Quartet of SMD Resistors Used to Sense Z-Axis Height

Here’s a neat trick for your next 3D-printer build or retrofit: a Z-axis sensor using a DIY strain gauge made from SMD resistors. We’re betting it could have plenty of other applications, too.

Conventional load cells, at least the ones you can pick up cheaply from the usual sources or harvest from old kitchen or bathroom scales, are usually way too big to be used on the extruder of a 3D-printer. [IvDm] wanted to build a touch sensor for his Hybercube printer, so he built his own load cell to do it. It consists of four 1000 ohm SMD resistors in the big 2512 device size. He mounted them to an X-shaped PCB and wired them in the classic Wheatstone bridge configuration, with two resistors on one side of the board and two on the other.

The extruder mounts into a hole in the center of the board and floats on it. Through an HX711 load cell driver chip, the bridge senses the slight flex of the board when the extruder bottoms out on the bed, and an ATtiny85 pulls a limit switch input to ground. [IvDm] even did some repeatability testing with this sensor and it turned out to be surprisingly consistent. The first minute or so of the video below shows it in action on the Hypercube.

We found the use of SMD resistors as strain gauges pretty clever here, but there’s plenty to do with off-the-shelf load cells: measuring how much filament is left on a roll, checking the thrust of a model rocket engine, or even figuring out if you’re peeing correctly.

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Move Aside Mercury: Measuring Temperature Accurately with an RTD

Temperature is one of the most frequently measured physical quantities, and features prominently in many of our projects, from weather stations to 3D printers. Most commonly we’ll see thermistors, thermocouples, infrared sensors, or a dedicated IC used to measure temperature. It’s even possible to use only an ordinary diode, leading to some interesting techniques.

Often we only need to know the temperature within a degree Celsius or two, and any of these tools are fine. Until fairly recently, when we needed to know the temperature precisely, reliably, and over a wide range we used mercury thermometers. The devices themselves were marvels of instrumentation, but mercury is a hazardous substance, and since 2011 NIST will no longer calibrate mercury thermometers.

A typical Pt100 RTD probe

Luckily, resistance temperature detectors (RTDs) are an excellent alternative. These usually consist of very thin wires of pure platinum, and are identified by their resistance at 0 °C. For example, a Pt100 RTD has a resistance of 100 Ω at 0 °C.

An accuracy of +/- 0.15 °C at 0 °C is typical, but accuracies down to +/- 0.03 °C are available. The functional temperature range is typically quite high, with -70 °C to 200 °C being common, with some specialized probes working well over 900 °C.

It’s not uncommon for the lead wires on these probes to be a meter or more in length, and this can be a significant source of error. To account for this, you will see that RTD probes are sold in two, three, and four wire configurations. Two-wire configurations do not account for lead wire resistance, three-wire probes account for lead resistance but assume all lead wires have the same resistance, and four-wire configurations are most effective at eliminating this error.

In this article we’ll be using a 3-wire probe as it’s a good balance between cost, space, and accuracy. I found this detailed treatment of the differences between probe types useful in making this decision.

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Assess Your Output with a Cheap DIY Urine Flowmeter

Some things about the human body are trivial to measure. Height, weight, blood pressure, pulse, temperature — these are all easily quantifiable with the simplest of instruments and can provide valuable insights into our state of health. Electrical activity in the heart and the brain can be captured with more complex instruments, too, and all manner of scopes can be inserted into various orifices to obtain actionable information about what’s going on.

But what about, err, going? Urine flow can be an important leading indicator for a host of diseases and conditions, but it generally relies on subjective reports from the patient. Is there a way to objectively measure how well urine is flowing? Of course there is.

The goal for [GreenEyedExplorer]’s simple uroflowmeter is simple: provide a cheap, easy to use instrument that any patient can use to quantify the rate of urine flow while voiding. Now, we know what you’re thinking — isn’t liquid flow usually measured in a closed system with a paddlewheel or something extending into the stream? Wouldn’t such a device for urine flow either be invasive or messy, or both? Rest assured, this technique is simple and tidy. A small load cell is attached to an ESP8266 through an HX711 load cell amp. A small pan on the load cell receives urine while voiding, and the force of the urine striking the pan is assessed by the software. Reports can be printed to share with your doctor, and records are kept to see how flow changes over time.

