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: Oddities

Who’d’a thunk it?

  • Low Budget Bench Supply: Digital Version

    This one costs slightly more than the analog tattoo power supply:

    Tattoo Digital Power Supply - front panel
    Tattoo Digital Power Supply – front panel

    The gold lion really spiffs up the Electronics Workbench!

    Somewhat to my surprise, the circuit uses a switching power supply based on a Reactor Micro RM6302 controller that can produce about an amp at voltages up to about 14 V:

    Tattoo Digital Power Supply - internal view
    Tattoo Digital Power Supply – internal view

    CAUTION: Everything on the input side of the transformer runs at line potential. I have my doubts about isolation, particularly under fault conditions.

    The trimpot on the PCB seems to adjust the output voltage, although it’s not clear what’s going on.

    The three wire AC line cord has a standard IEC entry block on the rear panel, albeit with the ground terminal not connected to anything inside the plastic case. It arrived with the hot wire soldered to a tiny fuse on the PCB and the neutral wire (red!) to the back-panel switch. There being no practical way to put the fuse before the switch, I rewired the hot side to the switch before the fuse and the unswitched neutral to the PCB; that’s as good as it’ll get.

    I also flipped the AC switch to put the ON position at the top. Sheesh.

    The two 1/4 inch jacks on the front panel are wired in series, so it didn’t matter which one got the tattoo needler or the foot switch:

    Tattoo Digital Power Supply - jacks in series
    Tattoo Digital Power Supply – jacks in series

    I rewired the sockets in parallel to eliminate the need for a shorting plug, although I cannot imagine any need for two outputs.

    The knob seemed unusually sloppy, which turned out to be due to a broken threaded sleeve around the pot shaft that prevented the crudely made nut from seating tightly:

    Tattoo Digital Power Supply - broken pot threads
    Tattoo Digital Power Supply – broken pot threads

    Given that the builders stuck everything else to the front panel with hot-melt glue, I followed suit:

    Tattoo Digital Power Supply - glued pot threads
    Tattoo Digital Power Supply – glued pot threads

    Which actually held it in place reasonably well, despite the hideous appearance. The knob covers the blob, so It Doesn’t Matter.

    The output range extends from about 1.2 V to just over 14 V at about an amp, but the knob seems erratic and the digital meter has only a casual relationship to the actual output voltage.

    I think if you regard this one as a parts kit, reverse-engineer the schematic (which surely descends directly from the RM6302 datasheet), and rebuild the electronics, it might work better.

    Bottom line: The analog version seems to be better as a low-budget power supply, not least because it has a metal case and an actual power transformer for galvanic isolation.

  • Wouxun KG-UV3D: Another Failure

    Once is happenstance, twice is coincidence:

    Wouxun KG-UV3D - failure
    Wouxun KG-UV3D – failure

    Three times is enemy action, but we’re not there yet. I was willing to believe something I’d done had killed both of the radios, even though it seemed unlikely for them to last five years and fail almost simultaneously.

    So I dismantled this one to see what’s inside. Pull off both knobs, remove the two screws at the bottom of the battery compartment, pry gently with a small screwdriver, and the whole PCB pulls out:

    Wouxun KG-UV3D - disassembly
    Wouxun KG-UV3D – disassembly

    A bit more prying separates the big pieces:

    Wouxun KG-UV3D - interior
    Wouxun KG-UV3D – interior

    Looking closely at the main PCB showed some problems I definitely didn’t cause:

    Wouxun KG-UV3D - PCB overview
    Wouxun KG-UV3D – PCB overview

    Although it’s been riding around on my bike, the white blotches on the PCB came from inadequate flux removal after hand soldering.

    A collection of images taken through the microscope reveals the problems:

    This slideshow requires JavaScript.

    I swabbed off the crud with denatured alcohol to no avail. The bottom side of the PCB has even more components and, I’m sure, even more crud, but I didn’t bother removing all the screws required to expose it, nor did I dismantle the other failed HT.

    I doubt Wouxun’s QC improved over the last few years, which means the two replacement KG-UV3D radios I just bought are already on their last legs, despite my paying top dollar to the same reputable source that sold me the first pair.

    We’ll be ready for new radios on new bikes by the time these fail.

