A die, proper

Written by smackaay on April 30, 2011 Categories: Work Tags: ,

Well, it’s been some time since I’ve made a die. This is a relatively simple one for a customer. I had some problems with alignment and some mixed up number on my part, but it seems to work adequately. As always, some pics…

So, here is the unpunched pin.

The pin, un-flattened

The pin, un-flattened

And here it is flattened… all while maintaining the angular alignment of the reed and guard.

The pin punched flat

The pin punched flat

initially it was a pain because the material would mash in between the guard and the plate but I solved that. Here are some more pics anyways…

The die open

The die open

The die coming closed on the plate

The die coming closed on the plate

Valve reed and guard in the pockets

Valve reed and guard in the pockets

Well, there ya go. Fun fun.

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From start to finish, a cutter.

Written by smackaay on April 26, 2011 Categories: Work

We had to build a certain cutter for a customer and I figured it’d be neat to document the drawing and then the finished product. This is a cutter I designed and I think it turned out nice.

Conception of the cutter

Conception of the cutter

And here’s some pics of the finished result.

From the side

From the side

Overview of the cutter

Overview of the cutter

Insert Installed

Insert Installed

Anyways, nothing spectacular, but I like to document these kinds of things. :)

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The new lab, again and a fish light controller

Written by smackaay on April 16, 2011 Categories: Electronics, Personal Projects Tags: , ,

Nothing special in todays update but I figured I’d post a few things for the fun of it. First off I guess is my lab. I’ve been using it for a month or so. A little small, but at least it’s not at work.

New lab as of April 2011

Nothing to write home about I guess, but I feel comfortable here! Anyways, my little project for the day is the fish light. My bulb burnt out in my fish tank and since it was a high UV one I’ve decide to make an LED version. Since I have an array of LED’s I decided to go with some Whit, UV and a few red ones for good measure (I don’t like blue LEDs).

LEDs!!!

LEDs!!!

And here’s the breadboard, messy!

LEDs!!!

the LED driver on the breadboard

The LED’s are driven on 4 channels with PWM output on separate channels. The idea for me is to provide an on-timer for the cycles through the day and to provide a source of UV light for the plants. The diodes are driven by 4 TIP117′s so that each channel (White, UV, Red) can be controlled individually based on whatever profile I want.

Unfortunately I’ve discovered that the number of LED’s that I used is insufficient for use in the tank, not enough light. So I’ve ordered over 500 white LED’s and 150 UV led’s and 100 Red LED’s. I won’t use them all but it’s always good to have LED’s. One issue may be driving all of these LED’s. I have a maximum output of 1A on each of the PNP TIP117′s so an output of about 14W is all I can produce. Hopefully that’ll be enough!

Again LED Array

Again, the LED Array

Anyways, here’s hopin’!

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The magic of EDM machines

Written by smackaay on April 8, 2011 Categories: Miscellaneous, Work Tags: , ,

The other day we were asked to remove a section out of a valve. It’s not a huge valve but milling it would’ve been difficult all the way to the center so we put it on the EDM to blast out the side to make the inside visible. through to the stuff on the inside. Here are the images.

another view

another view

EDMing of valve looking from the top

And a view from the top. gotta love the clean edges with the rough gritty surface.

EDMing of valve looking from the side

Here's a look at it from the side

This was all burned at 150 amps which is max for this machine.

A look as it was being burned, not much to see

Nothing crazy interesting, but I thought it may be neat.

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The underrated PIC10F200 (and 202/204/206 as well)

Written by smackaay on April 4, 2011 Categories: Electronics Tags: , , ,

Sitting around looking through my collection of parts during a brief stint of illness I came across my stash of 30 or so PIC10F200′s. These were my entry into the world of microcontrollers. Granted I wasn’t very good at electronics (and probably still not very good) and I found the lowest end microcontroller i could in order to understand them on a more fundamental basis. I found all of the peripherals on other microcontrollers to be a distraction and complicating factor from what I wanted to learn.

batch of 10f200's

My little batch if PIC10F200's, I got more in tubes

Nowadays, delving into 32bit architectures and whatnot, I’ve forgotten about the little MCU’s. Thinking about it they’re still incredibly useful in a myriad of circumstances. Only costing 59 cents or 30 cents at volume, and running at 4Mhz internally these have an amazing range of uses.

