Ed – Page 233 – The Smell of Molten Projects in the Morning

DRV8825 Stepper Driver: Adding a Home Output

The DRV8825 stepper driver chip has a -Home output going active during the (micro)step corresponding to 45°, where both winding currents equal 71% of the peak value:

Unfortunately, pin 27 is another unconnected pin on the DRV8825 PCB, without even a hint of a pad for E-Z soldering.

It’s also an open-drain output in need of a pullup, so I globbed on a 1/8 W 10 kΩ resistor in addition to the tiny wire from the IC pad to the left header pin:

DRV8825 PCB - Home signal output — DRV8825 PCB – Home signal output

Read it from the right: brown black black red gold. Even in person, the colors don’t look like that, not even a little bit: always measure before installation!

The right header pin is firmly soldered to the PCB ground pin I also used for the 1:8 microstep hack. The whole affair received a generous layer of hot melt glue in the hope of some mechanical stabilization, although hanging a scope probe off those pins can’t possibly end well.

The general idea is to provide a scope sync output independent of the motor speed, so I can look at the current waveforms:

3018 X - Fast - 12V - 140mm-min 1A-div — 3018 X – Fast – 12V – 140mm-min 1A-div

The alert reader will note the pulse occurs on the down-going side of the waveforms, which means I have the current probes clipped on backwards or, equivalently, on the wrong wire. The point is to get a stable sync, so it’s all good no matter which way the current goes.

2019-09-11

CNC 3018-Pro: LM6UU Linear-bearing Diamond Drag Bit Holder

The CNC 3018-Pro normally holds a small DC motor with a nicely cylindrical housing,so this was an easy adaptation of the MPCNC’s diamond drag bit holder:

CNC 3018-Pro - Diamond bit - overview — CNC 3018-Pro – Diamond bit – overview

The lip around the bottom part rests atop the tool clamp, with the spring reaction plate sized to clear the notch in the Z-axis stage.

The solid model looks about like you’d expect:

Diamond Scribe - Mount - solid model — Diamond Scribe – Mount – solid model

The New Thing compared to the MPCNC holder is wrapping LM6UU bearings around an actual 6 mm shaft, instead of using LM3UU bearings for the crappy diamond bit shank:

CNC 3018-Pro - Diamond bit - epoxy curing — CNC 3018-Pro – Diamond bit – epoxy curing

I cut the shank in two pieces, epoxied them into 3 mm holes drilled into the 6 mm shaft, then epoxied the knurled stop ring on the end. The ring is curing in the bench block to stay perpendicular to the 6 mm shaft.

The spring constant is 55 g/mm and it’s now set for 125 g preload:

CNC 3018-Pro - Diamond bit - force measurement — CNC 3018-Pro – Diamond bit – force measurement

A quick test says all the parts have begun flying in formation:

CNC 3018-Pro - Diamond bit - test CD — CNC 3018-Pro – Diamond bit – test CD

It’s definitely more rigid than the MPCNC!

The OpenSCAD source code as a GitHub Gist:

	// Diamond Scribe in linear bearings for CNC3018
	// Ed Nisley KE4ZNU – 2019-08-9

	Layout = "Build"; // [Build, Show, Base, Mount, Plate]

	/* [Hidden] */

	ThreadThick = 0.25; // [0.20, 0.25]
	ThreadWidth = 0.40; // [0.40, 0.40]

	/* [Hidden] */

	Protrusion = 0.1; // [0.01, 0.1]

	HoleWindage = 0.2;

	inch = 25.4;

	function IntegerMultiple(Size,Unit) = Unit * ceil(Size / Unit);

	ID = 0;
	OD = 1;
	LENGTH = 2;

	//- Adjust hole diameter to make the size come out right

	module PolyCyl(Dia,Height,ForceSides=0) { // based on nophead's polyholes
	Sides = (ForceSides != 0) ? ForceSides : (ceil(Dia) + 2);
	FixDia = Dia / cos(180/Sides);
	cylinder(r=(FixDia + HoleWindage)/2,h=Height,$fn=Sides);
	}

