Ed Nisley's Blog: Shop notes, electronics, firmware, machinery, 3D printing, laser cuttery, and curiosities. Contents: 100% human thinking, 0% AI slop.
Category: Software
General-purpose computers doing something specific
A place to store your vials of blended inkjet juice, plus a workstation for the plotter pen you’re refilling and that ink vial up front:
HP7475A Plotter Pen Refilling Station
The two pen holders accommodate ordinary fiber-tip pens and ceramic-tip pens. The slot along the front lets you keep track of the ink level, not that there’s much danger of running dry at 0.05 ml per refill from a vial holding 1 ml of blended ink. The big flange makes it harder for me to knock the damn thing over; avoiding an ink spill, even when you have a towel underneath, is a Good Thing.
The Slic3r tool path preview shows off the Hilbert Curve top & bottom infill:
Plotter Pen Refill Vial Holder – Slic3r preview
The OpenSCAD source code:
// HP7475A Plotter Pen Refill Station
// Ed Nisley KE4ZNU - August 2015
//- Extrusion parameters - must match reality!
ThreadThick = 0.25;
ThreadWidth = 0.40;
function IntegerMultiple(Size,Unit) = Unit * ceil(Size / Unit);
Protrusion = 0.1;
HoleWindage = 0.2;
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,
$fn=Sides);
}
//------
// Dimensions
WallThick = 6*ThreadWidth;
BaseThick = IntegerMultiple(1.0,ThreadThick);
VialOD = 8.0;
VialOC = VialOD + WallThick;
VialArray = [4,4]; // number of vials in each direction
PenOD = [14.7,11.7]; // regular fiber pen body, ceramic *cap* dia
NumPens = len(PenOD); // really works for just two pens...
PenLength = 38;
FlangeOD = 18;
echo(str("Max pen OD: ",max(PenOD)));
echo(str("Number of pens: ",len(PenOD)));
Holder = [(VialOC*VialArray[0] + WallThick),(VialOC*VialArray[1] + 2*FlangeOD + WallThick),(3*VialOD + BaseThick)];
HolderRound = 5.0;
//- Build it
difference() {
union() {
hull() {
for (i=[-1,1], j=[-1,1]) {
translate([i*(Holder[0]/2 - HolderRound),j*(Holder[1]/2 - HolderRound),0])
cylinder(r=HolderRound,h=Holder[2],$fn=8*4);
}
}
hull() {
for (i=[-1,1], j=[-1,1]) {
translate([i*Holder[1]/2,j*(Holder[1]/2 - HolderRound),0])
cylinder(r=HolderRound,h=BaseThick,$fn=8*4);
}
}
for (i=[0:len(PenOD) - 1])
translate([(i*Holder[0]/2 - Holder[0]/4),-Holder[1]/4,BaseThick]) { // spacing is a total hack
rotate(180/12)
cylinder(d=FlangeOD,h=PenLength,$fn=3*4);
}
}
for (i=[0:VialArray[0] - 1] , j=[0:VialArray[1] - 1]) {
vx = i*VialOC - (VialOC*(VialArray[0] - 1)/2);
vy = j*VialOC - (VialOC*(VialArray[1] - 1)/2) + FlangeOD;
translate([vx,vy,BaseThick])
rotate(180/8)
PolyCyl(VialOD,Holder[2],8);
}
translate([0,(VialOD/2 - Holder[1]/2),BaseThick])
rotate(180/8)
PolyCyl(VialOD,Holder[2],8); // edges along open side => snug fit
for (i=[0:len(PenOD) - 1])
translate([(i*Holder[0]/2 - Holder[0]/4),-Holder[1]/4,BaseThick]) { // spacing is a total hack
rotate(180/12)
PolyCyl(PenOD[i],(PenLength + Protrusion),3*4);
}
}
Mary flattens seam allowances and prepares appliqué pieces with a Clover MCI-900 Mini Iron. The stand resembles the wire gadgets that came with soldering irons, back in the day:
Clover MCI-900 Mini Iron – Clover holder
That stand may be suitable on a workbench, but it’s perilously unstable on an ironing board. After fiddling around for a while and becoming increasingly frustrated with it, she asked for a secure holder that wouldn’t fall over and perhaps had a heat shield around the hot end.
