Machine Shop – Page 175 – The Smell of Molten Projects in the Morning

Raspberry Pi vs. MicroSD-as-Disk Memory

The MPCNC has bCNC running on a Raspberry Pi, with a Samsung EVO MicroSD card serving as the “hard drive”:

Sandisk Extreme Plus vs. Samsung EVO MicroSD cards

The picture also shows a defunct Sandisk Extreme Plus killed by continuous video recording in my Fly6 bike camera. I later replaced the EVO with a video-rated Samsung card which has been running fine ever since, albeit with the occasional crash-and-reformat expected with “action” cameras.

With that as background, a different Samsung EVO card from the same batch has been running the MPCNC’s Raspberry Pi for about a year. Over the course of a few days last week, the RPi went from an occasional stall to a complete lockup, although waiting for minutes to hours would sometimes resolve the problem. As I’ve learned by now, it’s not a software crash, it’s the controller inside the card suffering from write amplification while trying to move data from failing sectors.

Applying f3write to the card shows the problem:

MPCNC MicroSD - f3write slowdown — MPCNC MicroSD – f3write slowdown

The write speed started out absurdly high as the card’s write cache fills, then slowed to to the flash memory’s ability to absorb data, and eventually ran out of steam during the last few files.

But, as you might not expect, f3read reported the data was fine:

sudo f3read /mnt/part
F3 read 7.0
Copyright (C) 2010 Digirati Internet LTDA.
This is free software; see the source for copying conditions.

                  SECTORS      ok/corrupted/changed/overwritten
Validating file 1.h2w ... 2097152/        0/      0/      0
Validating file 2.h2w ... 2097152/        0/      0/      0
Validating file 3.h2w ... 2097152/        0/      0/      0
Validating file 4.h2w ... 2097152/        0/      0/      0
Validating file 5.h2w ... 2097152/        0/      0/      0
Validating file 6.h2w ... 2097152/        0/      0/      0
Validating file 7.h2w ... 2097152/        0/      0/      0
Validating file 8.h2w ... 2097152/        0/      0/      0
Validating file 9.h2w ... 2097152/        0/      0/      0
Validating file 10.h2w ... 2097152/        0/      0/      0
Validating file 11.h2w ... 2097152/        0/      0/      0
Validating file 12.h2w ... 2097152/        0/      0/      0
Validating file 13.h2w ... 2097152/        0/      0/      0
Validating file 14.h2w ... 2097152/        0/      0/      0
Validating file 15.h2w ... 2097152/        0/      0/      0
Validating file 16.h2w ... 2097152/        0/      0/      0
Validating file 17.h2w ... 2097152/        0/      0/      0
Validating file 18.h2w ... 2097152/        0/      0/      0
Validating file 19.h2w ... 2097152/        0/      0/      0
Validating file 20.h2w ... 2097152/        0/      0/      0
Validating file 21.h2w ... 1322894/        0/      0/      0

  Data OK: 20.63 GB (43265934 sectors)
Data LOST: 0.00 Byte (0 sectors)
	       Corrupted: 0.00 Byte (0 sectors)
	Slightly changed: 0.00 Byte (0 sectors)
	     Overwritten: 0.00 Byte (0 sectors)
Average reading speed: 43.04 MB/s

Obviously, the card’s read speed isn’t affected by the write problems.

Assuming the actual data & programs on the card were still good, I slurped the partitions:

sudo partimage save /dev/sdf1 mpcnc_boot.gz
sudo partimage save /dev/sdf2 mpcnc_partition.gz

And wrote them back:

sudo partimage restmbr  mpcnc_boot.gz.000 
sudo partimage restore /dev/sdf1 mpcnc_boot.gz.000 
sudo partimage restore /dev/sdf2 mpcnc_partition.gz.000

Unshown: a finger fumble requiring MBR restoration.

Having forced the card controller to reallocate all the failed sectors, the card works now fine and runs at full speed again. This won’t last long, but it’ll be interesting to see how it plays out.

While I was at it, I wrote the partitions to a new-ish / unused Samsung EVO Plus card, now tucked under the MPCNC’s monitor in case of emergency.

An old SFF Optiplex with an SSD may be a better fallback.

