Bigfoot Turns Classic Sewing Machine Into A Leather-Eating Monster

If you try to sew leather on a standard consumer-grade machine, more often than not you’ll quickly learn its limits. Most machines are built for speed, and trying to get them to punch through heavy material at the low motor speeds often needed for leather work is a lesson in frustration.

How frustrating? Enough so that [Joseph Eoff] expended considerable effort to create this sewing machine speed controller for his nearly century-old Adler sewing machine. The machine was once powered by a foot treadle, which is probably why the project is dubbed “Bigfoot,” but now uses a 230 V universal motor. Such motors don’t deliver much torque when run at low speeds with the standard foot-pedal rheostat control, so [Joseph] worked up an Arduino-based controller with a tachometer for feedback and a high-power PWM driver for the motor.

There are a ton of details in [Joseph]’s post and even more in the original blog article, which is well worth a read, but a couple really stand out. The first is with the tachometer, which uses an off-the-shelf photointerrupter and slotted disc. [Joseph] was displeased with the sensor’s asymmetrical and unreliable output, so he made some modifications to the onboard comparator to square up the signal. Also interesting is the PID loop auto-tuning function he programmed into Bigfoot; press a button and the controller automatically ramps the motor speed up and down and stores the coefficients in memory. Nice!

The short video below shows Bigfoot in action with varying thicknesses of faux leather; there are also some clips in the original article that show the machine dealing with a triple thickness of leather at slow speed and not even breaking a sweat. Hats off to [Joseph] on a solid build that keeps a classic machine in the game. And if you want to get into the textile arts but don’t know where to start, we’ve got you covered.

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Jet Engine Tachometer Turned Into Unique CPU Utilization Meter

When you’ve got a piece of interesting old aviation hardware on your desk, what do you do with it? If you’re not willing to relegate it to paperweight status, your only real choice is to tear it down to see what makes it tick. And if you’re lucky, you’ll be able to put it to work based on what you learned.

That’s what happened when [Glen Akins] came across a tachometer for a jet airplane, which he promptly turned into a unique CPU utilization gauge for his computer. Much of the write-up is concerned with probing the instrument’s innards to learn its secrets, although it was clear from the outset that his tachometer, from Kollsman Instruments, was electrically driven. [Glen]’s investigation revealed a 3-phase synchronous motor inside the tach. The motor drives a permanent magnet, which spins inside a copper cup attached to the needle on the tach’s face. Eddy currents induced in the cup by the spinning magnet create a torque that turns the needle against the force of a hairspring. Pretty simple — but how to put the instrument to work?

[Glen]’s solution was to build what amounts to a variable frequency drive (VFD). His power supply is based on techniques he used to explore aircraft synchros, which we covered a while back. The drive uses a trio of MCP4802 8-bit DACs to generate three phase-shifted sine waves via direct digital synthesis with an RP2040. The 3-phase signal drives the motor and spins the dial, with 84-Hz corresponding to full-scale deflection.

The video below shows the resulting CPU utilization gauge — which just queries for the current load level and sends it to the RP2040 over serial — in action. It’s not exactly responsive to rapid changes, but that’s to be expected from a mechanical system. And compared to exploring such a nice instrument, it really doesn’t matter.

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More Drill Press Mods: Adding A VFD Means No More Belt Changes

A decent drill press is an essential machine tool for almost any kind of shop, and marks a significant step up in precision compared to a hand drill. The ability to drill square, true holes is one thing, but the added power over what’s possible with a portable tool is the real game changer. If only you didn’t have to switch around those damn belts to change speeds, though.

You don’t, of course, if you go through the effort to add a variable frequency drive to your drill press like [Midwest Cyberpunk] did, along with some other cool mods. The donor tool for these mods came from — where else? — Harbor Freight. Some will quibble with that choice, but the tool was pretty cheap, and really all [Midwest] was interested in here was some decent castings and a quill with acceptable runout, since the entire power train of the tool was slated for replacement. The original motor gave way to a beefy Baldor 3-phase/240-volt motor controlled by a VFD mounted on a bracket to the left of the drill press head, allowing the stock belt and step pulley transmission to be greatly simplified. Continue reading “More Drill Press Mods: Adding A VFD Means No More Belt Changes”

Drill press modded with a treadmill motor, speed controller, lights, and a tachometer.

Drill Press Runs Faster On A Treadmill Motor

Are you tired of the same old video style from your favorite content creators? We can’t say that we were, exactly. But nevertheless, we appreciate this creative departure from [Eric Strebel]’s regular fare as he soups up his drill press with an old treadmill motor and a few extra features.

