Plastic Strips Protect Ball Screws On This Homebrew CNC Router

October 26, 2020 by Dan Maloney 17 Comments

It’s a fact of life for CNC router owners — swarf. Whether it’s the fine dust from a sheet of MDF or nice fat chips from a piece of aluminum, the debris your tool creates gets everywhere. You can try to control it at its source, but swarf always finds a way to escape and cause problems.

Unwilling to deal with the accumulation of chips in the expensive ball screws of his homemade CNC router, [Nikodem Bartnik] took matters into his own hands and created these DIY telescopic ball screw covers. Yes, commercial ball screw covers are available, but they are targeted at professional machines, and so are not only too large for a homebrew machine like his but also priced for pro budgets. So [Nikodem] recreated their basic design: strips of thin material wound into a tight spring that forms a tube that can extend and retract. The first prototypes were from paper, which worked but proved to have too much friction. Version 2 was made from sheets of polyester film, slippery enough to get the job done and as a bonus, transparent. They look pretty sharp, and as you can see in the video below, seem to perform well.

It’s nice to see a build progress to the point where details like this can be addressed. We’ve been following [Nikodem]’s CNC build for years now, and it really has come a long way.

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Up Your Home Network Performance – Build Your Own Router!

June 19, 2020 by Lewin Day 118 Comments

Internet connections continue to increase in speed, and for a lucky few, it’s possible to get a Gigabit fibre connection at home. However, if you’re intending to use this connection to its fullest, you might find that your off-the-shelf router has become a bit of a bottleneck. [Wes Fenlon] of PC Gamer had this very problem, and found the perfect workaround – building a custom router instead!

The main problem with commodity routers is a lack of processing power. With networks growing ever faster, the hardware in routers hasn’t kept up with the needs of demanding power users. To solve this, [Wes] grabbed an old PC he had lying around, packing a quad-core i5 CPU and 16 GB of RAM. Fitted with an enterprise-grade 4-port Gigabit LAN card, and running ~~Netgear’s~~ (Sorry commenteers!) Netgate’s pfSense routing software, the old machine has enough power to be complete overkill for the application.

The side benefit of this method is configurability. pfSense has a far more powerful set of options than most common routers. It’s config page also runs far more smoothly, too. There’s also the possibility to run all sorts of useful plugins, like router-level ad blockers and traffic monitoring utilities.

Overall, it’s a great way to repurpose a surplus machine and improve your network performance on the cheap. Others have tried similar builds, too. It has us contemplating the possibilities for our own networks at home!

New Part Day: An Open Source Ethernet Switch In The Palm Of Your Hand

April 21, 2020 by Tom Nardi 91 Comments

When you can get a WiFi-enabled microcontroller for $3, it’s little surprise that many of the projects we see these days have ditched Ethernet. But the days of wired networking are far from over, and there’s still plenty of hardware out there that can benefit from being plugged in. But putting an Ethernet network into your project requires a switch, and that means yet another piece of hardware that needs to get crammed into the build.

Seeing the need for a small and lightweight Ethernet switch, BotBlox has developed the SwitchBlox. This 45 mm square board has everything you need to build a five device wired network, and nothing you don’t. Gone are the bulky RJ45 jacks and rows of blinkenlights, they won’t do you any good on the inside of a robot’s chassis. But that’s not to say it’s a bare bones experience, either. The diminutive switch features automatic crossover, support for input voltages from 7 V all the way up to 40 V, and management functions accessible over SPI.

If you want to get up and running as quickly as possible, a fully assembled SwitchBlox is available to purchase directly from BotBlox for £149.00. But if you’re not in any particular rush and interested in saving on cost, you can spin up your own version of the Creative Commons licensed board. The C++ management firmware and Python management GUI isn’t ready for prime time just yet, but you’ll be able to build a “dumb” version of the switch with the provided KiCad design files.

The published schematic in their repo uses a Microchip KSZ8895MQXCA as the Ethernet controller, with a Pulse HX1344NL supplying the magnetics for all the ports in a single surface mount package. Interestingly, the two images that BotBlox shows on their product page include different part numbers like H1102FNL and PT61017PEL for the magnetics, and the Pulse H1164NL for the Ethernet controller.

Make Networks Wired Again

There’s no question that WiFi has dramatically changed the way we connect devices. In fact, there’s an excellent chance you’re currently reading these words from a device that doesn’t even have the capability to connect to a wired network. If you’re looking to connect a device to the Internet quickly, it’s tough to beat.

But WiFi certainly isn’t perfect. For one, you have to contend with issues that are inherent to wireless communications such as high latency and susceptibility to interference. There’s also the logistical issues involved in making that initial connection since you need to specify an Access Point and (hopefully) an encryption key. In comparison, Ethernet will give you consistent performance in more or less any environment, and configuration is usually as simple as plugging in the cable and letting DHCP sort the rest out.