2018-10-16

American Standard Kitchen Faucet: Ceramic Valve Cores

The ceramic valve core from our kitchen faucet certainly qualifies for a spot on the bottom flange of the I-beam across our basement serving as a display case / collection area for shop curiosities, mementos, and the like. I am, if nothing else, a creature of fixed habits, because the spot where the core belonged already had one:

American Standard Ceramic Faucet Valve Cores - old vs new — American Standard Ceramic Faucet Valve Cores – old vs new

The core on the left dates back to the 2016 replacement, so they’ve apparently decided plastic will work fine for the handle socket.

Having the ceramic core fail after two years suggests the manufacturing process needs attention, though. I can still wring the slabs together, though, and they’d need a drop of oil to serve as bearing surfaces.

2018-10-12

MPCNC: Acrylic Engraving First Light

Just to see what happened, I chucked a drag knife in the collet pen holder:

MPCNC Collet Pen Holder - drag knife — MPCNC Collet Pen Holder – drag knife

The blade, being fixed in the collet and lashed to the adapter, doesn’t rotate: it’s not behaving as a true drag knife.

Twiddling the cut depth to about 0.2 mm produced a credible Guilloché pattern in some scrap acrylic:

MPCNC Collet Pen Holder - drag engraved acrylic - 0.2 mm depth — MPCNC Collet Pen Holder – drag engraved acrylic – 0.2 mm depth

The sidelight comes from an LED flashlight off to the side, with a bit of contrast tweaking to suppress the workbench clutter.

The MPCNC’s lack of rigidity produces visible jitters in the Guilloché pattern and backlash makes the characters somewhat wobbly, but it’s OK for a large and inexpensive CNC gantry machine.

A brace of diamond-point engraving bits are making their way around the planet even as I type. A symmetric 60° point may reduce the swarf thrown out by the drag knife, although it surely won’t improve the overall jitter and backlash.

2018-10-11

GCMC Guilloche Plot Generator

It turns out the Spirograph patterns I’d been using to wring out the MPCNC are also known as Guilloché, perhaps after the guy who invented a lathe-turning machine to engrave them. Sounds pretentious, but they still look nice:

Guilloche 591991062 - scanned — Guilloche 591991062 – scanned

With the ballpoint pen / knife collet holder in mind, I stripped the tool changes out of the Spirograph generator GCMC source code, set the “paper size” to a convenient 100 mm square, and tidied up the code a bit.

As with Spirograph patterns, changing the random number seed produces entirely different results. A collection differing in the last digit, previewed online:

Seed = 213478836:

Seed = 213478837:

Seed = 213478838:

Seed = 213478839:

They’re such unique snowflakes …

The Bash script now accepts a single parameter to force the PRNG seed to a value you presumably want to plot again, rather than just accept whatever the Gods of Cosmic Jest will pick for you.

The GCMC source code and Bash (or whatever) script feeding it as a GitHub Gist:

	// Spirograph simulator for MPCNC used as plotter
	// Ed Nisley KE4ZNU – 2017-12-23
	// Adapted for Guillioche plots with ball point pens – 2018-09-25

	// Spirograph equations:
	// https://en.wikipedia.org/wiki/Spirograph
	// Loosely based on GCMC cycloids.gcmc demo:
	// https://gitlab.com/gcmc/gcmc/tree/master/example/cycloids.gcmc

	// Required command line parameters:

	// -D Pen=n pen selection, 0 = no legend, 1 = current pen
	// -D PaperSize=[x,y] overall sheet size: [17in,11in]
	// -D PRNG_Seed=i non-zero random number seed

	include("tracepath.inc.gcmc");
	include("engrave.inc.gcmc");

	//—–
	// Greatest Common Divisor
	// https://en.wikipedia.org/wiki/Greatest_common_divisor#Using_Euclid's_algorithm
	// Inputs = integers without units

	function gcd(a,b) {
	if (!isnone(a) \|\| isfloat(a) \|\| !isnone(b) \|\| isfloat(b)) {
	warning("GCD params must be dimensionless integers:",a,b);
	}

	local d = 0; // power-of-two counter

	while (!((a \| b) & 1)) { // remove and tally common factors of two
	a >>= 1;
	b >>= 1;
	d++;
	}

	while (a != b) {
	if (!(a & 1)) {a >>= 1;} // discard non-common factor of 2
	elif (!(b & 1)) {b >>= 1;} // … likewise
	elif (a > b) {a = (a – b) >> 1;} // gcd(a,b) also divides a-b
	else {b = (b – a) >> 1;} // … likewise
	}

	local GCD = a*(1 << d); // form gcd

	// message("GCD: ",GCD);
	return GCD;