Consider the lowest end of the low end, the 10F200. Now it only has 256 words (12-bit wide instructions) and 16 bytes of RAM. It has 3 I/O and one input only pin. Now in a world of Arduinos and large pin count microcontrollers running at 40+Mhz , it may seem like this thing has no use but I beg to differ.

Today I was tinkering around with the little unit today and I was recalling some of the things I imagined I could do with the limited hardware. So today I wanted to see how well it could produce sound. Now this little thing is trivial for most MCU’s, simply output an appropriate square wave. My goal though was to produce a warble and program it in a C compiler. This was very easy and achievable.

The little sound circuit

The little sound circuit I was working on... using a LM2904 for amplification.

Now, granted, it’s not a very complicated circuit, but I found it to work admirably. The compiled code took up only 36% of the ROM and 38% of the RAM. That’s with 2 16 bit counters and an 8 bit function variable. it also used delay functions. Of interest to note though, I tried using floats, no go, the libraries filled up the ROM like boom!

Anyways, here are some used I dreamed up for the PIC10F200 over the years. They are mostly in support roles but I think they’re equally as useful as any other role within a project, especially given the MCU’s small footprint and low price. The applications I’ve thought up are as follows, keep in mind we only have 3 IO and one input.

  • A dice game: I actually created a prototype of this some time ago based on the idea that this would be my business card. It was simply a set of multiplexed LED’s (six in total) on a PCB that would show like the face of a dotted die. one input was used and the other three were for the IO. Bringing the IO to an input mode would turn off the leds.
  • Two button debouncing: Using a microcontroller for debouncing has been my favorite way to debounce inputs on a button. By using an internal count on the MCU you can simulate a charging/discharging capacitor and provide threshold values to simulate a ‘dead zone’
  • A little robot: Using the two output for motor control and the two inputs for sensing, you could potentially make a simply robot. the only problem with it may be the limited ROM for logic routines, but I suppose that’s the challenge.
  • Timer Lamp: The 10f200 has just enough IO for two buttons and two outputs (I = On/off, I=Timer function, O= LED out, O=Relay for lamp). my old project with a timer lamp was done with a PIC16F505 (a limited MCU in its own right) but the 10F200 would’ve done the job quite admirably.
  • Dimmers on AC lamps: This example is used by microchip extensively to promote the device, it is one of the many uses of this device.
  • Sound generation: Like I did today, it seems like a pretty worthwile use of the chip. Cheap and easy. small size also helps with the surface mount varieties.
  • One-wire wake up: You could use it as a separate node to watch a data line for signalling on the one-wire protocol. I have used this to fire up LED’s in a specified pattern and duration. With the SOP package tou can solder it directly to the LED and data line in a bizzaro single package.

Anyways, the uses are endless for such a limited but inexpensive device. I have no idea why such a limited device captivates my imagination but perhaps it’s the small size that makes it interesting and uncomplicated design and use.

So, for your troubles of reading a wall of text. Here’s a neat photo of an old diode for your perusal.

Neat picture of a diode

A bonus picture of an old school diode. Gotta love the little spring inside holding the junction together.

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Little LCD tester

Written by smackaay on April 2, 2011 Categories: Electronics Tags: , , ,

Well, after some playing around and getting my electronics feet back, I’ve finally rediscovered some passion. This little project is something I’ve wanted to do for quite some time. Basically it’s an HD44780 LCD tester. A very simple device but if you’re like me, when you receive an LCD in the mail, you want to be able to see the device in it’s glory.

