Building The Perfect Home Router

April 12, 2018 by Tom Nardi 43 Comments

When a favorite piece of hardware dies, it’s fairly common to experience a bit of dread. The thought that now you’ll have to go through the process of getting a replacement for the device can be very troubling, and is fraught with difficult questions. Is the hardware still available? Has it been made obsolete by something else in the time you’ve had it? But while it can be a hassle, there’s no question you can come out the other side better than you went in. Sometimes it takes the passing of an old piece of gear for you to really embrace what’s possible with the latest and greatest.

That’s exactly what happened to [Tyler Langlois]. When his trusty home router finally gave up the ghost, he was left with a couple of options. He could get another consumer router, upgrade to a enterprise-level model, or take the road less traveled and build his own router to his exacting specifications. Since you’re reading about it on Hackday, we’ll give you one guess as to which door he went through.

The blog post [Tyler] has written up about the saga of building his own router is an incredible resource for anyone who might be thinking of taking the plunge into DIY networking. From selecting the proper hardware to the nuances of getting all of the software packages installed, this is an absolute treasure trove. At the beginning of the post he mentions that the post shouldn’t be considered a comprehensive guide, but considering we’ve seen commercial hardware that wasn’t documented this well, we’d have to respectfully disagree on that point.

Some elements of his homespun may come as something of a surprise. For one, [Tyler] bucked the hive mentality and determined the Raspberry Pi simply wasn’t up to the task due (at least in part) to the single 100 Mbps network interface. He ended up going with an ESPRESSObin, a relatively niche Linux SBC that features an onboard gigabit switch in addition to a fairly hefty spec sheet. He also decided to forgo WiFi entirely, and leave the intricacies of wireless networking to a standalone access point from Ubiquity.

A router is often overlooked as just another piece of consumer kit sitting around the house, but it’s actually an excellent place to flex your creative and technical muscle. From adding a remote display to converting it into a mobile battle tank, there’s a lot more you can do with your router than stare at the blinkenlights.

The Tachometer Inside Your Smartphone

February 8, 2018 by Dan Maloney 26 Comments

It’s the latest in instrumentation for the well-appointed shop — an acoustically coupled fast Fourier transform tachometer. Sounds expensive, but it’s really just using a smartphone spectrum analyzer app to indirectly measure tool speeds. And it looks like it could be incredibly handy.

Normally, non-contact tachometers are optically coupled, using photoreceptors to measure light flashing off of a shaft or a tool. But that requires a clear view of the machine, often putting hands far too close to the danger zone. [Matthias Wandel]’s method doesn’t require line of sight because it relies on a cheap spectrum analyzer app to listen to a machine’s sound. The software displays peaks at various frequencies, and with a little analysis and some simple math, the shaft speed of the machine can be determined. [Matthias] explains how to exclude harmonics, where to find power line hum, isolating commutator artifacts, and how to do all the calculations. You’ll need to know a little about your tooling to get the right RPM, and obviously you’ll be limited by the audio frequency response of your phone or tablet. But we think this is a great tip.

[Matthias] is no stranger to shop innovations and putting technology to work in simple but elegant ways. We wonder if spectrum analysis could be used to find harmonics and help with his vibration damping solution for a contractor table saw.

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Router Rebooter Eliminates Hassles

January 31, 2018 by Bryan Cockfield 85 Comments

Some low-end or older routers might get you a decent WiFi network in your house or apartment, but often these cheaply made devices are plagued with subtle software problems that cause the router itself to become unresponsive after a few days of operating. One solution is to just power cycle the router by hand whenever the Internet disappears, but a better solution is to build something that does that for you.

[Charlie] had this problem as the de facto IT person in his family, and didn’t want to keep getting bothered for such a simple problem. His solution involves a relay, an ESP8266, and a Wemos D1 mini. The device connects to the Internet through the router and occasionally sends out pings to another address. If it can’t ping the address successfully after a certain time period, the device power cycles the router by activating the relay.

Since this isn’t the newest idea out there, there are many ways to solve this problem if you are constantly annoyed by router issues, whether from your own router or from friends and family who treat you as their personal IT department. One solution doesn’t involve any extra hardware at all as long as you have a computer near your router/modem already, and others solve this problem when it happens to the modem rather than the router.

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Optical Tach Addresses The Need For Spindle Speed Control

January 28, 2018 by Dan Maloney 8 Comments

With CNC machines, getting the best results depends on knowing how fast your tool is moving relative to the workpiece. But entry-level CNC routers don’t often include a spindle tachometer, forcing the operator to basically guess at the speed. This DIY optical spindle tach aims to fix that, and has a few nice construction tips to boot.

