Sorter Uses Cardboard To Organize Card Hoard

January 26, 2019 by Kristina Panos 13 Comments

If you collect trading cards of any kind, you know that storage quickly becomes an issue. Just ask [theguymasamato]. He used to be really into trading cards, and got back into it when his kids caught the bug. Now he’s sitting on 10,000+ cards that are largely unorganized except for a few that made it into sleeve pages. They tried to go through them by hand, but only ended up frustrated and overwhelmed. Then he found out about [Michael Portera]’s Pi-powered LEGO card sorter and got all fired up to build a three-part system that feeds cards in one by one, scans them, and sorts them into one of 22 meticulously-constructed cardboard boxes.

[theguymasamato]’s card sorter is the last stop for a card after the feeder has fed it in from the pile and the scanner has scanned it. The sorter lazy Susans around on a thrust bearing, which is driven by a 3D printed drive wheel attached to a stepper. The stepper is controlled with an Arduino.

Here’s where it gets crazy: the drive wheel and timing belt are made from the flutes of corrugated cardboard. As in, he used that wavy bit in the middle as gear teeth. Every one of those cardboard teeth is fortified with wood glue, a time-consuming process he vows to never repeat. Instead, [theguymasamato] recommends using shims to shore them up as he did in the card feeder. The whole thing was originally going to be made from cardboard. It proved to be too mushy to support the thrust bearing, so [theguymasamato] switched to MDF.

Right now, the sorter is homed via button press, but future plans for the device include an IR break beam switch. We’re excited for the scanner and can’t wait to see the whole system put together. While [theguymasamato] works on that, position yourself past the break to watch the build video.

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Silent Stepper Drive Makes A Nicer Watch Winder

January 24, 2019 by Lewin Day 12 Comments

Mechanical watches are great in that they never need batteries, but they are simultaneously less than great in that they will lose time if not worn or otherwise regularly agitated. The ridiculous solution to this is the watch winder, which automatically rotates your mechanical watches for you, while you’re not wearing them. This is probably the item you’ll miss the least once the apocalypse hits. [Kristopher] wanted a nice quiet watch winder for his bedside table, but existing solutions were either too loud or too expensive. As is often the case, hacking ensued.

[Kristopher] had decided that starting from scratch was too much hassle. The cheaper watch winders on the market had acceptable quality enclosures, but were simply too loud. [Kristopher] sourced a $40 unit from Amazon, and proceeded to gut the drivetrain. This was replaced with a Sparkfun stepper motor and a Trinamic SilentStepStick – an advanced stepper motor driver that uses several techniques to reduce noise during operation.

An Arduino Nano was substituted as the brains of the operation, communicating with the stepper driver and allowing the winder to be configured for different wind rates. [Kristopher] reports that the device operates near-silently, and the total cost came in well below that of a high-end luxury winder.

Mechanical watches don’t always get a lot of attention these days, but we’ve seen one built from the ground up before. As always, with tips – send ’em if you got ’em.

An Arduino Carbon Fiber Wrapping Machine

January 18, 2019 by Tom Nardi 23 Comments

Many of the projects we feature on Hackaday are motivated by pure greed. Not on the part of the hacker, mind you; but rather the company that’s charging such an outrageous price for a mass produced item that somebody decides they can do the same thing cheaper as a one-off project. Which is precisely how [Bryan Kevan] ended up building his own carbon fiber tube wrapping machine. Not only do the finished tubes look fantastic, but they cost him a fraction of what even the “cheap” commercial ones cost.

The principle behind producing the tubes is really pretty simple: carbon fiber ribbon (or “tow”, in the official parlance) gets wrapped around a rotating mandrel, ideally in interesting patterns, and epoxy is added to bind it all together. When it’s hardened up, you slide the new carbon fiber tube off the mandrel and away you go building a bike frame or whatever it is you needed light and strong tubes for. You could even do it by hand, if you had enough patience.

[Bryan] had done it by hand before, but was looking for a way to not only automate the process but make the final product a bit more uniform-looking. His idea was to rotate a horizontal PVC pipe as his mandrel, and move a “car” carrying the carbon fiber ribbon back and forth along its length. The PVC pipe just needs to rotate along its axis so he figured that would be easy enough; and using a GT2 belt and some pulleys, getting the carbon-laying car moving back and forth didn’t seem like much of a challenge either.

