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

Bafang BBS02: Terry Cable Stop Cap

The Terry Symmetry had shift cables running along the down tube, with cable housing stop bushings at the top:

Terry Bafang - OEM shift stop — Terry Bafang – OEM shift stop

Without the front derailleur and with the wiring harness cable on the left side, a tidy cap seemed in order:

Terry Bafang - shift stop cap — Terry Bafang – shift stop cap

The oversize passage give the cable a little flex room, although that’s probably unnecessary. I reused the original M5 screw, with a washer to spread the load.

The solid model is basically a hull around some cylinders:

Terry - Bafang shift cap - solid model — Terry – Bafang shift cap – solid model

The interior matches the stud brazed onto the downtube:

Terry - Bafang shift cap - interior - solid model — Terry – Bafang shift cap – interior – solid model

The only practical way to build the thing required a brim stabilizing it on the platform:

Terry - Bafang shift cap - slice preview — Terry – Bafang shift cap – slice preview

My usual 0.25 mm layers came out a bit crude on the vast overhang, but 0.15 mm layers worked fine.

The OpenSCAD source code snippet:

CapBlock = [18,18,16.5];

module ShiftCap() {

Rounding = 3.5;
CapM = 3.0;
StudBase = [12.5,12.5,4.5];
Stud = [5.0,9.3,15.5];

    difference() {
        hull() {
            translate([0,0,CapBlock.z - 0.5])
                PolyCyl(Washer5[OD],0.5,12);
            for (i=[-1,1], j=[-1,1])
                translate([i*(CapBlock.x/2 - Rounding),j*(CapBlock.y/2 - Rounding),0])
                    sphere(r=Rounding,$fn=12);
            translate([-CapBlock.x/2,-Harness[ID]/2 - StudBase.y/2,StudBase.z/2])
                rotate([0,90,0])
                    cylinder(d=Harness[ID] + 2*WallThick,h=CapBlock.x,$fn=12);
        }

        translate([0,0,-(FrameTube.z/2 - CapM)])
            Frame();

        PolyCyl(Screw5[ID],2*CapBlock.z,6);

        PolyCyl(Stud[OD],Stud[LENGTH],12);

        translate([0,0,StudBase.z/2])
            cube(StudBase,center=true);

        translate([0,-StudBase.y/2,StudBase.z/2])
            cube(StudBase + [0,-StudBase.y/2,0],center=true);

       translate([-CapBlock.x,-Harness[ID]/2 - StudBase.y/2,StudBase.z/2])
            rotate([0,90,0])
                cylinder(d=1.5*Harness[ID],h=2*CapBlock.x,$fn=12);

    }
}

Of course, I needed three tries to get the correct dimensions, but that’s what rapid prototyping is all about.

2021-06-23

Bafang BBS02: Terry Brake Sensor
The old-school “aero” brake levers on Gee’s Terry Symmetry bike have rubberoid cushion covers, so I slid the Bafang brake sensors inside:

Terry Bafang brake sensor – front

They make the grips somewhat wider, but I can’t figure out a less destructive way of installing the things.

I glued the magnet inside a holder contoured to fit the space available:

Terry – Bafang brake sensor – solid model

Knocking the corners off makes it much more finger-friendly.

It’s unobtrusive with the handle released:

Terry Bafang brake sensor – released

When you squeeze the lever, your fingers are nowhere near the magnet:

Terry Bafang brake sensor – pulled

The lower edge actually slides along the brake lever housing without touching, but it’s a near thing.

Those are the same magnets I used for the Bafang brake sensors on Mary’s Tour Easy, once again aligned to aim the strongest volume of the magnetic field toward the sensor. The brake sensors activate just before the pads touch the rims and release with the magnets a few millimeters away from the sensors.

A complete coat of JB Plastic Bonder urethane adhesive covers each magnet to both isolate it from the weather and conceal the fact that they’re recycled from a power toothbrush.

Now that I know they work in this position, I must ease adhesive underneath the sensors so they don’t move around under normal hand pressure.

