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.

Tag: Improvements

Making the world a better place, one piece at a time

  • HP 7475A Plotter: SuperFormula Demo Madness!

    A gallery of SuperFormula plots, resized / contrast stretched / ruthlessly compressed (clicky for more dots):

    The gray one at the middle-bottom suffered from that specular reflection; the automagic contrast stretch couldn’t boost the paper with those burned pixels in the way.

    Those sheets all have similar plots on the back, some plots used refilled pens that occasionally bled through the paper, others have obviously bad / dry pens, and you’ll spot abrupt color changes where I swapped out a defunct pen on the fly, but they should give you an idea of the variations.

    The more recent plots have a legend in the right bottom corner with coefficients and timestamps:

    SuperFormula Plot - legend detail
    SuperFormula Plot – legend detail

    Limiting the pen speed to 10 cm/s (down from the default 38.1 cm/s = 15.00 inch/s) affects only the outermost segments of the spikes; down near the dense center, the 9600 b/s serial data rate limits the plotting speed. Plotting slowly helps old pens with low flow rates draw reasonably dense lines.

    Each plot takes an hour, which should suffice for most dog-and-pony events.

    I fill a trio of Python lists with useful coefficient values, then choose random elements for each plot: a single value of m determines the number of points for all six traces, then six pairs of values set n1 and n2=n3. The lists are heavily weighted to produce spiky traces, rather than smooth ovals, so the “random” list selections aren’t uniformly distributed across the full numeric range of the values.

    Because the coefficient lists contain fixed values, the program can produce only a finite number of different plots, but I’m not expecting to see any duplicates. You can work out the possibilities by yourself.

    The modified Chiplotle demo code bears little resemblance to the original:

    from chiplotle import *
    from math import *
    from datetime import *
    import random
    
    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
       tscale = 0.45
       numpens = 6
       m_list = [n/10.0 for n in [11, 13, 17, 19, 23, 29, 31, 37, 41, 43, 47, 53, 59]];   # prime/10 = number of spikes
       n1_list = [n/100.0 for n in range(15,75,1) + range(80,120,5) + range(120,200,10)]  # ring-ness 0.1 to 2.0, higher is larger diameter
       n2_list = [n/100.0 for n in range(10,50,1) + range(55,100,5) + range(110,200,10)]  # spike-ness 0.1 to 2.0, lower means spiky points
       paramlist = [[n1,n2] for n1 in random.sample(n1_list,numpens) for n2 in random.sample(n2_list,numpens)]
       if  not False:
         plt=instantiate_plotters()[0]
         plt.write('IN;')
    #     plt.write(chr(27) + '.H200:')   # set hardware handshake block size
         plt.set_origin_center()
         plt.write(hpgl.SI(tscale*0.285,tscale*0.375))    # scale based on B size characters
         plt.write(hpgl.VS(10))                           # slow speed for those abrupt spikes
         pen = 1
         plt.select_pen(pen)
         plt.write(hpgl.PA([(paperx - 3000,-(papery - 600))]))
         plt.write(hpgl.LB("Started " + str(datetime.today())))
         m = random.choice(m_list)
         for n1, n2 in zip(random.sample(n1_list,numpens),random.sample(n2_list,numpens)):
            n3 = n2
            print "m: ", m, " n1: ", n1, " n2=n3: ", n2
            plt.write(hpgl.PA([(paperx - 3000,-(papery - 500 + 100*(pen - 1)))]))
            plt.select_pen(pen)
            plt.write(hpgl.LB("Pen " + str(pen) + ": m=" + str(m) + " n1=" + str(n1) + " n2=n3=" + str(n2)))
            e = supershape(paperx, papery, m, n1, n2, n3)
            plt.write(e)
            if pen < numpens: 
                pen += 1
            else:
                pen = 1
         pen = 1
         plt.select_pen(pen)
         plt.write(hpgl.PA([(paperx - 3000,-(papery - 500 + 100*numpens))]))
         plt.write(hpgl.LB("Ended   " + str(datetime.today())))
         plt.select_pen(0)
       else:
         e = supershape(paperx, papery, 1.9, 0.8, 3, 3)
         io.view(e)
    