	}

	//—–
	// Max and min functions

	function max(x,y) {
	return (x > y) ? x : y;
	}

	function min(x,y) {
	return (x < y) ? x : y;
	}

	//—–
	// Pseudo-random number generator
	// Based on xorshift:
	// https://en.wikipedia.org/wiki/Xorshift
	// http://www.jstatsoft.org/v08/i14/paper
	// Requires initial state from calling script
	// -D "PRNG_Seed=whatever"
	// You can get nine reasonably random digits from $(date +%N)

	function XORshift() {

	local x = PRNG_State;

	x ^= x << 13;
	x ^= x >> 17;
	x ^= x << 5;

	PRNG_State = x;
	return x;
	}

	//—–
	// Spirograph tooth counts mooched from:
	// http://nathanfriend.io/inspirograph/
	// Stators includes both inside and outside counts, because we're not fussy

	Stators = [96, 105, 144, 150];
	Rotors = [24, 30, 32, 36, 40, 45, 48, 50, 52, 56, 60, 63, 64, 72, 75, 80, 84];

	//—–
	// Start drawing things
	// Set initial parameters from command line!

	comment("PRNG seed: ",PRNG_Seed);
	PRNG_State = PRNG_Seed;

	// Define some useful constants

	AngleStep = 2.0deg;

	Margins = [12mm,12mm] * 2;

	comment("Paper size: ",PaperSize);

	PlotSize = PaperSize – Margins;
	comment("PlotSize: ",PlotSize);

	//—–
	// Set up gearing

	s = (XORshift() & 0xffff) % count(Stators);
	StatorTeeth = Stators[s];
	comment("Stator ",s,": ",StatorTeeth);

	r = (XORshift() & 0xffff) % count(Rotors);
	RotorTeeth = Rotors[r];
	comment("Rotor ",r,": ",RotorTeeth);

	GCD = gcd(StatorTeeth,RotorTeeth); // reduce teeth to ratio of least integers
	comment("GCD: ",GCD);
	StatorN = StatorTeeth / GCD;
	RotorM = RotorTeeth / GCD;

	L = to_float((XORshift() & 0x3ff) – 512) / 100.0; // normalized pen offset in rotor
	comment("Offset: ", L);

	sgn = sign((XORshift() & 0xff) – 128);
	K = sgn*to_float(RotorM) / to_float(StatorN); // normalized rotor dia
	comment("Dia ratio: ",K);

	Lobes = StatorN; // having removed all common factors
	Turns = RotorM;

	comment("Lobes: ", Lobes);
	comment("Turns: ", Turns);

	//—–
	// Crank out a list of points in normalized coordinates

	Path = {};
	Xmax = 0.0;
	Xmin = 0.0;
	Ymax = 0.0;
	Ymin = 0.0;

	for (a = 0.0deg ; a <= Turns*360deg ; a += AngleStep) {
	x = (1 – K)cos(a) + LKcos(a(1 – K)/K);
	if (x > Xmax) {Xmax = x;}
	elif (x < Xmin) {Xmin = x;}

	y = (1 – K)sin(a) – LKsin(a(1 – K)/K);
	if (y > Ymax) {Ymax = y;}
	elif (y < Ymin) {Ymin = y;}

	Path += {[x,y]};
	}

	//message("Max X: ", Xmax, " Y: ", Ymax);
	//message("Min X: ", Xmin, " Y: ", Ymin); // min will always be negative

	Xmax = max(Xmax,-Xmin); // odd lobes can cause min != max
	Ymax = max(Ymax,-Ymin); // … need really truly absolute maximum

	//—–
	// Scale points to actual plot size

	PlotScale = [PlotSize.x / (2Xmax), PlotSize.y / (2Ymax)];
	comment("Plot scale: ", PlotScale);

	Points = scale(Path,PlotScale); // fill page, origin at center

	//—–
	// Start drawing lines

	feedrate(1500.0mm);

	TravelZ = 1.5mm;
	PlotZ = -1.0mm;

	//—–
	// Box the outline for camera alignment

	goto([-,-,TravelZ]);
	goto([-PaperSize.x/2,-PaperSize.y/2,-]);
	goto([-,-,PlotZ]);

	foreach ( {[-1,1], [1,1], [1,-1], [-1,-1]} ; pt) {
	move([pt.xPaperSize.x/2,pt.yPaperSize.y/2,-]);
	}

	goto([-,-,TravelZ]);

	//—–
	// Draw the plot

	tracepath(Points, PlotZ);