The board inside the LCD tester

The board inside the LCD tester

I just made it with a PIC16F690 MCU and some random components. The output is of course the LCD but also two LEDs. The unit has provisions for the backlight though it’s just straight 5v out, you have to worry about resistances when you hook it up.

The button on the back of the unit basically prints extra 20 character long strings so you can see how the memory is addressed and see how things scroll over in printing.

Anyways, here are pics:

Finished unit from the back

Finished unit from the back. 5v barrel connector and a toggle switch for power

The unit from the front

The unit from the front. just the LEDs and the pinouts. Also note the knob on the top for the pot. that's for adjusting contrast.

The text out

The text out. this one on a 2004 lcd

Well, there we go. This will be a handy little device for testing whether any of them are any good.

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Cheap chinese digital calipers and you

Written by smackaay on March 28, 2011 Categories: Electronics Tags: , , , ,

Some time ago I bought a bunch of cheap Chinese digital calipers and I was surprised to find that there is a port on almost all of them out the top. Now having looked up the format for both Starrett and Mitutoyo SPC formats, I have determined that it matches neither.

A cheap chinese vernierThis one happens to be a Mastercraft one but you can buy one off Ebay for like 8 bucks delivered. You can see the connector is already installed with solder onto the first three pins.

the pinout is as follows, from left to right looking at the face:

  1. Ground
  2. Data
  3. Clock
  4. +1.5v (or whatever the battery happens to be)

Here’s a bit of a closeup:

A look at the pinouts

A look at the pinouts, hastily soldered.

So I hooked it up to my oscilloscope and determined that there is both a data line and a clock. Here are the specs:

  • Data is sent in a packet of 6 nybbles.
  • Data is sent every 100ms
  • Data is LSB first
  • The numbers only seem to represent what’s on the screen. It represents units of the smallest graduation in the current display mode (inch/mm). For example, if values are converted to decimal: 1.5055″ = 3011 units or 3.45mm = 345 units
virgin saleae logic

A look at my virgin Saleae logic analyser

And yes, I bought a Saleae Logic Analyser. Unfortunately it does not support synchronous serial analysis. This would’ve been a great tool, had the software supported it.

Anyways, I tried to get the output to work on the logic analyser but the signal was really spotty. I determined it was because it only output 1.5v. I quickly whipped up a breadboarded circuit with a 7014D op-amp setup like a comparator to amplify the singal to 5V

the board to amplify signals

the board to amplify signals

Simple simple. This allowed me to run the signal onto my logic analyzer. It worked great except for the software not being able to decode the data. Wasn’t an issue though, I decoded it mentally.

Anyways, I hope this is useful to somebody. I can’t guarantee anything is correct but these device might make for interesting low-cost DRO units or something. There are some caveats however:

  • The cheap verniers are exactly that, cheap!
  • They don’t handle any kind of moisture, even a humid day is enough to screw them up.
  • The update rate is a paltry 10Hz
  • You can’t trigger the output when you want to, unlike SPC outputs of other manufacturers.
  • Battery life sucks
  • You can’t feed higher voltages to the battery compartment, no likey!

Again, hope this was helpful to somebody out there on the interwebs.

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A look at a small solar panel set.

Written by smackaay on March 8, 2011 Categories: Electronics Tags: , , ,

A while back I had found a bunch of little solar cells on Ebay for cheap. I hadn’t really looked at them or tested them in any real way but today I wanted to see if they could power even a small project. As it turns out, I would require a great number of them in order to make even an LED light up (Assuming no capacitor or storage device). Since the sun was going down, I needed a constant source of light so I used my desk lamp. Here are the comparisons.

Solar cell

The individual solar cell

Those are the units I bought. I think I got like 30 for $10 or something. relatively cheap, but not really. I was expecting some decent performance, which I got, but not nearly as much as I expected.