I ran off a quick prototype to verify my measurements and provide a basis for further discussion:
Clover MCI-900 Mini Iron – Level holder
I proposed screwing that holder to a rectangle of leftover countertop extending under the hot end, with a U-shaped heat shield extending upward to keep fingers and fabric away from the blade. She decided the countertop might be entirely too heavy and the heat shield might be too confining, so she suggested just angling the iron upward and adding a flat platform to stabilize it.
Her wish being my command:
Clover MCI-900 Mini Iron – Angled holder
I’m still not convinced that having the hot end up in the air is a Good Thing, but she thinks it’s worth trying as-is. A pair of 10-32 screw holes under each end will let it mount to a base board, should that becomes necessary.
I’ll stick a foam sheet under the platform so it doesn’t slide around. The cord normally dangles downward off the side of the ironing board or work table, so the iron won’t get up and walk away, but it might pull the whole affair toward the edge.
I should fill the letters with JB Weld epoxy darkened with laser printer toner (who knew?) to make them stand out. They’re more conspicuous in person than in the picture, so maybe it doesn’t matter.
The slots holding the iron have a semicircular bottom and straight-wall sides, created by extruding hulled 2D shapes, arranging them along the iron’s central axis, and tilting the “iron” at the appropriate angle:
Clover Mini Iron Holder – solid model showing iron
That’s a 10° tilt, chosen because it looked right. The model recomputes itself around the key dimensions, so we can raise / lower the iron, change the angle, and so forth and so on, as needed.
Assuming that a hot end sticking out in mid-air isn’t too awful, this one looks like a keeper.
The OpenSCAD source code:
// Clover MCI-900 Mini Iron holder
// Ed Nisley KE4ZNU - August 2015
Layout = "Holder"; // Iron Holder
//- Extrusion parameters - must match reality!
ThreadThick = 0.25;
ThreadWidth = 0.40;
function IntegerMultiple(Size,Unit) = Unit * ceil(Size / Unit);
Protrusion = 0.1;
HoleWindage = 0.2;
inch = 25.4;
Tap10_32 = 0.159 * inch;
Clear10_32 = 0.190 * inch;
Head10_32 = 0.373 * inch;
Head10_32Thick = 0.110 * inch;
Nut10_32Dia = 0.433 * inch;
Nut10_32Thick = 0.130 * inch;
Washer10_32OD = 0.381 * inch;
Washer10_32ID = 0.204 * inch;
//------
// Dimensions
CornerRadius = 4.0;
CenterHeight = 25; // center at cord inlet on body
BodyLength = 110; // cord inlet to body curve at front flange
Incline = 10; // central angle slope
FrontOD = 29;
FrontBlock = [20,1.5*FrontOD + 2*CornerRadius,FrontOD/2 + CenterHeight + BodyLength*sin(Incline)];
CordOD = 10;
CordLen = 10;
RearOD = 22;
RearBlock = [15 + CordLen,1.5*RearOD + 2*CornerRadius,RearOD/2 + CenterHeight];
PlateWidth = 2*FrontBlock[1];
TextDepth = 3*ThreadThick;
ScrewOC = BodyLength - FrontBlock[0]/2;
ScrewDepth = CenterHeight - FrontOD/2 - 5;
echo(str("Screw OC: ",ScrewOC));
BuildSize = [200,250,200]; // largest possible thing
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,
$fn=Sides);
}
// Trim bottom from child object
module TrimBottom(BlockSize=BuildSize,Slice=CornerRadius) {
intersection() {
translate([0,0,BlockSize[2]/2])
cube(BlockSize,center=true);
translate([0,0,-Slice])
children();
}
}
// Build a rounded block-like thing
module RoundBlock(Size=[20,25,30],Radius=CornerRadius,Center=false) {
HS = Size/2 - [Radius,Radius,Radius];
translate([0,0,Center ? 0 : (HS[2] + Radius)])
hull() {
for (i=[-1,1], j=[-1,1], k=[-1,1]) {
translate([i*HS[0],j*HS[1],k*HS[2]])
sphere(r=Radius,$fn=4*4);
}
}
}
// Create a channel to hold something
// This will eventually be subtracted from a block
// The offsets are specialized for this application...