	//—–
	// Add legends
	// … only for nonzero Pen

	if (Pen) {
	feedrate(250mm);

	TextFont = FONT_HSANS_1_RS;
	TextSize = [2.5mm,2.5mm];
	TextLeading = 1.5; // line spacing as multiple of nominal text height

	line1 = typeset("Seed: " + PRNG_Seed + " Stator: " + StatorTeeth + " Rotor: " + RotorTeeth,TextFont);
	line2 = typeset("Offset: " + L + " GCD: " + GCD + " Lobes: " + Lobes + " Turns: " + Turns,TextFont);

	maxlength = TextSize.x * max(line1[-1].x,line2[-1].x);

	textpath = line1 + (line2 – [-, TextLeading, -]); // undef – n -> undef to preserve coordinates
	textorg = [-maxlength/2,PaperSize.y/2 – 0Margins.y/2 – 2TextLeading*TextSize.y/2];

	placepath = scale(textpath,TextSize) + textorg;
	comment("Legend begins");
	engrave(placepath,TravelZ,PlotZ);

	attrpath = typeset("Ed Nisley – KE4ZNU – softsolder.com",TextFont);
	attrorg = [-(TextSize.x * attrpath[-1].x)/2,-(PaperSize.y/2 – Margins.y/2 + 2TextLeadingTextSize.y)];
	placepath = scale(attrpath,TextSize) + attrorg;
	comment("Attribution begins");
	engrave(placepath,TravelZ,PlotZ);
	}

	goto([PaperSize.x/2,PaperSize.y/2,25.0mm]); // done, so get out of the way

view raw Guilloche.gcmc hosted with ❤ by GitHub

	# Guilloche G-Code Generator
	# Ed Nisley KE4ZNU – September 2018

	Paper='PaperSize=[100mm,100mm]'

	Flags="-P 2"
	LibPath="-I /opt/gcmc/library"
	Spirograph='/mnt/bulkdata/Project Files/Mostly Printed CNC/Patterns/Guilloche.gcmc'

	Prolog="/home/ed/.config/gcmc/prolog.gcmc"
	Epilog="/home/ed/.config/gcmc/epilog.gcmc"

	ts=$(date +%Y%m%d-%H%M%S)

	if [ -n "$1" ] # if parameter
	then
	rnd=$1 # .. use it
	else
	rnd=$(date +%N) # .. otherwise use nanoseconds
	fi

	fn='Guilloche_'${ts}_$rnd'.ngc'
	echo Output: $fn

	p=1

	rm -f $fn

	echo "(File: "$fn")" > $fn
	#cat $Prolog >> $fn

	gcmc -D Pen=$p -D $Paper -D PRNG_Seed=$rnd $Flags $LibPath -G $Prolog -g $Epilog "$Spirograph" >> $fn

	#cat $Epilog >> $fn

view raw guilloche.sh hosted with ❤ by GitHub

2018-10-10

MPCNC: Modified Drag Knife Adapter Spring Constant

The bars on the original MPCNC drag knife / plotter pen adapter had a 100 g/mm spring constant:

MPCNC - Plotter pen force test — MPCNC – Plotter pen force test

Making the bars slightly thicker improved their print-ability:

MPCNC knife adapter mods - OpenSCAD model — MPCNC knife adapter mods – OpenSCAD model

The reddish tint marks the new bars, with their location carefully tweaked to be coincident with the stock STL.

Shoving the pen into the scale with 0.1 mm steps produces another unnervingly linear plot:

Modified MPCNC pen adapter - Spring Constant data — Modified MPCNC pen adapter – Spring Constant data

Real plotter pens want about 20 g of force, so this isn’t the holder you’re looking for.

A bunch of plots at Z=-1.0 mm turned out well with the ballpoint pen insert, though:

MPCNC Modifed pen adapter - first plots — MPCNC Modifed pen adapter – first plots

The globs apparently come from plotting too fast for conditions; reducing the speed to 1500 mm/min works better.

2018-10-09

MPCNC: Modified Drag Knife Adapter

A trio of Cutter Cutting Plotter Blade Holders arrived:

Despite the name, they’re not well-suited for drag knife blades, because they’re collets gripping a 2 mm shaft. The blade doesn’t rotate unless the plotter / cutter rotates the entire holder, which is actually a thing.

I got ’em because the snout of a common ball-point pen refill measures about 2 mm:

Collet pen holder - detail — Collet pen holder – detail

The glob around the tip comes from plotting too fast for conditions; about 1500 mm/min works better for continuous lines and 250 mm/min improves text.