	//- Dimensions

	// Knife holder & suchlike

	ScribeOD = 3.0; // diamond scribe shaft

	Bearing = [6.0,12.0,19.0]; // linear bearing body, ID = shaft diameter

	Spring = [4.5,5.5,3*ThreadThick]; // compression spring around shaft, LENGTH = socket depth
	//Spring = [9.5,10.0,3*ThreadThick]; // compression spring around shaft, LENGTH = socket depth

	WallThick = 4.0; // minimum thickness / width

	Screw = [3.0,6.75,25.0]; // holding it all together, OD = washer

	Insert = [3.0,5.0,8.0]; // brass insert
	//Insert = [4.0,6.0,10.0];

	Clamp = [43.2,44.0,34.0]; // tool clamp ring, OD = clearance around top

	LipHeight = IntegerMultiple(2.0,ThreadThick); // above clamp for retaining

	BottomExtension = 25.0; // below clamp to reach workpiece

	MountOAL = LipHeight + Clamp[LENGTH] + BottomExtension; // total mount length
	echo(str("Mount OAL: ",MountOAL));

	Plate = [1.5ScribeOD,Clamp[ID] – 02*WallThick,WallThick]; // spring reaction plate

	NumScrews = 3;
	ScrewBCD = Bearing[OD] + Insert[OD] + 2*WallThick;

	echo(str("Retainer max OD: ",ScrewBCD – Screw[OD]));

	NumSides = 9*4; // cylinder facets (multiple of 3 for lathe trimming)

	// Basic mount shape

	module CNC3018Base() {

	translate([0,0,MountOAL – LipHeight])
	cylinder(d=Clamp[OD],h=LipHeight,$fn=NumSides);
	translate([0,0,MountOAL – LipHeight – Clamp[LENGTH] – Protrusion])
	cylinder(d=Clamp[ID],h=(Clamp[LENGTH] + 2*Protrusion),$fn=NumSides);
	cylinder(d1=Bearing[OD] + 2*WallThick,d2=Clamp[ID],h=BottomExtension + Protrusion,$fn=NumSides);

	}

	// Mount with holes & c

	module Mount() {

	difference() {
	CNC3018Base();

	translate([0,0,-Protrusion]) // bearing
	PolyCyl(Bearing[OD],2*MountOAL,NumSides);

	for (i=[0:NumScrews – 1]) // clamp screws
	rotate(i*360/NumScrews)
	translate([ScrewBCD/2,0,MountOAL – Clamp[LENGTH]])
	rotate(180/8)
	PolyCyl(Insert[OD],Clamp[LENGTH] + Protrusion,8);
	}

	}

	module SpringPlate() {

	difference() {
	cylinder(d=Plate[OD],h=Plate[LENGTH],$fn=NumSides);

	translate([0,0,-Protrusion])
	PolyCyl(Plate[ID],2*MountOAL,NumSides);

	translate([0,0,Plate[LENGTH] – Spring[LENGTH]]) // spring retainer
	PolyCyl(Spring[OD],Spring[LENGTH] + Protrusion,NumSides);

	for (i=[0:NumScrews – 1]) // clamp screws
	rotate(i*360/NumScrews)
	translate([ScrewBCD/2,0,-Protrusion])
	rotate(180/8)
	PolyCyl(Screw[ID],2*MountOAL,8);
	}

	}


	//—–
	// Build it

	if (Layout == "Base")
	CNC3018Base();

	if (Layout == "Mount")
	Mount();

	if (Layout == "Plate")
	SpringPlate();

	if (Layout == "Show") {
	Mount();
	translate([0,0,1.25*MountOAL])
	rotate([180,0,0])
	SpringPlate();
	}

	if (Layout == "Build") {

	translate([0,-0.75*Clamp[OD],MountOAL])
	rotate([180,0,0])
	Mount();
	translate([0,0.75*Plate[OD],0])
	SpringPlate();
	}

view raw Diamond Scribe.scad hosted with ❤ by GitHub

2019-09-10

Tour Easy: PTT Switch Replacement

The PTT switch on Mary’s Tour Easy became intermittent:

Tour Easy - failed PTT switch — Tour Easy – failed PTT switch

It’s been sitting there for least five years, as witnessed by the sun-yellowed hot melt glue blob, which is pretty good service from a switch intended for indoor use. The 3D printed button never fell off and, in fact, was difficult to remove, so that worked well.

