The Smell of Molten Projects in the Morning

Ed Nisley's Blog: Shop notes, electronics, firmware, machinery, 3D printing, laser cuttery, and curiosities. Contents: 100% human thinking, 0% AI slop.

Category: Electronics Workbench

Electrical & Electronic gadgets

  • Kindle Fire Picture Frame: Side Block

    A steel frame that Came With The House™ emerged from a hidden corner and, instants before tossing it in the recycle heap, I realized it had excellent upcycling potential:

    Kindle Fire Picture Frame - Test Run
    Kindle Fire Picture Frame – Test Run

    Stipulated: I need better pictures for not-so-techie audiences.

    Anyhow, my long-disused Kindle Fire fits perfectly into the welded-on clips, with just enough room for a right-angle USB cable, and Photo Frame Slideshow Premium does exactly what’s necessary to show pictures from internal storage with no network connection.

    All I needed was a small block holding the Kindle against the far side of the frame:

    Kindle Frame - side blocks
    Kindle Frame – side blocks

    A strip of double-stick carpet tape holds the block onto the frame. To extract the Kindle, should the need arise, slide it upward to clear the bottom clips, rotate it rearward, and out it comes.

    Getting a good block required three tries, because the basement has cooled off enough to trigger Marlin’s Thermal Runaway protection for the M2’s platform heater. A test fit after the first failure showed the long leg was 1 mm too wide and, after the second failure, I reduced the fan threshold to 15 s and the minimum layer time to 5 s, producing the third block without incident.

    The platform heater runs at 40 V and I considered bumping it to 43 V for a 15% power boost, but it has no trouble keeping up when the fan isn’t blowing chilly basement air across its surface.

    The OpenSCAD source code, such as it is, doesn’t deserve its own GitHub Gist:

    // Block to hold Kindle in a picture frame mount
    // Ed Nisley - KE4ZNU
    // November 2018
    
    Protrusion = 0.1;
    
    difference() {
    
      cube([18,44,10]);
      translate([-Protrusion,-Protrusion,-Protrusion])
        cube([18-4 + Protrusion,44-10 + Protrusion,10 + 2*Protrusion]);
    
    }
    
  • Lenovo Headset Volume Control Lube

    The volume control wart pod on the cable of my old and longsuffering Lenovo headset had been dropping out the right channel for a while, eventually prompting me to discover it comes apart by simply pulling on the halves:

    Lenovo Headset - control pod
    Lenovo Headset – control pod

    There being no way to get closer to the open-frame volume pot’s innards, I eased a drop of DeoxIT Red along its edge (upper in the photo), slipped another drop into what’s presumably the wiper opening in the knob, and ran it through enough cycles to spread the juice evenly.

    Reassemble in reverse order and It Just Works™ again.

  • Squidwrench Electronics Workshop: Session 6 Whiteboards

    Coverage of capacitors as charge-storage devices, rather than filters:

    Session 6 - Whiteboard 1 - overview
    Session 6 – Whiteboard 1 – overview

    We avoided all the calculus and derivations, taking the exponential waveform as a given for RC circuits:

    Session 6 - Whiteboard 1 - exponential detail
    Session 6 – Whiteboard 1 – exponential detail

    Discussions of dielectrics, plate spacing / area, and suchlike:

    Session 6 - Whiteboard 1 - dielectric permittivity
    Session 6 – Whiteboard 1 – dielectric permittivity

    Some handwaving discussion of construction, electrolytic capacitor innards, and The Plague:

    Session 6 - Whiteboard 1 - cap construction
    Session 6 – Whiteboard 1 – cap construction

    A 1 F cap charged through a 1.8 kΩ resistor during most of the session to show what an 1800 s time constant looked like. Nope, it never quite got to the 3.5 V from the power supply, even when we all decided it was time to shut down!

  • Monthly Image: AMP Plug Board

    Around 1960, somebody my father knew at the Harrisburg AMP factory gave me a chunk of plugboard bandsawed from a scrapped computer or industrial controller, because he knew I’d enjoy it:

    AMP Plug Board
    AMP Plug Board

    He was right.

