than relying on recreating the full feature set of the machine it was decided to eliminate certain things for simplicity. Settings for different fabric types or wash modes were eliminated, which is an easy choice if like most people all your washes are done in the same mode anyway. A water level sensor was found to be no longer functioning properly and was simpler to eliminate than repair.

The brain is a PIC microcontroller, with an ESP12 acting as a webserver for monitoring and control. Additionally, a glass lens was taken from some former medical equipment and neatly installed in the control panel of the machine before an OLED display, giving the machine far more feedback than before. Control is still done with the machine’s original buttons. Temperature sensors were added as well to allow the machine to shut itself down in the event of an overheating problem. It’s all tied together on what looks to be a classic single-sided homebrew PCB.

It’s a great project that shows it’s easy to bring modern electronic might to bear on vintage mechanical hardware, with great results. A washing machine lives to see another day, another load – and the landfill remains just that much lighter, to boot.

We’ve seen controller builds for old washing machines before, too – like replacing mechanical control with an Arduino.

[Thanks to Tirotron for sending this in!]

Fully-functional Oscilloscope On A PIC

December 10, 2017 by Bryan Cockfield 15 Comments

When troubleshooting circuits it’s handy to have an oscilloscope around, but often we aren’t in a lab setting with all of our fancy, expensive tools at our disposal. Luckily the price of some basic oscilloscopes has dropped considerably in the past several years, but if you want to roll out your own solution to the “portable oscilloscope” problem the electrical engineering students at Cornell produced an oscilloscope that only needs a few knobs, a PIC, and a small TV.

[Junpeng] and [Kevin] are taking their design class, and built this prototype to be inexpensive and portable while still maintaining a high sample rate and preserving all of the core functions of a traditional oscilloscope. The scope can function anywhere under 100 kHz, and outputs NTSC at 30 frames per second. The user can control the ground level, the voltage and time scales, and a trigger. The oscilloscope has one channel, but this could be expanded easily enough if it isn’t sufficient for a real field application.

All in all, this is a great demonstration of what you can accomplish with a microcontroller and (almost) an engineering degree. To that end, the students go into an incredible amount of detail about how the oscilloscope works since this is a design class. About twice a year we see a lot of these projects popping up, and it’s always interesting to see the new challenges facing students in these classes.

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Sensing Soil Moisture: You’re Doing It Wrong!

November 16, 2017 by Brian McEvoy 105 Comments

If you compulsively search online for inexpensive microcontroller add-ons, you will see soil moisture measurement kits. [aka] built a greenhouse with a host of hacked hardware including lights and automatic watering. What caught our attention among all these was Step 5 in their instructions where [aka] explains why the cheap soil sensing probes aren’t worth their weight in potting soil. Even worse, they may leave vacationers with a mistaken sense of security over their unattended plants.

The sensing stakes, which come with a small amplifier, work splendidly out of the box, but if you recall, passing current through electrodes via moisture is the recipe for electrolysis and that has a pretty profound effect on metal. [Aka] shows us the effects of electrolysis on these probes and mentions that damaged probes will cease to give useful information which could lead to overworked pumps and flooded helpless plants.

There is an easy solution. Graphite probes are inexpensive to make yourself. Simply harvest them from pencils or buy woodless pencils from the art store. Add some wires and hold them with shrink tube, and you have probes which won’t fail you or your plants.

Here’s some garden automation if this only whet your whistle, and here’s a robotic friend who takes care of the weeds for you.

PCB Tesla Coil Is Perfect Desk Toy

October 30, 2017 by Tom Nardi 43 Comments

A Tesla coil easily makes it to the top spot on our list of “Mad Scientist” equipment we want for the lab, second only to maybe a Jacob’s Ladder. Even then, it’s kind of unfair advantage because you know people only want a Jacob’s Ladder for that awesome sound it makes. Sound effects not withstanding, it’s Tesla coil all the way, no question.

Unfortunately, winding your own Tesla coil is kind of a hassle. Even on relatively small builds, you’ll generally need to setup some kind of winding jig just to do the secondary coil, which can be a project in itself. So when [Daniel Eindhoven] sent his no-wind Tesla coil into the tip line, it immediately got our attention.

The genius in his design is that the coils are actually etched into the PCB, completely taking the human effort out of the equation. Made up of 6 mil traces with 6 mil separation, the PCB coil manages to pack a 25 meter long, 160 turn coil into an incredibly compact package. As you might expect, such a tiny Tesla coil isn’t exactly going to be a powerhouse, and in fact [Daniel] has managed to get the entirely thing running on the 500 mA output of your standard USB 2.0 port.

In such a low-power setup, [Daniel] was also able to replace the traditional spark gap pulse generator with a PIC18F14K50 microcontroller, further simplifying the design. An advantage of using a microcontroller for the pulse generator is that it’s very easy to adjust the coil’s operating frequency, allowing for neat tricks like making the coil “sing” by bringing its frequency into the audible range.

For those looking to build their own version, [Daniel] has put the PCB schematic and firmware available for download on his site. He also mentions that, in collaboration with Elektor magazine, he will be producing a kit in the near future. Definitely something we’ll be keeping an eye out for.

Incidentally, this isn’t the first time [Daniel] has demonstrated his mastery of high voltage. He ~~scared~~ impressed us all the way back in 2010 with his 11,344 Joule capacitor bank, perfect for that laptop-destroying rail gun you’ve been meaning to build.

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