Bringing The Power Of EDM To The Home Shop

January 20, 2022 by Dan Maloney 17 Comments

When you see something made from metal that seems like it would be impossible to manufacture, chances are good it was made with some variety of electrical discharge machining. EDM is the method of choice for hard-to-machine metals, high aspect ratio hole drilling, and precise surface finishes that let mating parts slip together with almost zero clearance. The trouble is, EDM is a bit fussy, and as a result hasn’t made many inroads to the home shop.

[Action BOX] aims to change that with a DIY wire EDM machine. In wire EDM, a fine brass wire is used as an electrode to slowly erode metal in a dielectric bath. The wire is consumable, and has to constantly move from a supply spool through the workpiece and onto a takeup spool. Most of the build shown in the video below is concerned with the wire-handling mechanism, which is prototyped from 3D-printed parts and a heck of a lot of rollers and bearings. Maintaining the proper tension on the wire is critical, so a servo-controlled brake is fitted to the drivetrain, which itself is powered by a closed-loop stepper. Tension is measured by a pair of strain gauges and Arduinos, which control the position of the shaft brake servo and the speed of the motor on the takeup spool.

Unfortunately, in testing this setup proved to live up to EDM’s fussy reputation. The brass wire kept breaking as soon as cutting started, and [Action BOX] never made any actual cuts. There’s certainly promise, though, and we’re looking forward to developments. For more on EDM theory, check out [Ben Krasnow]’s look at EDM hole-drilling.

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Servo Plotter Needs Nothing Exotic

January 5, 2022 by Al Williams 28 Comments

Although the widespread use of 3D printers has made things like linear bearings and leadscrews more common, you still can’t run down to your local big-box hardware store and get them. However, you can get drawer slides and any hobby shop can sell you some RC servos. That and an Arduino can make a simple and easy plotter. Just ask [JimRD]. You can also watch it do its thing in the video below.

Of course, servos aren’t usually what you use in a plotter. But the slides convert the rotation of the servo into linear motion. One servo for X and one for Y is all you need. Another microservo lifts the pen up and down using a hinge you could also get from a hardware store.

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A robot that detects whether you are awake and gently taps you if not.

Wake-Up Robot Does It Gently

December 3, 2021 by Kristina Panos 6 Comments

For hundreds of years, people have fallen asleep while reading in bed late at night. These days it’s worse, what with us taking phones to the face instead when we start to nod off. At least they don’t have pointy corners like books. While you may not want to share your bedroom with a robot, this wake-up robot by [Norbert Zare] may be just the thing to keep you awake.

Here’s how it works: a Raspberry Pi camera on a servo wanders around at eye level, and the Pi it’s attached to uses OpenCV to determine whether those eyes are open or starting to get heavy. The bot can also speak — it uses eSpeak to introduce itself as a bot designed not to let you sleep. Then when it catches you snoozing, it repeatedly intones ‘wake up’ in a bored British accent.

We were sure that the thing was designed to slap [Norbert] in the face a la [Simone Giertz]’s robot alarm clock, but no, that long-fingered hand just slowly swings down and gently taps [Norbert] on the arm (or whatever is in the path of the slappy hand). Check out the short demo and build video after the break.

Do you want to be awoken even more gently? Try a sunlight lamp. We’ve got dozens in stock, but this one gradually gets about as bright as the sun.

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Cheap Big Servo For Robot Arm

November 19, 2021 by Lewin Day 10 Comments

[Skyentific] is looking to push the hobbyist robotics state of the art. Motors and their gears, the actuators, are typically the most expensive part. For his build, he realised he needed big servos capable of delivering plenty of torque. Thus, he set about creating a 3D-printed design to get the job done on a budget. (Video, embedded below.)

Stepper motors are the order of the day here, chosen for their low cost compared to brushless solutions, particularly when taking control hardware into account. In this design, the stepper motor drives a sun gear as part of a bigger planetary gearbox with a high gear ratio. Cross-roller bearings are used to allow the servo to effectively handle both radial and axial loads. The servo as a whole is designed to fit neatly into the joints of the robot arm itself, and has external mounting points provisioned as such.

It’s a neat servo that somewhat apes those used on full-sized industrial designs, at least in the sense of being an integrated part of the joints of a robot arm. It also comes in at a relatively-cheap $32 based on the materials used by [Skyentific].

We’ve seen some related work from [Skyentific] before, too – like this interesting cable-driven joint. Video after the break.