The stock MPCNC adapter has a single recess suited for Genuine Plotter Pens, but the knurled lock ring on these cheapies sticks out far enough to make them wobbly. This being an inconvenience up with which I need not put, a few lines of OpenSCAD tweak the stock STL:

The original STL is ivory, new cuts are cyan, and additions are reddish.

The two support beams are now 1.6 mm = four thread widths, for improved slicing with a 0.35 mm nozzle and a higher spring constant.

It’s by-and-large indistinguishable from the old adapter:

MPCNC - Pen Holder Detail — MPCNC – Pen Holder Detail

Which I was using upside-down, because the flange fit better.

The MPCNC works reasonably well as a pen plotter with a genuine ballpoint pen:

The OpenSCAD source code as a GitHub Gist:

	// Adding clearance for eBay collet pen holder

	MPCNC_OD = 12.0; // pen holder OD (matches STL curvature)
	MPCNC_Z = 8.9; // Z offset of pen axis

	Pen_OD = 11.5; // actual pen body OD

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

	Flange = [11.5,15.7,2.2]; // actual pen body flange

	Locknut = [16.0,16.0,2.8]; // knurled locknut
	Locknut_Offset = 4.5; // flange center to locknut

	Wall = [41.0,4 * 0.4,9.0]; // thicker walls for more spring and better fill

	$fn = 32; // default cylinder sides

	difference() {
	translate([-(101.3 + MPCNC_OD/2),-111.9,0]) // put pen axis above Y axis, flange centered on X axis
	import("/mnt/bulkdata/Project Files/Mostly Printed CNC/Accessories/Tool Holders/MPCNC_525_Drag_Knife-1860310.STL",
	convexity=5);

	if (true) // improve holder-to-mount fit if needed
	translate([0,60/2,8.90])
	rotate([90,0,0])
	cylinder(d=MPCNC_OD,h=60);

	translate([0,0,MPCNC_Z]) // improve flange slot clearance
	rotate([90,0,0])
	cylinder(d=Flange[OD] + 1.0,h=Flange[LENGTH] + 0.5,center=true);

	translate([0,Locknut_Offset – 0.5,MPCNC_Z]) // add locknut clearance
	rotate([-90,0,0])
	cylinder(d=Locknut[OD] + 1.5,h=Locknut[LENGTH] + 1.5,center=false);
	}

	# translate([-(27.0 + Wall.x/2),0,0]) { // embiggen walls for higher spring constant
	translate([0,-24.4,0])
	cube(Wall);
	translate([0,20.6 – Wall.y,0])
	cube(Wall);
	}

view raw MPCNC Drag Knife Adapter – Collet Pen Mod.scad hosted with ❤ by GitHub

2018-10-08

Halogen Desk Lamp Conversion: Preliminaries

A discarded 20 W halogen desk lamp arrived in the Basement Laboratory for rebuilding:

Halogen Desk Lamp - head layout — Halogen Desk Lamp – head layout

An incandescent bulb doesn’t care about AC or DC, so a simple transformer also serves as a counterweight in the base:

Halogen Desk Lamp - 12 V 20 W transformer — Halogen Desk Lamp – 12 V 20 W transformer

I might replace it with some steel sheets, although I have no immediate need for a bare transformer.

A case adds 19¢ to each 10 W 300 mA LED driver:

Halogen Desk Lamp - 10 W LED driver innards — Halogen Desk Lamp – 10 W LED driver innards

Nice strain relief on those line-voltage wires, eh?

A simple test setup with three 3 W COB LED panels:

Halogen Desk Lamp - 3x3W COB LED test — Halogen Desk Lamp – 3x3W COB LED test

I clamped them to the aluminum sheet for heatsinking before I lit ’em up. The circles traced directly from the lamp’s hardware give some idea of the eventual layout.

I have more-intense LEDs, but spreading the light over a larger area should work better for the intended purpose. These are pleasant warm-white LEDs, too.

The fourth LED raised the forward voltage beyond the supply’s 42 V maximum, causing the supply to blink on and off.

Much to my surprise, the driver has plenty of 60 Hz ripple:

COB LED 3x3W - 10 W driver - 100 mA-div 10 V-div — COB LED 3x3W – 10 W driver – 100 mA-div 10 V-div

The top trace averages 280 mA and the bottom trace 32 V, so the LEDs run at 9 W = 3 W apiece, as they should.

Now, for some metalworking …

2018-10-05