I took it apart and cleaned the contacts, but to no avail, so her bike now sports a new switch with a similar rounded dome:

Tour Easy - new PTT switch — Tour Easy – new PTT switch

I clipped the wires a bit beyond the terminals and soldered the new switch in place, so it’s the same cable as before.

Now, to see how long this one lasts …

2019-09-09

Rail Trail Tree Clearing

Trees along the Dutchess Rail Trail fall over for no obvious reason and sometimes block the path:

DCRT Fallen Tree - 1 - 2019-08-29 — DCRT Fallen Tree – 1 – 2019-08-29

But my tool hand is strong:

DCRT Fallen Tree - 2 - 2019-08-29 — DCRT Fallen Tree – 2 – 2019-08-29

The DPW folks can haul off the trunk, as it’s more than I can move.

2019-09-08

Floor Sweepings from eBay

Ordered 100 stainless steel M3 washers from a “US Seller”, received this:

M3 stainless steel washers - short count — M3 stainless steel washers – short count

Yeah, it looked a bit short to me, too.

The chopped and bent washers in the upper right corner suggest the seller got floor sweepings from his source, which is about what you’d expect for a bottom-dollar vendor.

The seller refunded half, which wasn’t particularly generous, but I wasn’t ready to go to the mat for two bucks.

2019-09-07

Raspberry Pi “Moster” Heatsink Retaping

A pair of colorful laser-cut stacked acrylic Raspberry Pi cases with “Moster” (*) heatsinks arrived, with the intent of dressing up the HP 7475A plotters for their next Show-n-Tell:

Moster RPi Heatsink - assembled case — Moster RPi Heatsink – assembled case

Unfortunately, the thermal tape on one of the CPU heatsinks was sufficiently wrinkled to prevent good contact with the CPU:

RPi taped heatsinks - as received — RPi taped heatsinks – as received

The seller sent a replacement copper slug with tape on one side. Presumably, they glue it to the heatsink with thermal silicone:

Moster RPi Heatsink - silicone adhesive — Moster RPi Heatsink – silicone adhesive

Of which, I have none on hand.

So I did what I should have done originally, which was to drop a few bucks on a lifetime supply of thermally conductive heatsink tape, apply it to the bare side of the slug and stick the slug to the heatsink with their tape:

Moster RPi Heatsink - replacement adhesive tape — Moster RPi Heatsink – replacement adhesive tape

The blue stuff is the separation film, with the tape being white. It doesn’t match the black tape on the other side, but seems gooey enough to work.

Done!

Despite the heatsink hype, ball grid array chips dissipate most of their heat through their pads (and perhaps a central thermal pad) into the PCB, so sticking a heatsink atop the package is largely decorative, along the lines of hotrod ornamentation.

The epoxy packages used in previous Raspberry Pi iterations had better thermal conductivity to their top surface:

RPi 3 B - epoxy CPU — RPi 3 B – epoxy CPU

Than the more recent metal-top packages, which surely have inert-gas fill under the lid:

RPi 3 B - metal CPU — RPi 3 B – metal CPU

Pix cropped after being pilfered from the Official Raspberry Pi site.

Yes, the heatsink does conduct some heat into the air, even if not nearly as much as you might want.

(*) I’m pretty sure “Moster” was a typo in the original eBay listing which took on a life of its own to become something of an unofficial trademark. All of the search results ship from Duluth, Georgia (USA), regardless of the nominal seller; feel free to draw your own conclusions.