module Channel(Dia,Length) {
rotate([0,90,0])
linear_extrude(height=Length)
rotate(90)
hull() {
for (i=[-1,1])
translate([i*Dia,2*Dia])
circle(d=Dia/8);
circle(d=Dia,$fn=8*4);
}
}
// Iron-shaped series of channels to be removed from blocks
module IronCutout() {
union() {
translate([-2*CordLen,0,0])
Channel(CordOD,2*CordLen + Protrusion);
Channel(RearOD,RearBlock[0] + Protrusion);
translate([BodyLength - FrontBlock[0]/2 - FrontBlock[0],0,0])
Channel(FrontOD,2*FrontBlock[0]);
}
}
//- Build it
if (Layout == "Iron")
IronCutout();
if (Layout == "Holder")
difference() {
union() {
translate([(BodyLength + CordLen)/2 - CordLen,0,0])
TrimBottom()
RoundBlock(Size=[(CordLen + BodyLength),PlateWidth,CornerRadius]);
translate([(RearBlock[0]/2 - CordLen),0,0])
TrimBottom()
RoundBlock(Size=RearBlock);
translate([BodyLength - FrontBlock[0]/2,0,0]) {
TrimBottom()
RoundBlock(Size=FrontBlock);
}
}
translate([0,0,CenterHeight])
rotate([0,-Incline,0])
IronCutout();
translate([0,0,-Protrusion])
PolyCyl(Tap10_32,ScrewDepth + Protrusion,6);
translate([ScrewOC,0,-Protrusion])
PolyCyl(Tap10_32,ScrewDepth + Protrusion,6);
translate([(RearBlock[0] - CordLen) + BodyLength/2 - FrontBlock[0],0,CornerRadius - TextDepth]) {
translate([0,10,0])
linear_extrude(height=TextDepth + Protrusion,convexity=1) // rendering glitches for convexity > 1
text("Mary",font="Ubuntu:style=Bold Italic",halign="center",valign="center");
translate([0,-10,0])
linear_extrude(height=TextDepth + Protrusion,convexity=1) // rendering glitches for convexity > 1
text("Nisley",font="Ubuntu:style=Bold Italic",halign="center",valign="center");
}
}
The M2 buzzed away for four hours on that puppy, with the first 2½ hours devoted to building the platform. That’s the downside of applying Hilbert Curve infill to two big flat surfaces, but the texture looks really good.
Compiling it from source required installing two dependencies, which I discovered by the simple expedient of iteratively smashing into “fatal error: parted/parted.h: No such file or directory” messages:
libudev-dev
libparted0-dev
With those in place, unleashing f3probe on the most recent replacement Sony 64 GB MicroSD card went swimmingly:
sudo ./f3probe --time-ops /dev/sdb
F3 probe 5.0
Copyright (C) 2010 Digirati Internet LTDA.
This is free software; see the source for copying conditions.
Please unplug and plug back the USB drive. Waiting... Thanks
Please unplug and plug back the USB drive. Waiting... Thanks
Please unplug and plug back the USB drive. Waiting... Thanks
Please unplug and plug back the USB drive. Waiting... Thanks
Please unplug and plug back the USB drive. Waiting... Thanks
Please unplug and plug back the USB drive. Waiting... Thanks
CAUTION CAUTION CAUTION
No more resets are needed, so do not unplug the drive
Probe finished, recovering blocks... Done
Good news: The device `/dev/sdb' is the real thing
Device geometry:
*Real* size: 60.37 GB (126613504 blocks)
Announced size: 60.37 GB (126613504 blocks)
Module: 64.00 GB (2^36 Bytes)
Physical block size: 512.00 Byte (2^9 Bytes)
Probe time: 61.19 seconds
Probe read op: count=775, total time=4.00s, avg op time=5.16ms
Probe write op: count=753, total time=3.77s, avg op time=5.00ms
Probe reset op: count=6, total time=53.42s, avg op time=8903.21ms
As predicted, most of the time passed while I fiddled with the SD Card adapter in the slot on the side of the U2711 monitor: push to release, push to insert, repeat as prompted.
Despite the f3fix program’s ability to “repair” counterfeit USB memory by resetting the partition to the actual capacity, I think that’s a Bad Idea. Based on my admittedly limited experience, counterfeit junk generally doesn’t come from the middle of the quality-control bell curve, so expecting that crap to actually work over the long term seems, shall we say, overconfident.