Unfortunately, that whole “plugging in” part can get tricky. Given their size, putting an Ethernet switch into your project to act as an internal bus only works if you’ve got space to burn and weight is of little concern. So as appealing as it might be to build a network into your robot to connect the Raspberry Pi, motor controllers, cameras, etc, it’s rarely been practical.

This little switch could change that, and the fact it’s released under an open source license means hackers and makers will be free to integrate it into their designs. With the addition of an open source management firmware, this device has some truly fascinating potential. When combined with a single board computer or suitably powerful microcontroller, you have the makings of a fully open source home router; something that the privacy and security minded among us have been dreaming of for years.

Peel Apart Your ISP’s Router

April 2, 2020 by Jenny List 35 Comments

Whether your home Internet connection comes by ADSL, fibre, cable, or even satellite, at some point in the chain between your ISP and your computer will be a router in your home. For some of us it’s a model we’ve bought ourselves and loaded up with a custom distro, but for the majority it’s a box supplied by our ISP and subject to their settings and restrictions. [Paddlesteamer] has just such a router, a Huawei model supplied by the Turkcell ISP, and decided to do a little snooping into its setup.

In a tale of three parts, we see the device unravel, from uncovering a shell to reverse engineering its update process, to delving in its firmware and finally removing all its restrictions entirely. It’s a fascinating process in which we learn a lot, such as the way a man-in-the-middle attack is performed on the router’s connection tot he ISP, or that it contains an authorised SSH key seemingly giving Huawei a back door into it. You may never do this with your ISP’s router, but it pays to be aware of what can be put in your home by them without your realising it.

The Golden Age of router hacking may be behind us as the likes of the Raspberry Pi have replaced surplus routers as a source of cheap Linux boards, but as this shows us there’s still a need to dive inside a router from time to time. After all, locked-down routers are hardly a new phenomenon.

Via Hacker News.

Carbide3D Router Teardown And Testing

January 27, 2020 by Al Williams 6 Comments

On the face of it, you’d think a small router would be pretty simple. After all, what is it other than a spinning motor? However, that motor has to handle some pretty serious torque depending on what you are routing. [Baki1] had his Carbide3D router die in the middle of a project, so he did what any of us would do. He tore it open.

In addition to showing off its insides, he also tried to figure out what was wrong with it. It looks like a blown triac was the culprit, and we assume that part 2 will be the repair and how that actually worked out.

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Nintendo Switch Doubles As Network Switch

December 16, 2019 by Tom Nardi 12 Comments

Coming straight to you from the “Department of Redundant Redundancies” comes this clever hack that turns a Switch into a switch. More specifically, a network switch. Not even a half bad one either, judging by the speed tests [Cynthia Revström] performed after setting it all up. We wouldn’t advise you dump your existing network gear in favor of a repurposed game system, but perhaps in a pinch…

Despite what you might be thinking, there’s no hardware modifications at work here. This is a fully functional Nintendo Switch that’s just had two USB to Ethernet adapters plugged into it. The secret ingredient is the addition of some Penguin Power, up and running on Nintendo’s latest and greatest thanks to a project called switchroot.

With Linux running on the system, all [Cynthia] had to do was make sure that the USB to Ethernet adapters were supported, and fiddle around with the brctl and ip commands to configure a bridge between the interfaces to get the packets moving. Putting the Switch between the main network and a test computer showed it had a throughput of just over 90 Mbps, which is about all that could be expected from the USB-connected network interfaces.

From here it wouldn’t have taken much more effort to get the system working as a wireless router and providing services like DHCP and NAT to clients. But since Nintendo didn’t see fit to call it the Router, that would’ve offered minimal meme value. There’s always next generation.

Seeing the Nintendo Switch do a surprisingly good job running as an Ethernet switch is even more surprising given the fact that it struggles to function with accessories that are actually intended for it. Though to be fair, the migration to USB-C has been a little rockier than most of us would have hoped.

Router Rebooter Without The Effort

November 2, 2019 by Jenny List 67 Comments

It’s one of the rituals of our age, rebooting the family router when the bandwidth falters. Flip the power, and after half a minute or so your YouTube video starts up again. Consumer-grade router hardware is not the most reliable computing equipment you will own, as [Nick Sayer] found out when the router at his vacation home wasn’t reliable enough to support his remote monitoring equipment. His solution is an auto-reboot device, that power-cycles the offending device on command.

An obvious method might be to switch the mains supply, but instead he’s taken the simpler option of switching the DC from the router’s wall wart power supply with a cunning arrangement of three MOSFETs to keep the router defaulting to on under all conditions except when it is commanded to power down by the ATtiny microcontroller overseeing it. This chip provides extra fail-safe and debouncing functions to ensure no accidental rebooting.

Driving the circuit is a Raspberry Pi that handles the house monitoring, on which a Python script checks for Internet access and asks for a reboot if there is none. For extra safety it requires access to be down for a sustained period before doing so in case of a router firmware upgrade.

This isn’t the first router rebooter, for a mains-switching ESP8266 take a look at this one.

Router picture: Asim18 [CC BY-SA 3.0]