Stealing 3D Prints By Sound

April 12, 2016 by Elliot Williams 48 Comments

In the open hardware world, we like to share 3D design files so that our friends and (global) neighbors can use and improve them. But we’ve all printed things from time to time that we’d like to keep secret. At least this is the premise behind this article in Science which proposes a novel method of 3D-printer-based industrial espionage: by recording the sound of the stepper motors and re-creating the toolpath.

Unfortunately, the article is behind a paywall so we’re short on the details, but everyone who’s played the Imperial March on their steppers has probably got the basic outline in their mind. Detecting the audio peak corresponding to a step pulse should be fairly easy. Disentangling the motions of two axes would be a bit harder, but presumably can be done based on different room-acoustic filtering of the two motors. Direction is the biggest question mark for us, but a stepper probably has a slightly audible glitch when reversing. Keeping track of these reversals could do the trick.

What do you think? Anyone know how they did it? Does someone with access to the full article want to write us up a summary in the comments?

[Thanks LVfire via Ars Technica]

[Edit: We were sent a copy of the full article (thanks [PersonUnknown]!) and it doesn’t explain any technical details at all. Save yourself the effort, and have fun speculating, because reading the article won’t help.]

Brushed DC Servo Drive

February 13, 2016 by Anool Mahidharia 37 Comments

Brushless DC motors, and their associated drive electronics, tend to be expensive and complicated. [Ottoragam] was looking for a cheaper alternative and built this Brushed DC motor servo controller and the results look pretty promising. Check out the video after the break.

He needed a low cost, closed loop drive for his home-brew CNC. The servo drive is able to supply a brushed DC motor with up to 7 A continuous current at up to 36 V which works out to about 250 W or 1/3 HP. It does closed loop control with feedback from a quadrature encoder. The drive accepts simple STEP and DIRECTION signals making it easy to interface with micro controllers and use it as a replacement for stepper motors in positioning applications. All of the control is handled by an ATmega328P. It takes the input signals and encoder data, does PID control, and drives the motor via the DRV8701 full bridge MOSFET driver. There’s also some error detection for motor over-current and driver under-voltage. Four IRFH7545 MOSFETs in H-bridge configuration form the output power stage.

This is still work in progress, and [Ottoragam] has a few features pending in his wish list. The important ones include adding a serial interface to make it easy to adjust the PID parameters and creating a GUI to make the adjustment easier. The project is Open Source and all source files available at his Github repository. The board is mostly surface mount, but the passives are all 0805, so it ought to be easy to assemble. The QFN footprint for the micro controller could be the only tricky one. [Ottoragam] would love to have some beta testers for his boards, and maybe some helpful comments to improve his design.

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Fail Of The Week : Watt A Loss

January 21, 2016 by Anool Mahidharia 27 Comments

This one is a bit dated, but the lessons are still relevant. [Zach Hoeken] posted about the challenges he faced building a CNC stepper driver. He was experimenting with Toshiba motor drivers back in 2012.

The modular motor driver boards he built were based on the THB6064AH – capable of 1/64th step, and 4.5 Amps at up to 50V. [Zach] built a test jig to run the boards through their paces. A couple of messed tracks was the least of his problems – easily fixed by cutting traces and using jumper wires to correct the errors. But the header footprints for the motor drive boards got reversed. The only way out was to solder the headers on the back side.

LESSON : Always check footprint orientation and pin numbering before sending boards to fab.

The surprising part was when someone as experienced as [Zach] messed up on Ohms Law. Based on the current he wanted the motors to run at, his sense resistors needed to be 3.2W, but he’d used SMD footprints (0805 likely) instead. Those tiny resistors couldn’t be used at all, and the 5W resistors plonked on looked like an ugly hack.

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Precision CNC Drawing With EtchABot

January 18, 2016 by Rud Merriam 20 Comments

Turning the classic toy Etch-A-Sketch into a CNC drawing tablet intrigues a large number of hackers. This version by [GeekMom] certainly takes the award for precision and utility. Once you build something like this, you can hardly stop writing firmware for it; [GeekMom] produced an entire Arduino library of code to allow joystick doodling, drawing web images, and a self-erasing spirograph mode. The topper is the version that runs as a clock!