  • HP 7475A Plotter: Refilled Pen Performance

    Squirting brightly colored CMY ink mixes into an assortment of not-quite-dead-yet plotter pens produced reasonable results:

    CMYK Refilled Pens - plot overview
    CMYK Refilled Pens – plot overview

    The blotches on the legend in the lower left corner show that a refilled plotter pen can accumulate a droplet of ink around its nib, which should come as no surprise. I wiped off the excess immediately after refilling each pen, let the assortment sit for a few hours to (presumably) let the new ink reach the nib, and wiped them off before inserting them in the plotter’s pen carousel. All I can say is that I used up a bunch of paper towels in the process…

    A closer look at the plot shows Pretty Good If You Ask Me results:

    CMYK Refilled Pens - plot detail
    CMYK Refilled Pens – plot detail

    The two blue-ish pens have less flow than the others, resulting in dotted lines that should be continuous. As nearly as I can tell, that’s a function of how much OEM ink has solidified in the fiber nib and, most likely, the fiber rod that draws ink from the sponge reservoir inside the body.

    And, of course, the colors produced by adding CMY printer ink to the surviving OEM ink aren’t found in any catalog. I’m also blithely ignoring the difference between the inks inside plotter pens intended for paper and those for overhead transparencies; at this late date, that’s defined to Not Matter.

  • Clover MCI-900 Mini Iron Holder

    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
    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
    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
    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.

    Because OpenSCAD now includes a text() function, engraving her name in the platform turned out to be no big deal:

    Clover Mini Iron Holder - model
    Clover Mini Iron Holder – model

    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
    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 &gt; 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 &gt; 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.

  • M2 Motor Mount: Better-looking Cable Cap

    An objection was raised to my original cable strain relief technique with the PETG motor mount:

    M2 Motor Mount - PETG installed - cable brace
    M2 Motor Mount – PETG installed – cable brace

    The proffered replacement had a difficult-to-print orientation:

    M2 Motor Mount - Cable Cap - original STL orientation
    M2 Motor Mount – Cable Cap – original STL orientation

    Which Meshlab’s Manipulators Tool rotated by 90°:

    M2 Motor Mount - Cable Cap
    M2 Motor Mount – Cable Cap

    And that printed without any drama (or support), at least after I sliced it to use a single perimeter thread that could cope with the arch:

    M2 Motor Mount - Cable Cap - on platform
    M2 Motor Mount – Cable Cap – on platform

    Then a few pretty cable ties wrapped everything up in a decorative package:

    M2 Motor Mount - Cable Cap - installed
    M2 Motor Mount – Cable Cap – installed

    And that’s that…

    Memo to Self: Bang on the ␛ key to get out of whatever mode the Manipulators Tool gets wedged into.

  • Sony HDR-AS30V: AKA-SF1 Skeleton Frame Latch Repair

    My Sony HDR-AS30V is an action camera, but requires an external case / frame to mount it on anything. Here’s the camera inside its AKA-SF1 Skeleton Frame atop my helmet:

    Sony HDR-AS30V camera on bike helmet - inverted
    Sony HDR-AS30V camera on bike helmet – inverted

    Four 1 mm tall ramps on the inside of the black base (the part just above the yellow sled) snap into 2.6 mm square sockets in the skeleton frame surrounding the camera. For an unknown reason(s) that surely involves applying forces I don’t remember, an opposing pair of those ramps broke off, leaving the other pair to loosely hold one end of the camera in place.

    In this picture, the left ramps (one visible) are missing, leaving a square-ish gray scar that’s nearly indistinguishable from the reflection on the intact ramp on the right:

    Sony HDR-AS30V Skeleton Mount - broken latch ramps
    Sony HDR-AS30V Skeleton Mount – broken latch ramps

    Surprisingly, the round head of a brass 0-80 machine screw fits neatly inside the square socket on the frame; they’re a bit more than 1 mm deep. The approach ramps visible below the sockets guide the latches on the base:

    Sony HDR-AS30V Skeleton Mount - frame sockets
    Sony HDR-AS30V Skeleton Mount – frame sockets

    So I figured I could just shave off the remaining two latch ramps, drill four holes at the proper spots, and replace the plastic ramps with metal screws.

