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

  • 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…

  • HP 7475A Plotter: Refilling the Pens

    Plotters date back to the days before companies started using DRM to protect their monopoly positions, so refilling plotter pens requires little more than prying out the plug and squirting in more ink. Refilling the disposable liquid ink pens and the green ceramic pen suggested this would work.

    I shaved down the side of a Genuine HP pen to find out why the plug didn’t pop out. It turns out the plug has a long and aggressively ribbed profile to ensure a gas-tight fit:

    HP Plotter Pen - exposed plug
    HP Plotter Pen – exposed plug

    The easiest way to refill those is to drill an off-center 1/16 inch hole in the plug, then inject ink into the sponge with a syringe and blunt needle (and bulk ink!) from an inkjet cartridge refill kit. Angling the needle through the sponge close to the pen wall, then filling slowly, loads the sponge from the bottom up and expels the air along the way.

    Inmac pens have a shallow plug, more of a flat cap, that pries out with zero drama:

    Inmac Plotter Pen - removed plug
    Inmac Plotter Pen – removed plug

    Dripping the ink atop the sponge seems to work well, although that sponge is definitely over-filled.

    Inmac caps push back in place with zero drama.

    The pens have fiber nibs with vent channels along their sides that allow air into the reservoir, so overfilling the sponge nets you a mess when you take the cap off the nib: those same channels allow excess ink to run from the reservoir around the nib, without (much to my surprise) wetting the fiber tip.

    About 0.2 ml of ink fills the reservoir to saturation, 0.1 ml leaves it wet, and 0.05 ml seems to work well. The 1.0 ml syringes I’m using require about 0.05 ml to fill the (blunt!) needle shaft & hub, plus the syringe tip below the 0.0 ml index, so measuring the ink by drops might make practical sense.

    The old physician’s trick of expelling that air by inverting the syringe and pressing the plunger until liquid squirts from the needle is so not happening…

    I’ve had zero success refilling fossilized pens, probably because the OEM ink slowly evaporating from the nib clogs all the gaps between the fibers with pigment or coagulated solvent. Preemptively refilling good pens when they first show signs of running dry generally works well.

    Given the number of New Old Stock pens I have that are still in their original wrappers, this is more of a “Does it work?” exercise than a necessity.

    But, y’know, maybe becoming the last plotter pen refiller on the planet will be my ticket to fame & fortune! For sure, we’ve all seen over-hyped Internet startups with worse business plans and (the admittedly few) typewriter repair shops occupy a stable niche.

  • HP 7475A Plotter: Ceramic-Tip Pen Refill

    The ceramic-tip green pen I’ve been using finally ran dry and, having nothing to lose, I tried refilling it.

    Grabbing the metal ferrule in the drill press chuck provided enough traction to twist / pull it off, revealing the pen nib assembly inside:

    HP 7475A Ceramic-tip pen - ferrule
    HP 7475A Ceramic-tip pen – ferrule

    A pin vise provided enough traction to remove the nib, which had the expected fiber cylinder extending into the ink reservoir:

    HP 7475A Ceramic-tip pen - disassembly
    HP 7475A Ceramic-tip pen – disassembly

    I injected 0.5 ml of yellow ink from my lifetime supply of bulk inkjet ink (*), then tried to inject 0.5 ml of cyan, which promptly overflowed. In retrospect, allowing a few minutes for the new ink to seep into whatever’s inside the reservoir would be prudent.

    After wiping the mess off the pen and reassembling it in reverse order, it works just like new:

    HP 7475A Ceramic-tip pen - C-Y refill
    HP 7475A Ceramic-tip pen – C-Y refill

    During the course of the first plot, the trace went from green to deep blue-green to a different green, which suggests the yellow ink took a while to make its presence known. No problem; whatever comes out of that tip is all good with me.

    The stain around the rim of the pen body above the flange suggests a cap that might come off with sufficient persuasion. If it’s firmly fused to the flange, which would make perfect sense, injecting ink through a small hole drilled in the end might produce better results than ripping the nib out yet again.

    (*) This leftover came from the never-sufficiently-to-be-damned HP2000C inkjet printer. ‘Nuff said.

  • HP 7475A Plotter: Superformula Demo

    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
    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
    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)