    I spent months rearranging those little cubes (some with cryptic legends!) into meaningful (to me) patterns, plugging cables between vital spots, and imagining how the whole thing worked:

    AMP Plug Board - detail
    AMP Plug Board – detail

    Long springs ran through the notches under the top of the blocks to connect the plug shells to circuit ground. The ends of the steel rails (still!) have raw bandsaw cuts, some of the blocks were sliced in two, the tip contact array behind the panel wasn’t included, and none of that mattered in the least.

    Only a fraction of the original treasure trove survives. It was absolutely my favorite “toy” ever.

    Quite some years ago, our Larval Engineer assembled the pattern you see; the hardware still had some attraction.

    I’ve asked Mary to toss it in the hole with whatever’s left of me, when that day arrives …

  • HP 6201B Power Supply Meter Switch Rehabilitation

    The meter range switch on Squidwrench’s HP 6201B bench power supply became erratic enough to get me to tear it apart:

    HP 6201B Power Supply - meter switch nut
    HP 6201B Power Supply – meter switch nut

    For future reference, apply a 9/16 inch deep socket after loosening two teeny setscrews in the knob.

    The date codes suggest a mid-70s assembly, but the design dates back to the 60s with no plug-in anything:

    HP 6201B Power Supply - meter switch in panel
    HP 6201B Power Supply – meter switch in panel

    Rather than unsolder eight switch leads, I wrangled it into a visible location:

    HP 6201B Power Supply - meter switch rear
    HP 6201B Power Supply – meter switch rear

    The knob and shaft sit on a separate metal bracket held in the white plastic ring with a pair of expanded prongs. Squashing the prongs together released the bracket, so I could see both sides of the switch wafer:

    HP 6201B Power Supply - meter switch front
    HP 6201B Power Supply – meter switch front

    Note the copious markings which would, in the event of an actual finger fumble, give me a better chance of reassembling the spilled guts. Turned out not to be necessary, but it’s good to be prepared!

    The actual repair consisted of easing a drop of DeoxIT Red into each side, spinning the central switch wafer / contacts a few dozen times, then reassembling in reverse order. Re-bending the prongs turned out to be the most difficult part, eventually requiring the designated Prydriver, and ended well enough.

    A quick test with a 100 Ω power resistor shows the supply was working fine and the switch produced the expected results without glitches or twitches:

    HP 6201B Power Supply - test load
    HP 6201B Power Supply – test load

    You just can’t beat the performance of old lab equipment!

  • MPCNC: Guilloche Engraving First Light

    A diamond point drag engraving bit in the MPCNC scratched a suitable Guilloché pattern into a scrap hard drive platter much much better than I had any reason to expect:

    MPCNC - Guilloche 835242896 - HD plattter - 0.1mm
    MPCNC – Guilloche 835242896 – HD plattter – 0.1mm

    That’s with a 0.1 mm cut depth, sidelit with an LED flashlight.

    Feeding those nine digits into the Guilloché pattern generator script should get you the same pattern; set the paper size to 109 mm and use Pen=0 to suppress the legend.

    The same pattern at 0.3 mm cut depth looks about the same:

    MPCNC - Guilloche 835242896 - HD plattter - 0.3mm
    MPCNC – Guilloche 835242896 – HD plattter – 0.3mm

    It’s slightly more prominent in real life, but not by enough to make a big difference. I should try a graduated series of tests, of course, which will require harvesting a few more platters from dead drives.

    Either side will look great under a 21HB5A tube, although the disks are fingerprint and dust magnets beyond compare.

  • Power Over Audio

    An obsolete Intuit / Roam Data credit card reader emerged from the heap:

    Intuit Roam Data Reader
    Intuit Roam Data Reader

    “Turn up the volume” suggested where the power comes from:

    Intuit Roam Data Reader - plug wiring
    Intuit Roam Data Reader – plug wiring

    They drive a LOUD, probably square-ish, audio signal through both “earphone”channels, rectify and regulate the output, and have plenty of power for the reader. The card data returns through the “mic” as another audio signal; I assume they choose an encoding well-suited for a dab of DSP decoding.

    Nowadays, of course, 3.5 mm jacks are obsolete, audio data travels by Bluetooth, and you must keep a myriad batteries charged at all times.