The OpenSCAD source code snippet:
```
module BrakeMagnet() {

    Magnet = [10.5,3.0,5.5];
    Plate = 2*ThreadThick;
    BrakeRad = 10.0;            // brake handle curve Radius
    Holder = [2*BrakeRad,7.0,Magnet.z + Plate];


    difference() {
        intersection() {
            translate([0,-BrakeRad,0])
                rotate(180/24)
                    cylinder(r=BrakeRad,h=Holder.z,$fn=24);
            translate([0,BrakeRad - Holder.y,Holder.z/2])
                cube([2*BrakeRad,2*BrakeRad,Holder.z],center=true);
            translate([0,0,-2*BrakeRad/sqrt(2) + Holder.z - 3.0 + BrakeRad])
                rotate([0,45,0])
                    cube(2*[BrakeRad,2*BrakeRad,BrakeRad],center=true);
        }
        translate([0,Magnet.y/2 - Holder.y - Protrusion/2,Magnet.z/2 + Plate + Protrusion/2])
            cube(Magnet + [0,Protrusion,Protrusion],center=true);
    }

}
```
2021-06-22
Bafang BBS02: Speed Sensor Alignment

My friend Gee’s bike is a Terry Symmetry, designed for (small) women, which poses challenges when mounting “normal size” components. The Bafang BBS02 speed sensor mount (with a reshaped nut) requires far more clearance between the chainstay and the wheel spokes than the Symmetry has:

Bafang BBS02 Speed Sensor – OEM bracket

The chainstay is nearly parallel to the spokes, so the sensor fits equally poorly anywhere its cable will allow.

The obvious solution is to reverse the mount and stick it to the outside of the chainstay, but it’s not mmmm symmetric: the other end is closed. Use a pull saw to cut off the closed end, stick the sensor post in the other way, and then it fits fine:

Bafang BBS02 Speed Sensor – reversed bracket – top

The sawed-off mount is visible from below:

Bafang BBS02 Speed Sensor – reversed bracket – bottom

It looks fine from the outside:

PXL_20210620_160950653 – Bafang BBS02 Speed Sensor – reversed bracket – left side

Mad props to Bafang for the LED showing when the magnet is properly positioned.

2021-06-21
Bafang BBS02: Drop-bar Throttle Adapter

The Bafang BBS02 package includes a thumb-activated throttle which, like the display, should clamp onto a 22.2 mm handlebar. The one on Mary’s bike fit neatly at the end of the left handgrip:

Tour Easy grips – left installed

There’s no similar location on a drop-bar bike that doesn’t get in the way, particularly on my friend Gee’s bike with narrow bars.

With a display handlebar adapter in hand, this seemed less awful than anything else I had in mind:

Bafang Throttle adapter – front view

That’s the front view, so it’s on the right side in front of the handlebar. I think it’s usable with either a thumb or fingertips from a hand on the top of the bar. The handlebar lacks tape, as mounting the brake sensors poses a challenge.

The view from the rear isn’t too revealing:

Bafang Throttle adapter – rear view

Not too unsightly, but definitely not a standard setup!

2021-06-18

Bafang BBS02: Drop-bar Display Adapter

All of the Bafang BBS02 displays have a compression clamp intended for more-or-less standard 22.2 mm handlebars, as found on typical upright BMX-ish bikes suitable for conversion to e-bikes and, oddly, our Tour Easy recumbents. My friend’s bike has drop-bar handlebars with a 25.4 mm (yes, exactly 1 inch) center section that just isn’t going to fit through that hole.

The least awful solution involved summoning an adapter from the vasty digital deep:

Display adapter mount - solid model — Display adapter mount – solid model

The hole clamps around the handlebar with an M3 SHCS pulling it snug and the display clamps around the peg to hold everything together:

Bafang Display adapter - front view — Bafang Display adapter – front view

There’s not much to see from the side:

Bafang Display adapter - left view — Bafang Display adapter – left view

Those scuffs arrived on the protective plastic film!