2019-09-06

Ripping Vinyl Records on a Raspberry Pi

Having already set up a Raspberry Pi streaming radio player for the living room, it seemed reasonable to also use it for recording audio from the long-disused turntable. A pair of RCA cables from the amplifier’s TAPE 2 REC outputs to the Behringer UCA202 USB audio interface got the audio where it needed to be:

RPi streamer - Behringer UCA202 USB audio box — RPi streamer – Behringer UCA202 USB audio box

Fiddle with the amp to select the phonograph, poke the TAPE 2 button to send audio to/from the UCA202, fire up an SSH session, kill the streaming audio program, and figure out what audio hardware is out there:

$ arecord -l
**** List of CAPTURE Hardware Devices ****
card 1: CODEC [USB Audio CODEC], device 0: USB Audio [USB Audio]
  Subdevices: 1/1
  Subdevice #0: subdevice #0

Not much else to choose from on a Raspberry Pi, so see what the UCA202 can do:

$ arecord --dump-hw-params 
Recording WAVE 'stdin' : Unsigned 8 bit, Rate 8000 Hz, Mono
HW Params of device "default":
--------------------
ACCESS:  MMAP_INTERLEAVED RW_INTERLEAVED
FORMAT:  S8 S16_LE
SUBFORMAT:  STD
SAMPLE_BITS: [8 16]
FRAME_BITS: [8 32]
CHANNELS: [1 2]
RATE: [8000 48000]
PERIOD_TIME: [1000 65536000]
PERIOD_SIZE: [16 524288]
PERIOD_BYTES: [64 524288]
PERIODS: [2 1024]
BUFFER_TIME: (666 131072000]
BUFFER_SIZE: [32 1048576]
BUFFER_BYTES: [64 1048576]
TICK_TIME: ALL
--------------------
arecord: set_params:1233: Sample format non available
Available formats:
- S8
- S16_LE

Given those limited choices, 16 bit little-endian at 48 kHz seems like a no-brainer.

Find out all the ALSA device names:

$ arecord -L
null
    Discard all samples (playback) or generate zero samples (capture)
sysdefault:CARD=CODEC
    USB Audio CODEC, USB Audio
    Default Audio Device
front:CARD=CODEC,DEV=0
    USB Audio CODEC, USB Audio
    Front speakers
surround21:CARD=CODEC,DEV=0
    USB Audio CODEC, USB Audio
    2.1 Surround output to Front and Subwoofer speakers
surround40:CARD=CODEC,DEV=0
    USB Audio CODEC, USB Audio
    4.0 Surround output to Front and Rear speakers
surround41:CARD=CODEC,DEV=0
    USB Audio CODEC, USB Audio
    4.1 Surround output to Front, Rear and Subwoofer speakers
surround50:CARD=CODEC,DEV=0
    USB Audio CODEC, USB Audio
    5.0 Surround output to Front, Center and Rear speakers
surround51:CARD=CODEC,DEV=0
    USB Audio CODEC, USB Audio
    5.1 Surround output to Front, Center, Rear and Subwoofer speakers
surround71:CARD=CODEC,DEV=0
    USB Audio CODEC, USB Audio
    7.1 Surround output to Front, Center, Side, Rear and Woofer speakers
iec958:CARD=CODEC,DEV=0
    USB Audio CODEC, USB Audio
    IEC958 (S/PDIF) Digital Audio Output
dmix:CARD=CODEC,DEV=0
    USB Audio CODEC, USB Audio
    Direct sample mixing device
dsnoop:CARD=CODEC,DEV=0
    USB Audio CODEC, USB Audio
    Direct sample snooping device
hw:CARD=CODEC,DEV=0
    USB Audio CODEC, USB Audio
    Direct hardware device without any conversions
plughw:CARD=CODEC,DEV=0
    USB Audio CODEC, USB Audio
    Hardware device with all software conversions

They all point to the same hardware, so AFAICT the default device will work fine.