The f3 doc also told me about lsblk, which may come in handy every now & again:
lsblk
NAME MAJ:MIN RM SIZE RO TYPE MOUNTPOINT
sda 8:0 0 111.8G 0 disk
├─sda1 8:1 0 56.8G 0 part /
└─sda2 8:2 0 9.3G 0 part [SWAP]
sdb 8:16 1 60.4G 0 disk
└─sdb1 8:17 1 60.4G 0 part /media/ed/9C33-6BBD
sr0 11:0 1 1024M 0 rom
Now I have a reminder of how to do this for The Next Time…
Setting n2=n3=1.5 generates smoothly rounded shapes, rather than the spiky ones produced by n2=n3=1.0, so I combined the two into a single demo routine:
HP 7475A – SuperFormula patterns
A closer look shows all the curves meet at the points, of which there are 37:
HP 7475A – SuperFormula patterns – detail
The spikes suffer from limited resolution: each curve has 10 k points, but if the extreme end of a spike lies between two points, then it gets blunted on the page. Doubling the number of points would help, although I think this has already gone well beyond the, ah, point of diminishing returns.
I used the three remaining “disposable” liquid ink pens for the spiked curves; the black pen was beyond repair. They produce gorgeous lines, although the magenta ink seems a bit thinned out by the water I used to rinse the remains of the last refill out of the spiral vent channel.
I modified the Chiplotle supershape() function to default to my choices for point_count and travel, then copied the superformula() function and changed it to return polar coordinates, because I’ll eventually try scaling the linear value as a function of the total angle, which is much easier in polar coordinates.
The demo code produces the patterns in the picture by iterating over interesting values of n1 and n2=n3, stepping through the pen carousel for each pattern. As before, m should be prime/10 to produce a prime number of spikes / bumps. You could add more iteration values, but six of ’em seem entirely sufficient.
A real demo should include a large collection of known-good parameter sets, from which it can pick six sets to make a plot. A legend documenting the parameters for each pattern, plus the date & time, would bolster the geek cred.
The Python source code with the modified Chiplotle routines:
from chiplotle import *
from math import *
def superformula_polar(a, b, m, n1, n2, n3, phi):
''' Computes the position of the point on a
superformula curve.
Superformula has first been proposed by Johan Gielis
and is a generalization of superellipse.
see: http://en.wikipedia.org/wiki/Superformula
Tweaked to return polar coordinates
'''
t1 = cos(m * phi / 4.0) / a
t1 = abs(t1)
t1 = pow(t1, n2)
t2 = sin(m * phi / 4.0) / b
t2 = abs(t2)
t2 = pow(t2, n3)
t3 = -1 / float(n1)
r = pow(t1 + t2, t3)
if abs(r) == 0:
return (0,0)
else:
# return (r * cos(phi), r * sin(phi))
return (r,phi)
def supershape(width, height, m, n1, n2, n3,
point_count=10*1000, percentage=1.0, a=1.0, b=1.0, travel=None):
'''Supershape, generated using the superformula first proposed
by Johan Gielis.
- `points_count` is the total number of points to compute.
- `travel` is the length of the outline drawn in radians.
3.1416 * 2 is a complete cycle.
'''
travel = travel or (10*2*pi)
## compute points...
phis = [i * travel / point_count
for i in range(1 + int(point_count * percentage))]
points = [superformula_polar(a, b, m, n1, n2, n3, x) for x in phis]
## scale and transpose...
path = [ ]
for r, a in points:
x = width * r * cos(a)
y = height * r * sin(a)
path.append(Coordinate(x, y))
return Path(path)
## RUN DEMO CODE
if __name__ == '__main__':
paperx = 8000
papery = 5000
if not False:
plt=instantiate_plotters()[0]
plt.set_origin_center()
plt.write(hpgl.VS(10))
pen = 1
for m in [3.7]:
for n1 in [0.20, 0.60, 0.8]:
for n2 in [1.0, 1.5]:
n3 = n2
e = supershape(paperx, papery, m, n1, n2, n3)
plt.select_pen(pen)
if pen < 6:
pen += 1
else:
pen = 1
plt.write(e)
plt.select_pen(0)
else:
e = supershape(paperx, papery, 1.9, 0.8, 3, 3)
io.view(e)
Although the Superformula can produce a bewildering variety of patterns, I wanted to build an automated demo that plotted interesting sets of similar results. Herewith, some notes after an evening of fiddling around with the machinery.