The major hassle with making a CNC version of this toy is the slop in the drawing mechanism. There is a large amount of backlash when you reverse the drawing direction. If that isn’t bad enough, the backlash is different in the vertical or horizontal directions. Part of [GeekMom’s] presentation is on how to measure and correct for this backlash.

The EtchABot uses three small stepper motors. Two drive the drawing controls and the third flips the device forward to erase the previous drawing. The motors are each controlled by a ULN2003 stepper motor drivers. An Arduino Uno provides the intelligence. Optional components are a DS3231 Real Time Clock and a dual axis X-Y joystick for the clock and doodling capability. Laser cut wood creates a base for holding the Etch-A-Sketch and the electronics.

The write up and details for this project are impressive. Be sure to check out the other entries in [GeekMom’s] blog. Watch the complete spirograph video after the break.

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Mostly Wood Motorized Camera Slider

December 26, 2015 by Dan Maloney 6 Comments

Camera slides can make for interesting dolly shots in your videos, or can spice up an otherwise drab time-lapse sequence. When it came time for one of his own, [Bob] did what any hacker would do and rolled his own motorized camera slide in the wood shop.

We always like to see work based on a hacker’s own prior art, and [Bob] managed to leverage parts and techniques from his impromptu claw machine build for this slider. The rollers in this project use the same 3/4″ angle aluminum and skateboard bearings as the previous build. The bearings roll on a plywood strip capped with the same angle stock for durability and low friction. The stepper motor bracket and pillow blocks are 3D printed, as are the timing pulleys. [Bob] admits that the whole rig is a little noisy and blames it on the rough quality of the pulley prints. He has plans to replace them with commercially available pulleys, which should help; one further suggestion we have is to code a soft-start algorithm into the ATtiny85 to eliminate that jerkiness you see when he demos the slider in the video below.

There are plenty of ways to move a camera along a single axis, and a surprising number of them use parts from the roller sports. We’ve covered quite a few of them before, like this slide that uses skateboard trucks, or this non-motorized rig built from fence posts and inline skate wheels.

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A Pragmatic Guide To Motors With Jonathan Beri

December 17, 2015 by Brandon Dunson 8 Comments

[Jonathan Beri] is a Maker of all sorts, with an affinity for robots, APIs, and Open Source. By day he works on making Android & iOS SDKs easier to use and by night he can found begging a PID controller to “just work already.” Recently he contributed to, “Make: JavaScript Robotics,” printed by Maker Media (2015).

[Jonathan] covers a lot of ground during his motors talk at the 2015 Hackaday SuperConference. He discusses brushed DC, stepper, servo, and brushless motors. Although just scraping the surface of each type of motor [Jonathan] touches the important details you can use to determine which type of motor is best for your project. The slide show he has put together has quite a bit of information and tips for beginners that might go overlooked when choosing a motor. For instance a list of 30 attributes that should be considered when selecting a motor. Included in that list are the 7 attributes [Jonathan] places priority on when he chooses a motor for one of his projects. We’ll delve deeper into that after the break.

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Giant Stepper Motor Gets You Up To Speed On Theory

August 20, 2015 by Dan Maloney 27 Comments

Few hackers have trouble understanding basic electric motors. We’ve all taken apart something that has a permanent magnet DC motor in it and hooked up its two leads to a battery to make it spin. Reverse the polarity, reverse the spin; remove the power, stop the spin. Stepper motors (and their close cousins, brushless DC motors) are a little tougher to grok, though, especially for the beginner. But with a giant 3D printed stepper motor, [Proto G] has made getting your head around electronically commutated motors a little easier.

While we’ve seen 3D printed stepper motors before, the size and simple layout of this one really lends to understanding the theory. With a 3D-printed frame, coils wound on nails, and rare-earth magnets glued to a rotor, this is an approachable build that lays the internals of a stepper motor out for all to see and understand. You can easily watch how the rotor lines up as the various coils are energized in a circular pattern, although it might be more revealing to include bi-color LEDs to indicate which coils are energized and what the polarity is. Those would be especially helpful demonstrating the concept of half-stepping. We’d also like to see more detail on the controller electronics, although admittedly all the video-worthy action is in the motor itself.

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