This is the competitor. It’s the old Archer 6-12V solar cell pack. It’s quite old (25 years), the lens is dirty but it still works quite well.

Archer Solar Panel

The old Archer solar panel

And here is the test cell/array that I soldered together.

Solar panels together

The solar cells soldered in a group of 4

Now, keep in mind that this was all done with a desk lamp. I maintained a certain distance from the bulb and only used the maximum measurement received by moving the panel around. Also given are comparitive measurements for the overall visible area exposed to light.

Old Archer Panel Cheapy EBay panel
Measured Voltage 5.245V .162V
Measured Amperage 305 uA 628 uA
Calculated Watts 1.6 mW .1 mW
Measured Area 14.05 Sq.in. 1.6524 Sq.in.
Cell Sizes .788in x .563in 1.063in x .433in
mW per Sq.in. .113mW per sq.in .06 mW per sq.in

That all being said,you could still run quite a few little things at that low current rating if you were to link together all of the cells for whatever reason. unfortunately, nothing that I want to do could use them. So the lesson for the day is “Quality over Quantity”

Also, as an aside, here’s my new Agilent U1271A multimeter. Works like a dream!!!

Agilent u1271A

My new Agilent u1271A, yay!

Perhaps tomorrow or someday I’ll give figures for sunlit voltages/amperages.

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Happy 2011! uuh, I guess a bit late though.

Written by smackaay on March 3, 2011 Categories: Electronics, Personal Projects, Programming, Work Tags: , , , , , ,

It’s been well over two months since I last posted. Frankly, not a lot has happened in the meantime anyways. Work is going well and life is pretty good. That said, I’ve begun to regain my inspiration for electronics again and I’ve been going hog wild building stuff in the evenings. Just some stuff to touch on I guess…

My Lab

Well, again I have a secluded labratory in the shop I work at. It consists of 2 desks, two shelves and all of my equipment. It’s nice to hang around and listen to music and stuff while having access to all of the manufacturing facilities I could ask for!

Here’s a picture of my lab as I was setting it up.

The new lab as of 2011

The new lab as of 2011, this is an early picture. there is more equipment, parts and shelves now

It’s a real treat here and I’ve been sitting up here for many hours on my projects lately. Yay!

A veroboard planner PDF

Not really a project per say, however, somebody might want it. It’s for printed pcbs from PCBIran which have a ground loop on the outside and sets of rows and columns. Somebody may find it useful. I dunno.

BOARD PLANNER 01

The Shop

The shop I’m at is investing in new technology (IE. CNC mill and CNC Ram EDM) and I figured it’d be neat to take an overview picture. Sure is crowded though. :) The mill, as was stated earlier, is a Haas VF-5 with a 40 taper and the Machine is a large CHMER EDM, more on that thing later in the post

Shop Growing

The shop I work at is growing, but not in floor space. :)

It’s actually much tidier now, this is when we were installing the EDM.

Rotary Table and CHMER EDM

I am developing a rotary table interface for the CHMER Ram EDM. The fools at CHMER decided that the machine requires NO extra M-codes for interfacing to external hardware… WHY!!!??!?

So now I have to monitor the outrush current of the pump, turn it on and off a prescribed number of times and then the rotary table can index. I’m still kind of in shock that nobody has ever presented CHMER with this problem. Weird!

The TI Launchpad

I have just ordered the TI launchpad for $4.60 or whatever it cost. TI is attempting to break into the hobbyist market something fierce. unfortunately, after looking at the development tools available, they are all way overpriced.

While they do provide a code-size limited version, which is useful for most things, I think people like to have unfettered access to their chips and what kind they use from a particular vendor. When the development tools that allow this are in the $500 range, that’s simply too much.

