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

  • Brother BAS-311 Control Head Salvage

    A control head from an ancient Brother BAS-311 sewing machine emerged from a recent Squidwrench clearing-out session:

    Brother BAS-311 Control Head
    Brother BAS-311 Control Head

    The sturdy metal enclosure ought to be good for something, I thought, so I rescued it from the trash.

    One of the ten button-head screws galled in place and resisted a few days of penetrating oil, so I drilled it out:

    Drilled-out button screw head
    Drilled-out button screw head

    The PCB has no ICs! It simply routes all the LED and button pins through the pillar into the sewing machine controller:

    Brother BAS-311 Control Head - interior
    Brother BAS-311 Control Head – interior

    The ribbon cable alternates the usual flat strip with sections of split conductors:

    Segmented ribbon cable
    Segmented ribbon cable

    The split segments let it roll up into the pillar, with enough flexibility to allow rotating the head. I’ve seen segmented twisted-pair ribbon cable, but never just flat conductors.

    Maybe the control head can become Art in its next life?

  • Fluorescent Shop Light Ballasts, Redux

    As usual, several shoplights didn’t survive the winter, so I gutted and rebuilt them with LED tubes. Even the fancy shoplights with genuine electronic ballasts survive less than nine years, as two of those eight “new” lamps have failed so far.

    The dead ballast looks the same as it did before:

    Electronic ballast - label
    Electronic ballast – label

    Some deft work with a cold chisel and my Designated Prydriver popped the top to reveal a plastic-wrapped circuit board:

    Electronic ballast - interior wrapped
    Electronic ballast – interior wrapped

    Perhaps the flexy gunk reduces the sound level:

    Electronic ballast - interior A
    Electronic ballast – interior A

    While also preventing casual failure analysis and organ harvesting:

    Electronic ballast - interior B
    Electronic ballast – interior B

    The black gunk smells more like plastic and less like old-school tar. It’s definitely not a peel-able conformal coating.

    One the other paw, the two magnetic ballasts in another lamp sported actual metal-film capacitors, which I harvested and tossed into the Big Box o’ Film Caps:

    Shoplight choke ballast - film cap
    Shoplight choke ballast – film cap

    If a dying ballast didn’t also kill its fluorescent tube(s), I’d be less annoyed. I’m running the remaining tubes through the surviving fixtures, but the end is nigh for both.

    The new LED tubes produce more light than the old fluorescents, although I still don’t like their 6500 K “daylight glow” color.

  • Sena PS410 Serial Server: Shelf with Calculations

    A crude shelf bandsawed from a plank moves the Sena PS410 serial server and an old Ethernet switch off the bench:

    Serial server shelf - front
    Serial server shelf – front

    The brackets holding it to the studs came from a 2×4 inch scrap:

    Serial server shelf - rear
    Serial server shelf – rear

    Obviously, the Basement Laboratory lacks stylin’ home decor.

    None of which would be worth mentioning, except for some Shop Calculations scrawled on the 2×4:

    Wood shop calculations
    Wood shop calculations

    It’s in my handwriting, although whatever it related to is long gone.

    Trigonometry FTW!

  • Fake Flash

    This 2 GB flash drive arrived with datasheets & sample files for a (computerized) sewing machine Mary eventually decided she wasn’t going to get (because computerized):

    Fake Flash drive
    Fake Flash drive

    Being of sound mind, we reformatted it and dropped it in the bag o’ random drives. She eventually used it for one of her gardening presentations, whereupon the library’s (Windows) laptop said it needed formatting; she pulled out a backup drive and continued the mission.

    Lather, rinse, verify a good format, verify presentation files on the Token Windows Box, and repeat, right down to having another library’s laptop kvetch about the drive.

    Soooo, I did what I should have done in the first place:

    sudo f3probe -t /dev/sdc
    F3 probe 6.0
    Copyright (C) 2010 Digirati Internet LTDA.
    This is free software; see the source for copying conditions.
    
    WARNING: Probing normally takes from a few seconds to 15 minutes, but
             it can take longer. Please be patient.
    
    Probe finished, recovering blocks... Done
    
    Bad news: The device `/dev/sdc' is a counterfeit of type limbo
    
    You can "fix" this device using the following command:
    f3fix --last-sec=25154 /dev/sdc
    
    Device geometry:
    	         *Usable* size: 12.28 MB (25155 blocks)
    	        Announced size: 1.86 GB (3893248 blocks)
    	                Module: 2.00 GB (2^31 Bytes)
    	Approximate cache size: 511.00 MB (1046528 blocks), need-reset=no
    	   Physical block size: 512.00 Byte (2^9 Bytes)
    
    Probe time: 55'18"
     Operation: total time / count = avg time
          Read: 8'35" / 3145715 = 163us
         Write: 46'37" / 18838872 = 148us
         Reset: 350.7ms / 2 = 175.3ms
    

    Huh.

    As long as you don’t write more than a few megabytes, it’s all good, which was apparently enough for its original use.

    The front of the PCB looks normal:

    Fake Flash - controller
    Fake Flash – controller

    But it seems they really didn’t want you to see the flash chip:

    Fake Flash - covered chip
    Fake Flash – covered chip

    Given the two rows of unused pads, it must be a really small chip!

    Memo to Self: Always examine the dentition of any Equus ferus received as a gift.

  • Canon NB-5L Batteries: Final Status

    A friend now owns my trusty Canon SX230HS camera, but, given the restrictions on shipping lithium batteries, we agreed there was no point in transferring ownership of my nearly dead batteries.

    For completeness, their final state:

    Canon NB-5L - 2018-03-25
    Canon NB-5L – 2018-03-25

    The original Canon OEM battery (orange curve) looms above all the offerings from various Amazon sellers.

    Searching for NB-5L will excavate many posts relating my misadventures, tests, and test fixtures:

    NB-5L Holder - Coil spring - Fit layout
    NB-5L Holder – Coil spring – Fit layout

    Maybe I should build an astable multivibrator with a slip-in battery compartment.

  • Hazards of Outdoor Wiring

    Spotted behind a small strip mall during one of our walks:

     

    Rotted power cable
    Rotted power cable

    Perhaps the cable wasn’t rated for outdoor use?

    The earth ground conductor isn’t insulated and the nonconductive filler strands look scary, but neither should kill you outright.

    As far as I can tell, the insulation around the individual conductors remains intact, but it’s surely brittle and ready to fall off at the slightest touch.

    The breaker box and cable are out of reach and, I suppose, out of mind.

  • Vape Cartridge

    Being the kind of guy who lives under a rock, I thought this thing lying at the end of the driveway might be a USB widget:

    Vape cartridge - side
    Vape cartridge – side

    But the contacts are all wrong:

    Vape cartridge - contacts
    Vape cartridge – contacts

    It has an opening on the other end:

    Vape cartridge - exhaust port
    Vape cartridge – exhaust port

    An easy teardown produces a yard sale of parts:

    Vape cartridge - components
    Vape cartridge – components

    The fiber snippet inside the coil carries the same sickly sweet scent as exhaled by passing vapers.

    Some casual searching suggests it’s a Juul Vape Pod. The Juul site insists on lower browser armor than I’m willing to grant it; you’re on your own.

    The heating coil press-fits into slots cut in the contacts:

    Vape cartridge - heater and contacts
    Vape cartridge – heater and contacts

    It’s about 1 Ω cold, so I foolishly assume there’s a current limiter somewhere in the circuitry.

    The little steel tube goes into the Tray o’ Cutoffs, where it might come in handy some day, the debris hits the trash, and I washed my hands up to the elbows.

    Ya learn something new every day around here and, obviously, I must get out more …