The first two parameters set the more-or-less maximum X and Y values in plotter units; the plot is centered at zero and will extend that far in both the positive and negative directions. For US paper:
A = Letter = 11 x 8½ inch → 4900 x 3900
B = 17 x 11 inch → 8000 x 5000
The point_count parameter defines the number of points to be plotted for the entire figure. They’re uniformly distributed in angle, not in distance, so some parts of the figure will plot very densely and others sparsely, but the plotter will connect all of the points with straight lines and it’ll look reasonably OK. For the figures below, 10*1000 works well.
The travel value defines the number of full cycles that the figure will make, in units of 2π. Ten cycles seems about right.
The four parameters in between those are the m, n1, n2, and n3 values plugged directly into the basic Superformula. The latter two are exponents of the trig terms; 1.0 seems less bizarre than anything else.
Sooo, that leaves only two knobs…
With travel set for 10 full cycles, m works best when set to a value that’s equal to prime/10, which produces prime points around the figure. Thus, if you want 11 points, use m=1.1 and for 51 points, use m=5.1. Some non-prime numbers produce useful patterns (as below), others collapse into just a few points.
The n1 parameter is an overall exponent for the whole formula in the form -1/n1. Increasing values, from 0.1 to about 2.0, expand the innermost points of the pattern outward and turn the figure into more of a ring and less of a lattice.
So, for example, with m=3.1, setting n1= 0.15, 0.30, 0.60 produces this pattern with 31 points:
HP 7475A – Superformula – m 3.1 vary n1
Varying both at once, thusly: (m,n1) = (1.9,0.20)=green (3.7,0.30)=red (4.9,0.40)=blue
produces this pattern:
HP 7475A – Superformula – m 1.9 3.7 4.9 n1 0.2 0.3 0.4
Yeah, 49 isn’t a prime number. It’s interesting, though.
Note that n1 doesn’t set the absolute location of the innermost points; you must see how it interacts with m before leaping to any conclusions.
It’s still not much in the way of Art, but it does keep the plotter chugging along for quite a while and that’s the whole point. I must yank the functions out of the Chiplotle library, set my default values, add one point to automagically close the last vertex, and maybe convert them to polar coordinates to adjust the magnitude as a function of angle.
Yes, that poor green ceramic-tip pen is running out of ink after all these decades.
The previous cards were made in Korea, but this one came from Taiwan with a different serial number format:
Sony SR-64UX 64 GB MicroSDXC card – back
The tiny letters on the front identify it as an SR-64UX, but I haven’t been able to find any definitive Sony source describing the various cards; their catalog page listing cards for digital still cameras may be as good as it gets. This one seems to have a higher read speed, for whatever little good that may do.
It stored and regurgitated the usual deluge of video files with no problem, which is only to be expected. This time around, I checked the MD5 sums, rather than unleashing diff on the huge files:
cd /media/ed/9C33-6BBD/
for f in * ; do find /mnt/video/ -name $f | xargs md5sum $f ; done
11e31c9ba3befbef6dd3630bb68064d6 MAH00539.MP4
11e31c9ba3befbef6dd3630bb68064d6 /mnt/video/2015-07-05/MAH00539.MP4
... snippage ...
It now sits in the fancy plastic display case that the HDR-AS30V camera came in until the previous replacement card fails.
Verily, ImageMagick can do nearly anything you want to an image, as long as you know how to ask for it:
for f in *png ; do convert $f -density 300 -define jpeg:extent=200KB ${f%%.*}.jpg ; done
That converts a directory full of VLC’s video snapshot images from PNG format, which require nigh onto 4 MB each, into correspondingly named JPG files under 200 kB. The image quality may not be the greatest, but it’s good enough to document road hazards in emails.
Rt 376 2015-07-06 – Walker to Maloney – 3
The density option overrides VLC’s default 72 dpi, which doesn’t matter until a program attempts to show the image at “actual size”.
I didn’t realize that the define option existed, but it seems to be how you jam specific controls into the various image coders & decoders. Some of the “artifacts”, well, I can’t even pronounce…
VLC’s snapshot file names look like vlcsnap-2015-07-06-12h10m27s10.png, so bulk renaming and resequencing will be in order.