Stepper Motors Quick And Simple

April 9, 2021 by Chris Lott 37 Comments

If you want a simple and easy introduction to stepper motors, check out the [IMSAI Guy]’s short video where he designs a very basic stepper motor controller and packs in a lot of quick lessons along the way. (Embedded below.)

He first goes over the fundamentals of a stepper motor in a practical, hands-on approach, and also shows us how to ring out the connections if the pinout is unknown. Next he demonstrates stepping the motor manually and then makes a simple FET driver circuit. Just when you’re expecting a small microcontroller to appear, the [IMSAI Guy] instead digs deep into his junk box and explains how to drive the motor with a 22V10 GAL (an electrically erasable PAL) and a 555 timer module. Based on a clearly-explained logic table for driving the coils, a sneaky way to introduce Karnaugh maps, he proceeds to write the output equations in WinCUPL.

Mature Readers will recall the “Happy PAL” Character

WinCUPL is the modern version of CUPL (Compiler for Universal Programmable Logic) originally written by a company called Assisted Technology, now owned by Altium. CUPL and peers like PALASM from Monolithic Memories, Inc. (MMI) and ABEL from Data I/O Corporation were basic Hardware Description Languages specifically designed for PALs, GALs, and CPLDs. PALs were small arrays of logic gates with fusible interconnections, and your design is “burned” into the fuses much like a (EE)PROM. When designing with PALs, you could clearly visualize the connections in your mind, something that has since been remedied by the advent of modern FPGAs.

Alas, he cuts out the part where the source code is compiled and the 22V10 is programmed, and jumps directly into testing the circuit on a breadboard. Spoiler alert — it does work. Zooming in close and squinting, the nifty 555 timer breadboard module that he points out is called a TP353, which you can find from your favorite online supplier.

There is a lot to learn in this tutorial, and the [IMSAI Guy] does a great job at making the subject approachable to hobbyists and novices. We also covered another of his tutorials a couple of weeks ago on image sensors. Thanks to [itsevilbert] for the tip.

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Totally Useless Coffee Dispenser Is Anything But

April 5, 2021 by Kristina Panos 15 Comments

Good coffee is nice to have, sure, but frankly, caffeine is caffeine and we’ll take it any way we can get it. That includes freeze-dried, if that’s all you’ve got. We won’t judge anyone for their taste in caffeinated beverages, and to call this coffee dispenser ‘totally useless’ is just patently untrue. It clearly has a use, and even if you don’t like freeze-dried coffee, you could sacrifice one jar worth of Nescafe and fill it with Skittles or anything else that will fit in the little collector basket.

In this machine, the cup is the trigger — the 3D-printed plate underneath activates a micro switch embedded in the scrap wood base, and this triggers a micro:bit around back to actuate the stepper motor that twirls the collector basket around. Although [smogdog] has provided all the files, you’d have to come up with your own connector to suspend the thing over the cup and carve your own base.

We love it when we can see what a machine is doing, so not only is it useful, it’s beautiful. And it worked, at least for a little while. For some reason, it keeps burning out stepper motors. Check it out in proof-of-concept action after the break.

We’ve seen the Micro:bit do a lot, and this pinball machine is among the most fun.

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TV Turned Automatic Etch A Sketch With Raspberry Pi

January 16, 2021 by Tom Nardi 5 Comments

Considering one of the biggest draws of the original Etch a Sketch was how simple it was, it’s always interesting to see the incredible lengths folks will go to recreate that low-tech experience with modern hardware. A perfect example is this giant wall mounted rendition of the iconic art toy created by [Ben Bernstein]. With a Raspberry Pi and some custom electronics onboard, it can even do its own drawing while you sit back and watch.

At a high level, what we’re seeing here is a standard Samsung LCD TV with a 3D printed Etch a Sketch shell mounted on top of it. That alone would be a pretty neat project, and had [Ben] just thrown some videos of designs getting sketched out onto the display, he could have achieved a similar end result with a lot less work. But where’s the fun in that?

It took hundreds of hours to print the shell.

To make his jumbo Etch a Sketch functional, [Ben] spent more than a year developing the hardware and software necessary to read the user input from the two large 3D printed knobs mounted under the TV. The knobs are connected to stepper motors with custom PCBs mounted to their backs that hold a A4988 driver chip as well as a AS5600 absolute magnetic rotary encoder. This solution allows the Raspberry Pi to not only read the rotation of the knobs when a person is using the Etch a Sketch interactively, but spin them realistically when the software takes over and starts doing an autonomous drawing.

Several Python scripts pull all the various pieces of hardware together and produce the final user interface. The software [Ben] wrote can take an image and generate paths that the Etch a Sketch can use to realistically draw it. The points that the line is to pass through, as well as variables that control knob rotation and pointer speed, are saved into a JSON file so they can easily be loaded later. Towards the end of the Imgur gallery [Ben] has created for this project, you can see the software working its way through a few example sketches.