Try recording something directly to the RPi’s /tmp directory, using the --format=dat shortcut for “stereo 16 bit 48 kHz” and --mmap to (maybe) avoid useless I/O:

$ arecord --format=dat --mmap --vumeter=stereo --duration=$(( 30 * 60 ))  /tmp/Side\ 1.wav
Recording WAVE '/tmp/Side 1.wav' : Signed 16 bit Little Endian, Rate 48000 Hz, Stereo
                                  +02%|01%+                                   overrun!!! (at least 1.840 ms long)
                                  +02%|02%+                                   overrun!!! (at least 247.720 ms long)
                                +# 07%|06%##+                                 overrun!!! (at least 449.849 ms long)
                                 + 03%|02%+                                   overrun!!! (at least 116.850 ms long)

Huh. Looks like “writing to disk” sometimes takes far too long, which seems to be the default for MicroSD cards.

The same thing happened over NFS to the file server in the basement:

$ arecord --format=dat --mmap --vumeter=stereo --duration=$(( 30 * 60 ))  /mnt/part/Transfers/Side\ 1.wav

Recording WAVE '/mnt/part/Transfers/Side 1.wav' : Signed 16 bit Little Endian, Rate 48000 Hz, Stereo

                               +   09%|07%  +                                 overrun!!! (at least 660.372 ms long)

                                +# 08%|06%# +                                 overrun!!! (at least 687.906 ms long)

So maybe it’s an I/O thing on the RPi’s multiplexed / overloaded USB + Ethernet hardware?

Trying a USB memory jammed into the RPi, under the assumption it might be better at recording than the MicroSD Card:

$ arecord --format=dat --mmap --vumeter=stereo --duration=$(( 30 * 60 ))  /mnt/part/Side\ 1.wav
Recording WAVE '/mnt/part/Side 1.wav' : Signed 16 bit Little Endian, Rate 48000 Hz, Stereo
                                  +01%|01%+                                   overrun!!! (at least 236.983 ms long)

Well, if it’s overrunning the default buffer, obviously it needs Moah Buffah:

$ arecord --format=dat --mmap --vumeter=stereo --buffer-time=1000000 --duration=$(( 30 * 60 ))  /mnt/part/Side\ 1.wav
Recording WAVE '/mnt/part/Side 1.wav' : Signed 16 bit Little Endian, Rate 48000 Hz, Stereo
                               +## 10%|06%# +                                 overrun!!! (at least 359.288 ms long)

When brute force doesn’t work, you’re just not using enough of it:

$ arecord --format=dat --mmap --vumeter=stereo --buffer-time=2000000 --duration=$(( 30 * 60 ))  /mnt/part/Side\ 1.wav
Recording WAVE '/mnt/part/Side 1.wav' : Signed 16 bit Little Endian, Rate 48000 Hz, Stereo
                                  +00%|00%+

Sampling four bytes at 48 kHz fills 192 kB/s, so a 2 s buffer blots up 384 kB, which seems survivable even on a Raspberry Pi.

The audio arrives at 11.5 MB/min, so an LP side with 20 min of audio will require about 250 MB of disk space. The USB memory was an ancient 2 GB card, so all four sides filled it halfway:

$ ll /mnt/part
total 1.1G
drwxr-xr-x  2 ed   root 4.0K Dec 31  1969  ./
drwxr-xr-x 17 root root 4.0K Jun  7 19:15  ../
-rwxr-xr-x  1 ed   root 281M Sep  1 14:38 'Side 1.wav'*
-rwxr-xr-x  1 ed   root 242M Sep  1 15:01 'Side 2.wav'*
-rwxr-xr-x  1 ed   root 265M Sep  1 15:27 'Side 3.wav'*
-rwxr-xr-x  1 ed   root 330M Sep  1 15:58 'Side 4.wav'*

Side 4 is a bit longer than the rest, because I was folding laundry and the recording stopped at the 30 minute timeout after 10 minutes of silence.

Now, to load ’em into Audacity, chop ’em into tracks, and save the lot as MP3 files …

2019-09-05