The frame of the winder is built from the hacker’s favorite: 20/20 aluminum extrusion. Add to that an Arduino Uno, two stepper motors with their appropriate drivers, and the usual assortment of 3D printed odds and ends. [Bryan] says getting the math figured out for generating interesting wrap patterns was a bit tricky and took a fair amount of trial and error, but wasn’t a showstopper. Though we’d suggest following his example and using party ribbon during testing rather than the carbon stuff, as producing a few bird nests at the onset seems almost a guarantee.

One of the trickiest parts of the project ended up being removing the carbon fiber tubes from the PVC mandrel once they were done. [Bryan] eventually settled on a process which involved spraying the PVC with WD-40, wrapping it in parchment paper, and then using a strip of 3M blue painter’s tape to keep the parchment paper from moving. If you can toss the whole mandrel in the freezer after wrapping to shrink it down a bit, even better.

So was all this work worth it in the end? [Bryan] says he was originally looking at spending up to $70 USD per foot for the carbon fiber tubes he needed for his bike frame, but by buying the raw materials and winding them himself, he ended up producing his tubes for closer to $3 per foot. Some might question the strength and consistency of these DIY tubes, but for a ~95% price reduction, we’d be willing to give it a shot.

Years ago we covered a Kickstarter campaign for a very similar carbon winder. Probably due to the relatively limited uses of such a gadget, the winder didn’t hit the funding goal. But just like the current wave of very impressive homebrew laser cutters, the best results might come from just building the thing yourself.

‘Bit’ Installation Combines Art, Markov Chains

December 17, 2018 by Lewin Day 7 Comments

A Markov chain is a mathematical concept of a sequence of events, in which each future event depends only on the state of the previous events. Like most mathematical concepts, it has wide-ranging applications from gambling to the stock market, but in this case, [Jonghong Park] has applied it to art.

The installation, known simply as ‘bit’, consists of four machines. Each machine has two microswitches, which are moved around two wooden discs by a stepper motor. The microswitches read bumps on the surface of the disc as either a 0 or 1, and the two bits from the microswitches represent the machine’s “state”.

When a machine is called, the stepper motor rotates 1/240th of a revolution, and then the microswitches read the machine’s current state. Based on this state and the Markov Chain algorithm coded into the machines, a machine with the corresponding state is then called, which in turn moves, continuing the chain.

The piece is intended to reflect the idea of a deterministic universe, one in which the current state can be used to predict all future states. As an art piece, it combines its message with a visually attractive presentation of understated black metal and neatly finished wood.

We love a good art installation here at Hackaday – like this amazing snowflake install from a couple years back. Video after the break.

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Vintage Plotter Turned Fruit Spectrometer

December 14, 2018 by Tom Nardi 9 Comments

Fruit can be a tricky thing: if you buy it ripe you’ll be racing against time to eat the pieces before they turn into a mushy mess, but if you buy the ones which are a bit before their prime it’s not always easy to tell when they’re ready to eat. Do you smell it? Squeeze it? Toss it on the counter to see if it bounces? In the end you forget about them and they go bad anyway. That’s why here at Hackaday we sustain ourselves with only collected rainwater and thermo-stabilized military rations.

But thankfully Cornell students [Christina Chang], [Michelle Feng], and [Russell Silva] have come up with a delightfully high-tech solution to this decidedly low-tech problem. Rather than rely on human senses to determine when a counter full of fruit has ripened, they propose an automated system which uses a motorized spectrometer to scan an arrangement of fruit. The device measures the fruit’s reflectance at 678 nm, which can be used to determine the surface concentration of chlorophyll-a; a prime indicator of ripeness.

If that sounds a bit above your pay grade, don’t worry. The students were able to build a functional prototype using a 1980’s era plotter, a Raspberry Pi, and a low-cost AS7263 NIR spectral sensor from SparkFun which just so happens to have a peak responsivity of 680 nm. The scanning is performed by a PIC32MX250F128B development board with an attached TFT LCD display so the results can be easily viewed. The Raspberry Pi is used in conjunction with a Adafruit PCA9685 I2C PWM driver to control the plotter’s stepper motors. The scanning and motor control could be done with the PIC32 alone, but to save time the students decided to use the Raspberry Pi to command the PCA9685 as that was what the documentation and software was readily available for.