We’ve seen several projects that motorize an Etch a Sketch to draw complex images, but this may be the first example we’ve seen where everything was done in software. This digital version doesn’t need to follow the traditional “rules”, but we appreciate that [Ben] stuck to them anyway. Incidentally this isn’t the first Etch a Sketch TV conversion to grace these pages, though to be fair, the other project took a radically different approach.

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Ten Robot Mechanisms For Your Design Toolbox

December 25, 2020 by Danie Conradie 10 Comments

The convergence of mechanics and electronics in robotics brings with it a lot of challenges. Thanks to 3D printing and low cost components, it’s possible to quickly and easily experiment with a variety of robotics mechanism for various use cases. [Paul Gould] has been doing exactly this, and is giving us a taste of ten designs he will be open sourcing in the near future. Video after the break.

Three of the designs are capstan mechanisms, with different motors and layouts, tested for [Paul]’s latest quadruped robot. Capstan mechanisms are a few centuries old, and were originally used on sailing ships to give the required mechanical advantage to tension large sails and hoist cargo.

Two of the mechanisms employ GUS Simpson Drives, which use a combination of belts and a rolling joint. These were inspired by the LIMS2-AMBIDEX developed at the University of Korea. The ever-popular cycloidal gearbox also makes and appearance in the form of a high torque dual disk linked, two stage, NEMA17 driven gearbox.

[Paul] also built a room sized skycam-like claw robot for his daughter, suspended by four ball chain strings reeled in by four brushless motors with ESP32 powered motor controllers. We are looking forward to having a close look at these designs when [Paul] releases them, and to see how his quadruped robot will turn out.

[Thanks TTN for the tip!]

Microstepping A PCB Motor

December 11, 2020 by Danie Conradie 24 Comments

Over the last 2 years [Carl Bujega] has made a name for himself with his PCB motor designs. His latest adventure is to turn it into a stepper motor by adding position control with microstepping.

The NEMA stepper motors most of us know are synchronous stepper motors, while [Carl]’s design is a permanent magnet design. It uses four coils on the stator, and two permanent magnets on the rotor/dial. By varying the current through each of the four poles with a stepper driver (microstepping), the position of the rotor should theoretically be controllable with good resolution. Unfortunately, this was easier said than done. He achieved position control, but it kept skipping steps in certain positions.

The motor and controller consist of a single flexible PCB, to reduce the layer spacing and increase the coils’ magnetic field strength. However, this created other problems, since the motor shaft didn’t have a solid mounting point, and the PCB flexed as the stator coils were energized. Soldering the controller was also a problem, as the through-hole headers ripped out easily and the PCB bulged while reflowing on a hot plate, in one case even popping off components. [Carl] eventually mounted one of the PCB motors inside a 3D printed frame to rigidly constrain all the motor components, but it still suffered from missed steps. Any suggestions for fixing the problem? Drop them in the comments below.

Like his other PCB motors, the torque is very low, but should be suitable for gauges or clocks. A PCB clock with an integrated motor would be pretty cool to have on the workshop wall.

The TMC2300 stepper driver [Carl] used belongs to the same family of drivers that enable silent stepping for 3D printers. We’ve covered a few of [Carl]’s PCB actuator adventures, from his original design to linear actuators and a flexible POV display.

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Reduce, Reuse, Injection Mold

November 21, 2020 by Al Williams 34 Comments

Many people have the means now to create little plastic objects thanks to 3D printing. However, injection molding is far less common. Another uncommon tech is plastic recycling, although we do occasionally see people converting waste plastic into filament. [Manuel] wants to solve both of those problems and created an injection molder specifically for recycling.

The machine — Smart Injector — is automated thanks to an Arduino. It’s pretty complex mechanically, so in addition to CAD models there are several PDF guides and a ton of pictures showing how it all goes together.

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Cryptic Calendar Makes For A Useful Wall Ornament

October 30, 2020 by Lewin Day 7 Comments

Hackers love a good clock build, but its longer term cousin, the calendar, is more seldom seen in the wild. Regardless, they can be just as useful and elegant a project, as this cryptic design from [Wolfspaw] demonstrates.

The project consists of a series of rotating wheels, displaying a series of arcane symbols. When the markings on the wheel align correctly with the viewing window, they display the date, month, and day of the week, respectively. The wheels themselves are fitted with 3D printed gear rings, which are turned by stepper motors under the control of an Arduino Nano. Hall effect sensors and magnets are used to keep everything appropriately aligned, while a DS3231 real time clock handles timekeeping duties.

It’s a tidy build, and we think the cryptic design adds a little mystery, making this an excellent conversation piece. The build is actually a remix of a project we’ve featured before, scaled and given a unique twist to suit [Wolfspaw]’s own personal aesthetic. Video after the break.

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