    I clamped the skeleton frame to the Sherline’s tooling plate, aligned it parallel to the X axis, put the laser spot dead center in the square socket, then snapped the base onto the frame. The laser spot shows where the drill will hit:

    Sony HDR-AS30V Skeleton Mount - laser hole alignment
    Sony HDR-AS30V Skeleton Mount – laser hole alignment

    A carbide drill did the honors:

    Sony HDR-AS30V Skeleton Mount - 0-80 hole drilling
    Sony HDR-AS30V Skeleton Mount – 0-80 hole drilling

    That’s a #55 = 0.0520 hole for 50% thread, rather than the proper 3/64 = 0.0469 hole for 75% thread, because that’s the closest short carbide drill I had; an ordinary steel twist drill, even in the screw-machine length I use on the Sherline, would probably scamper away. The hole isn’t quite on the sloped bottom edge of the base, but it’s pretty close.

    The first hole didn’t emerge quite in the center of its ramp scar:

    Sony HDR-AS30V Skeleton Mount - hole position - interior
    Sony HDR-AS30V Skeleton Mount – hole position – interior

    Which made sense after I thought about it: the ramp tapers to nothing in the direction of the offset, so the hole actually was in the middle of the matching socket.

    Threading the holes required nothing more than finger-spinning an 0-80 tap:

    Sony HDR-AS30V Skeleton Mount - tapping 0-80
    Sony HDR-AS30V Skeleton Mount – tapping 0-80

    The feeble thread engagement didn’t matter, because those mysterious tabs-with-slots (possibly for tie-down strings?) just above the holes were a perfect fit for 0-80 brass nuts:

    Sony HDR-AS30V Skeleton Mount - reassembled
    Sony HDR-AS30V Skeleton Mount – reassembled

    The screw heads extend into the sockets, hold the frame solidly in the base, and make it impossible to pull out. Although the frame still slides / snaps into the base, that seems like it will wear out the sockets in fairly short order, so I’ll unlatch the frame (with the yellow slide latch on top), open it up, ease it into position, and then latch it in place. That was the only way to remove it from the original latches, so it’s not a big deal.

    I should add a drop of epoxy to each of those nuts and perhaps fill the screw slots with epoxy to keep them from abrading the plastic inside the sockets. Maybe a dab of epoxy on the heads, followed by latching the frame in place, would form four square pegs to exactly fill the sockets.

    This was a straightforward repair that should not have been necessary…

  • Testing USB Memory Devices

    Tantris recommended the f3 set of programs to verify USB memory devices, which certainly seemed as though it would be faster and much less labor-intensive than my low-tech manual method.

    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…

  • Helmet Mirror Mount: Elevation Set Screw Slide

    The elevation tension adjustment on both our bike helmet mirror mounts have become a bit sloppy. That’s no surprise, because I expected the tiny set screw in the tiny square hole near the top to eventually wear a depression in the ABS plastic arc upon which it bears:

    Helmet mirror mount - 3D model - Fit layout
    Helmet mirror mount – 3D model – Fit layout

    The only surprise was that it took four years. That’s far longer than all of the commercial mirror and their mounts lasted; this one’s definitely a keeper.

    So I got to do something I planned pretty much from the beginning of the project: cut a snippet of phosphor bronze spring stock to go between the Elevation mount and the arc, then bend the ends bent inward so they don’t slash an errant fingertip:

    Helmet mirror mount - elevation slide
    Helmet mirror mount – elevation slide

    Slipped in place, the ends look like they stick out anyway, but they’re really just about flush:

    Helmet mirror mount - El slide in place
    Helmet mirror mount – El slide in place

    Tightening the set screw pushes the strip against the arc, where it provides enough resistance to prevent slipping and enough smoothness for easy adjustment.

    While I had the mounts up on the repair stand, I unscrewed the mirror shaft and snugged up the Azimuth pivot screw by a micro-smidgen to tighten that motion.

    Four years ago, those ABS parts popped off the much-hacked Thing-O-Matic’s platform. The M2 produces somewhat better-looking results, but that yellow plastic has a certain charm…