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A One-Servo Mechanical Seven-Segment Display

November 13, 2021 by Dan Maloney 21 Comments

The seven-segment display may be a bit prosaic after all these years, but that doesn’t mean there aren’t ways to spice it up. Coming up with a mechanical version of the typical photon-based display is a popular project, of which we’ve seen plenty of examples over the years. But this seven-segment display is quite a mechanical treat, and a unique way to flip through the digits.

With most mechanical displays, we’re used to seeing the state of each segment changed with some kind of actuator, like a solenoid or servo. [Shinsaku Hiura] decided on a sleeker design using a 3D-printed barrel carrying one cam for each segment. Each hinged segment is attached to an arm that acts as a follower, riding on its cam and flipping on or off in a set pattern. Which digit is displayed depends on the position of the barrel, which is controlled with a single servo and a pair of gears. It trades mechanical complexity for electrical simplicity and overall elegance, and as you can see from the video below, it’s pretty snappy.

We think the best part of this build is figuring out the shape of the cams. We wonder how they compare to the cam profiles in [Greg Zumwalt]’s mechanical display; it uses two separate discs with grooves, but the principle is pretty much the same.

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RC Minecraft Boat Patrols The Pool For Treasure

October 28, 2021 by Tom Nardi 5 Comments

Looking to recreate those relaxing Minecraft fishing sessions in real life, [electrosync] recently set out to 3D print himself a blocky remote controlled boat, complete with a similarly cubic occupant to ride in it. Each element of the build, from the oars to the bobber on the end of the fishing line, has been designed to look as faithful to the source material as possible. In fact, the whole thing is so accurate to the game that it’s almost surreal to see it rowing around the pool.

That said, some of the resemblance is only skin deep. For example the rowing action, though it appears to be properly synchronized to the boat’s movement through the water, is completely for show. A standard propeller and rudder arrangement under the boat provide propulsion and directional control, and [electrosync] notes its actually powerful enough to push the boat very near to its scale top speed from the game, despite the exceptionally poor hydrodynamics of what’s essentially just a rectangle.

Speaking of which, [electrosync] even went through the trouble of printing the hull in wood-fill PLA and coating it in polyester resin to make sure it was watertight. Granted he could have just made the boat out of wood in the first place, saving himself the nearly 60 hours it took to print the hull parts, but that would have been cheating.

Beyond the servos and motors that move the boat and the oars, [electrosync] had to give his 3D printed fisherman a considerable amount of dexterity. Servos embedded into the 3D printed parts allow “Steve” to rotate at the hips and raise and lower his arm. With a fishing pole slipped into a hole printed into the hand, he’s able to cast out his magnetic bobber and see whats biting.

We’ve actually seen quite a number of projects that allow virtual objects inside Minecraft to interact with the real world, but comparatively few efforts to recreate objects from the game’s blocky universe, so the change of pace is nice.

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Quit Hunching Over Your Screen With A Little Robotic Help

October 20, 2021 by Dave Rowntree 8 Comments

[Norbert Zare] has identified a problem many of us suffer from – chronically bad posture. Its very common to see computer users hunched forwards over a screen, which eventually will lead to back problems. He mentions that most posture correction devices are pretty boring, so the obvious solution to [Norbert] was to build a simple robot to give you a friendly nudge into the correct position.

This simple Arduino-based build uses the ubiquitous MPU-6050 which provides 3-axis acceleration and 3-axis gyro data all processed on-chip, so it can measure where you’re going, which way you are orientated and how fast you are rotating. This is communicated via the I²C bus, so hooking into an Arduino or Raspberry Pi is a simple affair. There are plenty of Open Source libraries to work with this very common device, which helps reduce the learning curve for those unfamiliar with programming a fairly complex device.

At the moment, he is mounting the sensor on his body, and hard-wiring it, so there’s already some scope for improvement there. The operating premise is simple, if the body angle is more than 55 degrees off vertical, move the servos and shove the body back in to the correct position.

The project GitHub has the code needed, and the project page over on Hackaday.io shows the wiring diagram.

We have seen quite a few projects on this subject over the years, like this one that sends you mobile notifications, an ultrasonic rangefinder-based device, and one that even uses a webcam to keep an eye on you. This one has the silliness-factor, and we like that round these parts. Keep an eye on [Norbert] we’re sure there more good stuff to come!

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