Perhaps there will be some good 3rd party support like Atmel and Microchip has and they can really take their MCU’s to the next level. It’d be very cool. :)

The Rest

Well, there is probably still more to say after such a long hiatus but I can’t think of it now. I do have some other ideas banging around in my head like a new design of the coolant refractometer which won’t foul. A robot that is machined beautifully and function on sonar. And a new coolant nozzle design that will kick Spider Cool’s ass from here to main street (I’m actually pretty stoked about this one).

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The new Haas Mill Features

Written by smackaay on December 22, 2010 Categories: Programming, Work Tags: , ,

The company I work for has recently purchased a Haas VF-5 40 taper machine to augment the capabilities of the shop. Seeing as they didn’t have one before, this will greatly improve the capabilities of the shop.

The item of interest to me is the fact that it’s brand new and Haas has made a number of changes to their CNC mill line. Aside from their new higher contrast 2-tone paint job and sharper featured shrouding, here are some interesting changes that they’ve made. This may not be new to some people but if you haven’t used a haas made in the last 4 years or so, this may be of interest.

The Control

Haas Control 2010

The new haas control

Nothing amazing about this control aside from the fact that the screen has a lot more info packed on the screen. Selecting one of the screen buttons toggles between the panels rather than actually displaying a different screen. None of the buttons have changed their functionality otherwise. I do find the screen switchovers to be a bit laggy and difficult to read at a distance but it is otherwise OK. Also Probong has a much more integrated setup than in previous versions whereby you can offset tooling from the tooling screen.

The Jog Pendant

Haas Pendant

The Haas Jog Pendant now has an LCD screen and greater functionality

Like the image says, the pendant now has an LCD screen. It also features two sets of dials and a toggle lever for axis slelection rather than the rotary switch allowing you to use it without looking too much at the labels.

The larger dial on the face is an analog dial that allows jogging at various speeds and goes about a quater turn left and right that springs back. the smaller one serves the original purpose of increment jogging. Increments are chosen on the screen rather than on a dial.

Also, things like current program, offsets, and various other minutia can be displayed.

Haas Jog Pendant LCD

The Screen on the Haas Pendant

There are is a problem though. That being the noticable lag from the pulse encoder to motion occuring on the machine. Often times when you want to move there is a considerable time difference from when you turn either the analog wheel or the pulse encoder. Also when you use the pulse encoder at a high rate, it skips many of the ticks or gets “jumpy”. the motion is not smooth.

Overall though the functionality is greatly enhanced.

The rest of the machine

Here are some of the other changes I’ve noticed.

  • Quieter Spindle
  • Different Coolant arrangement
  • Different design on the programmable coolant
  • Larger casting
  • Side window locks
  • an additional set of shelves on the side with a light
  • Power saving settings
  • Different Shrouding and duo-tone paint.
  • Removal of coolant tray around table
  • Shrouding around chip spigot
  • Raised handlebars for moving coolant tray

There are probably more changes than are what is listed here. Here are some pictures of the machine

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Inside of a Yukiwa Rotary Table Control… and WTF!

Written by smackaay on December 2, 2010 Categories: Work

So today I we got the power going to a brand new Yukiwa rotary table, unfortunately, it seems to produce dangerous voltages on the case of the actual rotary table itself… dunno why.

Anyways, if anyone’s interested in seeing the innards of the device, here’s some pics.

Unit and rotary table in behind

Inside of the AC3 unit

By the way, this is one of the most beautifully made rotary tables I’ve ever seen.

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The finished result of an old project

Written by smackaay on November 29, 2010 Categories: Electronics

A bout a year or so back I had designed an enclosure for a friend of mine. You can see the object here on an old blog post of mine. I’ve forgotten to take pictures of it for some time and when I visited him I decided to take a couple for documentation’s sake.

Here they are:

From the back of the enclosure

From the back of the enclosure

Top of the enclosure

A look at the top of the enclosure

Of course, it wasn’t me who did the electronics work inside. You can see the site of the person who did do this at http://s2innovations.com/. It’s a pretty nifty device I must say.

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