First off, that commentator in the video is right — 2.6 horsepower is a crazy amount for a drill press. Fortunately, [Eric] also added a variable speed controller and a digital tachometer to keep things in check. As an added bonus, he no longer has to get under the hood and mess with the belts.

We like what [Eric] brings to the drill press motor mod, which is already well-documented on YouTube. We love the re-use of an office chair bracket as a new motor mount. It’s probably our favorite bit aside from the 2-color forward/reverse switch plate idea: print it in whatever letter color you want with proud lettering, paint the whole thing black, and sand off the letters so the color shows. Check it out after the break.

There are many ways to make your own drill press, and one of the easiest is to mount a hand drill.

Did you miss the Industrial Design Hack Chat with [Eric]? It’s okay, you can read the transcript over on IO.

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TinyTacho: Rotational Speed Measurement Without The Bulk

An electronic tachometer is a straightforward enough device, in which the light reflections from a white spot on a rotating object are detected and counted over time, measuring the revolutions per minute (RPM). It’s a technique that has its roots in analogue electronics where the resulting pulses would have fed a charge pump, and it’s a task well suited to a microcontroller that simply counts them. But do you need an all-singing, all-dancing chip to do the job? [Stefan Wagner] has done it with a humble ATtiny13.

His TinyTacho is a small PCB with an IR LED and photodiode on one end, a small OLED display on its front, and a coin cell holder on its rear. The electronics may be extremely simple, but there’s still quite some effort to get it within the ATtiny’s meagre resources. Counting the revolutions is easy enough, but the chip has no I2C interface of its own and some bitbanging code is required. You can find all the design files and software you need in a GitHub repository, and he’s put up a video of the device in action that you can see below the break.

Tachometers are a popular project hereabouts, and we’ve featured a lot of them over the years. Perhaps the best place to direct readers then is not to another project, but to how to use a tachometer.

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The Swiss Army Knife Of Bench Tools

[splat238] had a ton of spare sensors laying around that he had either bought for a separate project or on an impulse buy, so he knew he had to do something with them. He decided to build his own digital multi-tool focusing on sensors that would be particularly useful in a workshop setting. Coincidentally, he was inspired by a previous hack that we covered a while back.

He’s equipped his device with a bubble level, tachometer, IR thermometer, protractor, laser pointer, and many, many more features that would make great additions to any hacker’s workspace. There’s a good summary of each sensor, making his Instructable somewhat of a quick guide to common sensing modalities for hardware designers. The tachometer, thermometer, laser pointer, and a few other capabilities are notable upgrades from the project we highlighted previously. We also appreciate the bigger display, allowing for more detailed user feedback particularly in using the compass and bullseye digital level among other features.

The number of components in [splat238’s] build is too extensive to detail one-by-one in this article, so please see his Instructable linked above for all the details. [splat238] made his own PCB for mounting each sensor and did a good job making the design modular so you wouldn’t need to add certain components if you don’t need them. Most of the components take some through-hole soldering with only a handful of 0805 resistors required otherwise. The housing was designed such that the user can handle the tool with one hand and can switch between each function with a push of a button.

Finally, the device is powered using a rechargeable lithium-polymer battery making it very reusable. And, if there weren’t enough features already, the battery can be charged via USB or through two solar panels mounted into the housing unit. Okay, solar charging might be a case of featuritis, but still a cool build either way.

Check out some other handy DIY tools on Hackaday.

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Steampunk Brushless Motor Demo Pushes All The Maker Buttons

We’ll be honest right up front: there’s nothing new in [David Cambridge]’s brushless motor and controller build. If you’re looking for earth-shattering innovation, you’d best look elsewhere. But if you enjoy an aimless use of just about every technique and material in the hacker’s toolkit employed with extreme craftsmanship, then this might be for you. And Nixies — he’s got Nixies in there too.

[David]’s build started out as a personal exploration of brushless motors and how they work. Some 3D-printed parts, a single coil of wire, and a magnetic reed switch resulted in a simple pulse motor that performed surprisingly well. This morphed into a six-coil motor with Hall-effect sensors and a homebrew controller. This is where [David] pulled out all the stops on tools — a lathe, a plasma cutter, a welder, a milling machine, and a nice selection of woodworking tools went into making parts for the final motor as well as an enclosure for the project. And because he hadn’t checked off quite all the boxes yet, [David] decided to use the 3D-printed frame as a pattern for casting one from aluminum.

The finished motor, with a redesigned rotor to deal better with eddy currents, joined the wood and metal enclosure along with a Nixie tube tachometer and etched brass control plates. It’s a great look for a project that’s clearly a labor of self-edification and skill-building, and we love it. We’ve seen other BLDC demonstrators before, but few that look as good as this one does.

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