The OpenSCAD source code includes some cruft from an idea that didn’t work out quite right:

HandlebarMax = 1*inch;                      // middle handlebar diameter
HandlebarMin = 24.0;                        //  .. tape section

BafangClampID = 22.3;                       // new handlebar diameter


… snippage …

// Handlebar mount for controller

module DispMount() {

ClampRing = [HandlebarMax,HandlebarMax + 2*WallThick,10.0];
ClampOffset = (HandlebarMax + BafangClampID)/2 + 6.0;

DispStudLenth = 16.5;

NumSides = 24;

Tilt = 0*atan2((ClampRing[OD] - BafangClampID)/2,ClampOffset);
echo(str("Tilt: ",Tilt));

    difference() {
        union() {
            hull() {
                cylinder(d=ClampRing[OD],h=ClampRing[LENGTH],$fn=NumSides);
                translate([0,ClampOffset,0])
                    cylinder(d=BafangClampID,h=ClampRing[LENGTH],$fn=NumSides);
            }
            translate([0,ClampOffset,0])
                cylinder(d=BafangClampID,h=ClampRing[LENGTH] + DispStudLenth,$fn=NumSides);
            translate([-ClampRing[ID]/4,-(ClampRing[OD]/2),ClampRing[LENGTH]/2])
                rotate([0,90,0]) rotate(180/8)
                    cylinder(d=ClampRing[LENGTH]/cos(180/8),h=ClampRing[ID]/2,$fn=8);
        }
        cube([Kerf,4*ClampOffset,4*DispStudLenth],center=true);
        translate([0,0,-Protrusion])
            cylinder(d=ClampRing[ID],h=ClampRing[LENGTH] + 2*Protrusion,$fn=NumSides);
        translate([-ClampRing[ID]/2,-(ClampRing[OD]/2),ClampRing[LENGTH]/2])
            rotate([0,90,0]) rotate(180/8)
                PolyCyl(Screw3[ID],ClampRing[ID],8);
        for (i=[-1,1])
            translate([i*ClampRing[ID]/4,-(ClampRing[OD]/2),ClampRing[LENGTH]/2])
                rotate([0,i*90,0]) rotate(180/8)
                    PolyCyl(Washer3[OD],ClampRing[ID],$fn=8);

        translate([-5,25,EmbossDepth/2 - Protrusion/2])
            rotate(Tilt)
                cube([4.5,21.5,EmbossDepth + Protrusion],center=true);

    }

    translate([-5,25,0])
        linear_extrude(height=EmbossDepth)
            rotate(90 + Tilt) mirror([0,1,0])
              text(text="KE4ZNU",size=3.3,spacing=1.05,font="Bitstream Vera Sans:style=Bold",
                   halign="center",valign="center");

}

It’s rock-solid stable: pushing the buttons doesn’t budge it in the least.

2021-06-17

Bafang BBS02 Programming Adapter: CP2102 Version

The last view before sticking the lid in place with hot melt glue:

Bafang BBS02 - CP2102 Programming Adapter — Bafang BBS02 – CP2102 Programming Adapter

The cable on the right goes to the motor controller through the display pigtail cable, sporting colors from a parallel universe.

A (possibly not counterfeit) CP2102 USB-to-serial adapter allows a slightly smaller case than one with the known-fake FTDI adapter and added some identification:

Bafang BBS02 - CP2102 Programming Adapter - case solid model — Bafang BBS02 – CP2102 Programming Adapter – case solid model

It splits along the midline for printing, of course.

The OpenSCAD source code replaces the previous version:

// Programming cable case

ProgCavity = [60.0,18.0,7.0];
ProgBlock = [70.0,24.0,13.0];
ProgCableOD = 4.0;

module ProgrammerCase() {

    difference() {
        hull() {
            for (i=[-1,1], j=[-1,1])
                translate([i*(ProgBlock.x/2 - CornerRadius),j*i*(ProgBlock.y/2 - CornerRadius),-ProgBlock.z/2])
                    cylinder(r=CornerRadius,h=ProgBlock.z,$fn=12);
            }
        translate([-ProgBlock.x,0,0])
            rotate([0,90,0])
                PolyCyl(ProgCableOD,3*ProgBlock.x,6);
        cube(ProgCavity,center=true);

        translate([0,0,ProgBlock.z/2 + ProgCavity.z/2 - EmbossDepth])
            cube(ProgCavity,center=true);
        translate([0,0,-(ProgBlock.z/2 + ProgCavity.z/2 - EmbossDepth)])
            cube(ProgCavity,center=true);