To perform a scan, the stepper motors home the AS7263 sensor module, and then passes it under the fruit which is laying on a clear acrylic sheet. Moving the length of the acrylic sheet, the sensor is able to scan not only multiple pieces of fruit but the entirety of each piece; allowing it to determine for example if a section of a banana has already turned. The relative ripeness of the fruit is displayed to the user on the LCD display as a heatmap: the brighter the color the more ripe it is.

At the end of their paper, [Christina], [Michelle], and [Russell] note that while the scanner worked well there’s still room for improvement. A more scientific approach to calculating how ripe each fruit is would make the device more accurate and take out the guess work on the part of the end user, and issues with darker colored fruit could potentially be resolved with additional calibration.

While a spectrometer might sound like the kind of equipment that only exists in multi-million dollar research laboratories, we occasionally see projects like this which make the technology much more accessible. This year we saw a compact spectrometer in the Hackaday Prize, and going a bit farther back in time we even featured a roundup of some of the most impressive spectrometer builds on Hackaday.io.

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Mechanizing A Eurorack Sequencer

December 6, 2018 by Brian Benchoff 3 Comments

Eurorack has taken over the synthesizer community, and hundreds of people are building their own eurorack modules. [Michael Forrest] designed and built his own Eurorack sequencer module that doesn’t use weird things like capacitors and chips to store a signal. Instead, he’s doing it with stepper motors and some clever engineering.

The basic idea of a Eurorack sequencer is to somehow store a series of values and play them back repeatedly. Connect that sequence to a clock, and you get the same pattern of sounds out of your synth. This can be done digitally with a circular buffer, in the analog domain with a bunch of FETs and caps, or in this case, on a piece of paper glued to a stepper motor.

The key bit of mechanism for this build is a stepper motor with 96 steps per rotation. This is important, because the module is controlled by a clock pulse from the sequencer. Since 96 is evenly divisible by 8 and 16, that means this sequencer will play back in 4/4 time. That NEMA 17 motor with 200 steps per resolution simply won’t work in this situation. Rather, it will technically work, but it’ll be unusable.

The electronics for this build are surprisingly simple, with an Arduino taking in the clock pulse and sending the step signals to an H-driver. The motor spins a paper disk, which is read with a photoresistor and a LED. It’s simple enough to be fun, and yes, it is mounted to a proper Eurorack-sized panel. You can check out the video of this build below.

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Stepper Motor Mods Improve CNC Flat Coil Winder

November 4, 2018 by Dan Maloney 56 Comments

Finding just the right off-the-shelf part to complete a project is a satisfying experience – buy it, bolt it on, get on with business. Things don’t always work out so easily, though, which often requires the even more satisfying experience of modifying an existing part to do the job. Modifying a stepper motor by drilling a hole down its shaft probably qualifies for the satisfying mod of the year award.

That’s what [Russ] did to make needed improvements to his CNC flat-coil winder, which uses a modified delta-style 3D-printer to roll fine magnet wire out onto adhesive paper to form beautiful coils of various sizes and shapes. [Russ] has been tweaking his design since we featured it and coming up with better and better coils. While experimenting, the passive roller at the business end proved to be a liability. The problem was that the contact point lagged behind the center axis of the delta, leading to problems with the G-code. [Russ] figured that a new tool with the contact point at the dead center would help. The downside would be having to actively swivel the tool in concert with the X- and Y-axis movements. The video below shows his mods, which include disassembling the NEMA-17 stepper and drilling out the shaft to pass the coil wire. [Russ] also spent some time reversing the rotor in the frame and provided a small preload spring to keep the coil roller in contact with the paper.

A real-time coil winding session starts at the 21:18 mark, and we’ve got to admit it’s oddly soothing to watch. We’re not sure exactly what [Russ] intends to do with these coils, and by his own admission, neither is he. But it’s still pretty cool to see, and the stepper motor mods are a neat trick to keep in mind.

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