All kidding aside, this could be an important diagnostic tool, and at 10€ to build, it empowers anyone to take charge of their health. And since [GreenEyedExplorer] is actually a urologist, we’re taking this one seriously.

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Hackaday Prize Entry: OrthoSense, a Smart Knee Brace for Physical Therapy

If you have knee surgery, you can probably count on some physical therapy to go with it. But one thing you might not be able to count on is getting enough attention from your therapist. This was the case with [Vignesh]’s mother, who suffers from osteoarthritis (OA). Her physiotherapist kept a busy schedule and couldn’t see her very often, leaving her to wonder at her rehabilitation progress.

[Vignesh] already had a longstanding interest in bio-engineering and wearables. His mother’s experience led him down a rabbit hole of research about the particulars of OA rehabilitation. He found that less than 35% of patients adhere to the home regimen they were given. While there are a lot of factors at play, the lack of feedback and reinforcement are key components. [Vignesh] sought to develop a simple system for patients and therapists to share information.

The fruit of this labor is Orthosense, an intelligent knee brace system that measures gait angle, joint acoustics, and joint strain.  The user puts on the brace, pairs it with a device, and goes through their therapy routine. Sensors embedded in the brace upload their data to the cloud over Bluetooth.

Joint strain is measured by a narrow strip of conductive fabric running down the length of the knee. As the user does their exercises, the fabric stretches and relaxes, changing resistances all the while. The changes are measured against a Wheatstone bridge voltage divider. The knee’s gait angle is measured with an IMU and is calculated relative to the hip angle—this gives a reference point for the data collected by the strain sensor. An electret mic and a sensitive contact mic built for body sounds picks up all the pops and squeaks emitted by the knee. Analysis of this data provides insight into the condition of the cartilage and bones that make up the joint. As you might imagine, unhealthy cartilage is noisier than healthy cartilage.

[Vignesh]’s prototype is based the tinyTILE because of the onboard IMU, ADC, and Bluetooth. Since all things Curie are being discontinued, the next version will either use something nRF52832 or a BC127 module and a la carte sensors. [Vignesh] envisions a lot for this system, and we are nodding our heads to all of it.

Crossing Wheatstone Bridges

The Wheatstone bridge is a way of measuring resistance with great accuracy and despite having been invented over 150 years ago, it still finds plenty of use today. Even searching for it on Hackaday brings up its use in a number of hacks. It’s a fundamental experimental device, and you should know about it.

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Automatic Resistance: Resistors Controlled by the Environment

Resistors are one of the fundamental components used in electronic circuits. They do one thing: resist the flow of electrical current. There is more than one way to skin a cat, and there is more than one way for a resistor to work. In previous articles I talked about fixed value resistors as well as variable resistors.

There is one other major group of variable resistors which I didn’t get into: resistors which change value without human intervention. These change by environmental means: temperature, voltage, light, magnetic fields and physical strain. They’re commonly used for automation and without them our lives would be very different.

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Cheap Torque Sensor Goes Back to Basics on Strain Gauges

Sooner or later, we’ve all got to deal with torque measurement. Most of us will never need to go beyond the satisfying click of a micrometer-style torque wrench or the grating buzz of a cordless drill-driver as the clutch releases. But at some point you may actually need to measure torque, in which case this guide to torque sensors might be just the thing.

[Taylor Schweizer]’s four-part series on torque is pretty comprehensive. The link above is to the actual build of his DIY torque transducer, but the preceding three installments are well worth the read too. [Taylor] describes himself as an e-waste connoisseur and tantalizes us with the possibility that his build will be with salvaged parts, but in the end a $20 bag of strain gauges and an LM358 were the quickest way to his proof of concept. The strain gauges were super-glued to a socket extension, hot glue was liberally applied for insulation and strain relief, and the whole thing wired up to a Teensy for data capture. A quick script and dump of the data to Excel and you’ve got a way to visualize torque.

An LCD display for real-time measurements is in the works, as are improvements to the instrumentation amp – for which [Taylor] might want to refer to [Bil Herd]’s or [Brandon Dunson]’s recent posts on the subject.

[via r/arduino]