  • MPCNC: Epoxy-filled Connector

    When I wired up the MPCNC’s tool length probe, I planned to reinforce the wiring with a dab of epoxy. What I didn’t notice in my enthusiasm, alas, was the opening from the rear to the front in each pin slot:

    Epoxied connector - rear
    Epoxied connector – rear

    Which let the epoxy flow completely through the connector:

    Epoxied connector - front
    Epoxied connector – front

    So I cut the mess off and applied heatstink tubing on each wire, just like I should have in the first place.

    Now you know the rest of the story …

    I really dislike pin headers as cable connectors, but that’s what the Protoneer CNC board uses:

    MPCNC - Protoneer Wiring - SSR
    MPCNC – Protoneer Wiring – SSR

    It’ll be Good Enough if I don’t do anything else particularly stupid.

  • Monthly Image: Snow-dusted Spider Silk

    The recent bitter cold and gusty winds swirled a dry snowfall around our back patio, where it clung to the (otherwise invisible) spider silk strands on the cedar shakes:

    Snow-dusted spider silk
    Snow-dusted spider silk

    It’d be Art if a human did it!

  • Eyebrow Lights

    A high energy collision / accident / mishap in front of Adams Fairacre Farms (a.k.a., the grocery store) demolished 20 feet of their dry laid stone wall along Rt 44, flattened several bushes, gouged trenches in the grass, and scattered plastic debris into the parking lot. The remains of a headlight eyebrow running light emerged from a snow pile:

    Eyebrow light - front
    Eyebrow light – front

    From the back:

    Eyebrow light - back
    Eyebrow light – back

    Contrary to what I expected, it has one white LED at each end of the chromed reflecting channel, topped with a shaped plastic lens collecting the light:

    Eyebrow light - Lens mount
    Eyebrow light – Lens mount

    The LED PCBs are in series, which produced a backwards wire color code on one end:

    Eyebrow light - LED PCB 1
    Eyebrow light – LED PCB 1

    The other end looked more reasonable:

    Eyebrow light - LED PCB 2
    Eyebrow light – LED PCB 2

    The white SMD LEDs draw 300+ mA at 3.6 V, so they’re obviously depending on external current limiting provided by the regulator PCB, sporting a TLE4242 linear current regulator and a handful of passives:

    Eyebrow light - Regulator PCB
    Eyebrow light – Regulator PCB

    AFAICT, they didn’t use the chip’s PWM control input or its LED failure status output.

    Extracting the various PCBs from the wreckage and reconnecting the wires produced a satisfactory result:

    Eyebrow light - resurrection
    Eyebrow light – resurrection

    The regulator limits the LED current to 120 mA at any input from a bit over 7 V to well past 12 V, with each LED dropping 3.0 V.

    Dunno what I’ll use this junk for, but at least I know a bit more about eyebrow lights. The chip date codes suggest 2010 and 2012; perhaps linear regulators have become passe by now.

  • Doing Biz On eBay

    I’ve always wondered what the Chinese-script company names on eBay meant, so I fed some into Google Translate (clicky for more dots):

    Chinese eBay Company Names
    Chinese eBay Company Names

    Huh.

    As the saying goes, ol’ Deng must be living “… modestly, if the kind of money he was getting out of me meant anything to him.”

  • Blog Summary: 2017

    Page views for 2017:

    Top Posts 2017
    Top Posts 2017

    Plumbing and car troubles continue to plague folks in Search Engine City.

    If I could monetize my broom handle thread IP, I’d be rich, I tell you, rich.

    Some interesting (and rounded) numbers from the ads you (presumably) don’t see, because adblocking.

    The blog gets just under 30 k page views/month, call it 1 k/day. Because most of the traffic arrives from search engines, each viewer looks at only 1.6 pages. Dividing the two suggests 18 k viewers/month.

    WordPress now shows 90 k ad impressions/month. Dividing 90 k impressions by 18 k viewers gives 5 ad impressions/viewer, which is about what you’d expect from the three ads appearing on the main page and each post seen individually: 3 ads/page × 1.6 page views/visitor = 4.8 ads/visitor.

    Before the big WP advertising push, they reported 15 k ad impressions/month for roughly the same 30 k page views/month and 1.6 pages/visitor. At one ad per page (which I don’t know for sure, but it seems reasonable), 30 k views should produce 30 k ad impressions. I can’t account for the discrepancy.

    Those of you using ad blockers (which I highly recommend!) don’t know what you’re missing.

    Onward, into the New Year …