Analyzing CNC Tool Chatter With Audacity

When you’re operating a machine that’s powerful enough to tear a solid metal block to shards, it pays to be attentive to details. The angular momentum of the spindle of a modern CNC machine can be trouble if it gets unleashed the wrong way, which is why generations of machinists have developed an ear for the telltale sign of impending doom: chatter.

To help develop that ear, [Zachary Tong] did a spectral analysis of the sounds of his new CNC machine during its “first chip” outing. The benchtop machine is no slouch – an Avid Pro 2436 with a 3 hp S30C tool-changing spindle. But like any benchtop machine, it lacks the sheer mass needed to reduce vibration, and tool chatter can be a problem.

The analysis begins at about the 5:13 mark in the video below, where [Zach] fed the soundtrack of his video into Audacity. Switching from waveform to spectrogram mode, he was able to identify a strong signal at about 5,000 Hz, corresponding to the spindle coming up to speed. The white noise of the mist cooling system was clearly visible too, as were harmonic vibrations up and down the spectrum. Most interesting, though, was the slight dip in frequency during the cut, indicating loading on the spindle. [Zach] then analyzed the data from the cut in the frequency domain and found the expected spindle harmonics, as well the harmonics from the three flutes on the tool. Mixed in among these were spikes indicating chatter – nothing major, but still enough to measure.

Audacity has turned out to be an incredibly useful tool with a broad range of applications. Whether it be finding bats, dumping ROMs, detecting lightning strikes, or cloning remote controls, Audacity is often the hacker’s tool of choice.

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Audio Algorithm Detects When Your Team Scores

[François] lives in Canada, and as you might expect, he loves hockey. Since his local team (the Habs) is in the playoffs, he decided to make an awesome setup for his living room that puts on a light show whenever his team scores a goal. This would be simple if there was a nice API to notify him whenever a goal is scored, but he couldn’t find anything of the sort. Instead, he designed a machine-learning algorithm that detects when his home team scores by listening to his TV’s audio feed.

goal[François] started off by listening to the audio of some recorded games. Whenever a goal is scored, the commentator yells out and the goal horn is sounded. This makes it pretty obvious to the listener that a goal has been scored, but detecting it with a computer is a bit harder. [François] also wanted to detect when his home team scored a goal, but not when the opposing team scored, making the problem even more complicated!

Since the commentator’s yell and the goal horn don’t sound exactly the same for each goal, [François] decided to write an algorithm that identifies and learns from patterns in the audio. If a home team goal is detected, he sends commands to some Phillips Hue bulbs that flash his team’s colors. His algorithm tries its best to avoid false positives when the opposing team scores, and in practice it successfully identified 75% of home team goals with 0 false positives—not bad! Be sure to check out the setup in action after the break.

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Video Voice Visualization

For their ECE 4760 final project at Cornell, [Varun, Hyun, and Madhuri] created a real-time sound spectrogram that visually outputs audio frequencies such as voice patterns and bird songs in gray-scale video to any NTSC television with no noticeable delay.

The system can take input from either the on-board microphone element or the 3.5mm audio jack. One ATMega1284 microcontroller is used for the audio processing and FFT stage, while a second ‘1284 converts the signal to video for NTSC output. The mic and line audio inputs are amplified individually with LM358 op-amps. Since the audio is sampled at 8KHz, a low-pass filter gets rid of frequencies above 4KHz.

After the break, you can see the team demonstrate their project by speaking and whistling bird calls into the microphone as well as feeding recorded bird calls through the line input. They built three controls into the project to freeze the video, slow it down by a factor of two, and convert between linear and logarithmic scales. There are also short clips of the recorded bird call visualization and an old-timey dial-up modem.

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Hammond Organ Sends Messages Which Can Be Decoded By A Spectrogram

hammond-organ-encodes-messages-spectrogram

Here’s an interesting use for an old organ. Let it get in on your Ham radio action. [Forrest Cook]  is showing off his project which uses a Hammond Organ to encode messages which can be displayed by a Spectrogram. We’ve seen this type of message encoding before (just not involving a musical instrument). It’s rather popular with Hams in the form of the fldigi program.

An Arduino was connected to the organ via a UNL2003 darlington array chip. This chip is driving some reed relays which make the organ connections to create the sine wave tones. With that hardware in place it’s a matter of formatting data to generate the target audio. [Forrest] wrote his own Arduino sketch which takes characters from the serial port (pushed over USB by the laptop), maps then to a stored 5×7 character font set, then drives the pins to produce the tones. As you can see in the clip after the break the resulting audio can be turned into quite readable text.

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