The CNC router in question is the popular Sienci, and the 3D-printed brackets for the photodiode and LED are somewhat specific for that machine. But [tmbarbour] has included STL files in his exhaustively detailed write-up, so modifying them to fit another machine should be easy. The sensor hangs down just far enough to watch a reflector on one of the flats of the collet nut; we’d worry about the reflector surviving tool changes, but it’s just a piece of shiny tape that’s easily replaced. The sensor feeds into a DIO pin on a Nano, and a small OLED display shows a digital readout along with an analog gauge. The display update speed is decent — not too laggy. Impressive build overall, and we like the idea of using a piece of PLA filament as a rivet to hold the diodes into the sensor arm.

Want to measure machine speed but don’t have a 3D printer? No worries — a 2D-printed color-shifting tach can work too.

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Why You Should Use Your Router As A Security Camera

November 28, 2017 by Lewin Day 28 Comments

A home security camera can be great for peace of mind, and keeping an eye on the house while you’re away. The popular option these days is an IP-based device that is accessible over the Internet through an ethernet or wireless connection to your home router. But what if you could cut out the middle man, and instead turn your router itself into the security camera? [Fred] is here to show us how it’s done .

The hack begins by parsing the original router’s firmware. Through a simple text search, a debug page was identified which allowed telnet access to the router to be enabled. This gives access to a root shell, allowing full control over the Linux system running the show.

After backing everything up, [Fred] grabbed the source code from Netgear and recompiled the kernal with USB video and Video4Linux2 support. This allows the router to talk to a standard USB webcam. It’s then a simple matter of using opkg to install software to set up the router to record video when motion is detected.

Overall, it’s fairly straightforward, but [Fred] came up with an ingenious twist. Because the router itself is acting as the security camera, he is able to set up the camera to only arm itself when his smartphone (and thus, [Fred] himself) is not at home. This prevents the recording of footage of [Fred] moving around the house, allowing the router to only record important footage for security purposes.

It’s possible to do great things with routers – most of them are just tiny boxes running Linux anyway. Check out this one used as an online energy meter.

Becoming Your Own ISP, Just For Fun

November 18, 2017 by Lewin Day 46 Comments

When moving into a new house, it’s important to arrange for the connection of basic utilities. Electricity, water, and gas are simple enough, and then it’s generally fairly easy to set up a connection to an ISP for your internet connection. A router plugs into a phone line, or maybe a fiber connection and lovely packets start flowing out of the wall. But if you’re connected to the internet through an ISP, how is the ISP connected? [Kenneth] answers this in the form of an amusing tale.

It was during the purchase of data centre rack space that [Kenneth]’s challenge was laid down by a friend. Rather then simply rely on the connection provided by the data centre, they would instead rely on forging their own connection to the ‘net, essentially becoming their own Internet Service Provider.

This is known as creating an Autonomous System. To do this involves several challenges, the first of which is understanding just how things work at this level of networking. [Kenneth] explains the vagaries of the Border Gateway Protocol, and why its neccessary to secure your own address space. There’s also an amusing discussion on the routing hardware required for such a feat and why [Kenneth]’s setup may fall over within the next two years or so.

It’s not for the faint hearted, and takes a fair bit of paperwork, but [Kenneth] has provided an excellent guide to the process if you really, really just need to own your own corner of the internet. That said, there are other networking tricks to cut your teeth on if you’d like a simpler challenge, like tunneling IP over ICMP.

CNC Robot Makes A Move

October 12, 2017 by DJ Harrigan 30 Comments

Another day, another Kickstarter. While we aren’t often keen on touting products, we are keen on seeing robotics and unusual mechanisms put to use. The Goliath CNC has long since surpassed its $90,000 goal in an effort to put routing robots in workshops everywhere.

Due to their cost and complexity, you often only find omni-wheels on robots scurrying around universities or the benches of robotics hobbyists, but the Goliath makes use of nine wheels configured as three sets in a triangular pattern. This is important as any CNC needs to make compound paths, and for wheeled robots an omni-wheel base is often the best bet for compound 2D translation.

What really caught our eye is the Goliath’s unique positioning system. While most CNC machines have the luxury of end-stops or servomotors capable of precise positional control, the Goliath has two “base sensors” that are tethered to the top of the machine and mounted to the edge of the workpiece. Each sensor connects to the host computer via USB and uses vaguely termed “Radio Frequency technology” that provides a 100Hz update for the machine’s coordinate system. This setup is sure to beat out dead-reckoning for positional awareness, but details are scant on how it precisely operates. We’d love to know more if you’ve used a similar setup for local positioning as this is still a daunting task for indoor robots.

A re-skinned DeWalt 611 router makes for the core of the robot, which is a common option for many a desktop milling machine and other bizarre, mobile CNCs like the Shaper Origin. While we’re certain that traditional computer controlled routers and proper machining centers are here to stay, we certainly wouldn’t mind if the future of digital manufacturing had a few more compact options like these.