    }

    translate([0,4,ProgBlock.z/2 - EmbossDepth])
        linear_extrude(height=EmbossDepth)
            text(text="Bafang BBS02",
                 size=5,spacing=1.00,font="Bitstream Vera Sans:style=Bold",
                 halign="center",valign="center");

    translate([0,-4,ProgBlock.z/2 - EmbossDepth])
        linear_extrude(height=EmbossDepth)
            text(text="Programmer",
                 size=5,spacing=1.00,font="Bitstream Vera Sans:style=Bold",
                 halign="center",valign="center");

    translate([0,4,-ProgBlock.z/2])
        linear_extrude(height=EmbossDepth)
            mirror([1,0])
                text(text="Ed Nisley",
                    size=5,spacing=1.00,font="Bitstream Vera Sans:style=Bold",
                    halign="center",valign="center");
    translate([0,-4,-ProgBlock.z/2])
        linear_extrude(height=EmbossDepth)
            mirror([1,0])
                text(text="softsolder.com",
                    size=5,spacing=1.00,font="Bitstream Vera Sans:style=Bold",
                    halign="center",valign="center");

}

// Half case sections for printing

module HalfCase(Section = "Upper") {

    intersection() {
       translate([0,0,ProgBlock.z/4])
            cube([2*ProgBlock.x,2*ProgBlock.y,ProgBlock.z/2],center=true);
        if (Section == "Upper")
            ProgrammerCase();
        else
            translate([0,0,ProgBlock.z/2])
                ProgrammerCase();
    }
}

// .. snippage ..

        translate([0,2*Block.x/2 * gap,0]) {

            translate([gap*ProgBlock.x/2,0,ProgBlock.z/2])
                rotate([180,0,0])
                    HalfCase("Upper");
            translate([-gap*ProgBlock.x/2,0,0])
                HalfCase("Lower");
        }

My friend rides about the same way we do, except from a much higher perch, so I’ll start her off with a configuration similar to the one we settled on for Mary’s Tour Easy.

2021-06-15

Microscope Stage Positioner: Rigid MakerBeam Edition

Rebuilding the XYZ stage positioner with MakerBeam aluminum struts, but without the steel brackets, produce a much more rigid result:

Microscope Stage Positioner – rigid Makerbeam

This requires drilling holes through the extrusions:

Microscope Stage Positioner – Makerbeam drilling

Running the center drill down until it just nicks the sides produces enough of a pilot hole through the center section to capture the 3 mm drill. If I had to drill enough holes to make a fixture worthwhile, I could probably eliminate the divots.

Two more holes + epoxied M3 brass inserts attached the 60 mm beam directly to the Z Axis stage, thereby eliminating the vertical beam and a steel bracket:

Microscope Stage Positioner – Makerbeam joints

The M3 SHCS attaching the 100 mm beam goes through both beams. I think you could get the same result with a Tee Nut or a 12 mm Square Head bolt, should you have those lying around and don’t want to drill another hole. The Corner Cube screwed into both beams prevents rotation and helps ensure perpendicularity.

The Y stage now attaches directly to the beam, rather than through a pair of Corner Cubes, because I realized I wasn’t ever going to adjust its position.

The Z Axis stage stands on the plastic plate through a hellish mixture of metric and USA-ian screws. Basically, the 6-40 screws into the stage were long enough, the 6-32 screws through the plate fit the existing holes, and M3 screws are for MakerBeam:

Microscope Stage Positioner – Z Axis base

To my utter astonishment, the threads in the end of the vertical beam had the proper alignment to let a Square Head bolt snug the beam against the 40 mm beam on the plate. As a result, the L Bracket just prevents the vertical beam from turning on the screw and the combination is as rigid as you (well, I) could want.

The 40 mm beam has two spurious holes, because I thought I could avoid drilling another hole in the baseplate. Nobody will ever notice.

After squaring and tightening everything, the 100 mm beam along the Y Axis is now horizontal within 0.2 mm and the X Axis is horizontal to better than I can measure.

It’s definitely Good Enough™ for me:

Microscope Stage Positioner – in use

Remember, nothing exceeds like excess …

2021-06-08