Category: Maker

Normalised RMS voltage of a full wave phase controlled power waveform

The recent article Soldering iron – temperature control failure gave a plot of V’rms vs conduction angle for a simple full wave phase controlled AC waveform, and I have been asked to explain the derivation.

The phase controlled switch turns on at some delayed time from the zero crossing of the AC waveform, and conducts until the next zero crossing.

With the simplest circuits, there is a practical limit to the achievable stable range of conduction angle, and a minimum of about 50° to a maximum of about 160° is typical.

The RMS voltage is the square root of the mean of the square of the instantaneous voltage. We can write an expression for the normalised RMS voltage as a function of conduction angle θ. Continue reading Normalised RMS voltage of a full wave phase controlled power waveform

Last update: 6th January, 2020, 6:12 PM

Soldering iron – temperature control failure

I wanted to modify a soldering iron to insert brass threaded inserts into holes drilled in plastic parts, and for this application looked to eBay for an inexpensive temperature controlled soldering iron that could be adjusted down to around 200°.

Well first check was of its temperature when set to 200°.

Ouch, that is a fail. The Chinese cheats have supplied product that does not comply with its description. Continue reading Soldering iron – temperature control failure

Last update: 1st January, 2020, 2:47 AM

Acrylic plinth for small card modules – CNC router make

At Acrylic plinth for small card modules I described a contruction from sheet materials using a saw or score and snap.

In this article, I made a small plinth using the CNC router.

The design was created in Fusion 360 by importing a pic of the target module, calibrating it, and then laying up the plinth outline and the four holes. The first hole was dimensioned for diameter, then copied to the other three positions. Apart from dimensioning the first hole, all other design was visual.

Above is the design sketch. As a check, a dimension was take from the two widest spaced holes and compared with measurement of the actual board, and it was within 0.05mm. Continue reading Acrylic plinth for small card modules – CNC router make

Last update: 22nd November, 2019, 12:56 PM

CNC6040 router project – cut of enclosure for grbl_ESP32

One of the intended applications of the CNC router is to cut openings in metal and plastic enclosure boxes boxes for things like LCD displays, tactile button switches, connectors etc.

First ‘production’ job was a box to contain the grbl_ESP32 gcode interpreter, part of the CNC router if you like.

This module is the grbl_ESP32 box in the block diagram above. Continue reading CNC6040 router project – cut of enclosure for grbl_ESP32

Last update: 16th November, 2019, 6:35 AM

CNC6040 router project – test cut of a Jiffy box

One of the intended applications of the CNC router is to cut openings in Jiffy boxes for things like LCD displays, tactile button switches, connectors etc.

After a lot of testing, it came time to try it on some target work.

Above is a scrap Jiffy box and the milling job is to cut holes for three pushbuttons (tactile momentary switches on a veroboard base with 10mm caps) and the holes for M3 screws and pillars. Continue reading CNC6040 router project – test cut of a Jiffy box

Last update: 21st October, 2019, 8:54 AM

CNC6040 router project – spindle speed linearisation – using new grbl_ESP32 feature

A known issue with the common CNC6040 router and similar devices is very poor calibration / linearity of the spindle motor response to gcode Sx commands.

Above is the system block diagram. The grbl_ESP32 gcode interpeter processes a gcode S (speed) command, converting it to a variable duty cycle PWM waveform on parallel port pin 1. Continue reading CNC6040 router project – spindle speed linearisation – using new grbl_ESP32 feature

Last update: 28th December, 2020, 7:53 AM

CNC6040 router project – spindle speed linearisation

A known issue with the common CNC6040 router and similar devices is very poor calibration / linearity of the spindle motor response to gcode Sx commands.

Above is the system block diagram. The grbl_ESP32 gcode interpeter processes a gcode S (speed) command, converting it to a variable duty cycle PWM waveform on parallel port pin 1. Continue reading CNC6040 router project – spindle speed linearisation

Last update: 12th October, 2019, 5:14 AM

OpenLog for TinyTrak – inline DE9 adapter

OpenLog for TinyTrak described a data logger for APRS NMEA data.

This article shows an innovative inline adapter for adding an Openlog to an existing APRS installation where the GPS is powered with 5V via the DE9 connector.

Above, the adapter comprises a DE9 male and DE9 female connector cabled together as a through connection, and the Openlog is wired into one of the backshells, wrapped in heat shrink tube, and velcro’d to the backshell. Continue reading OpenLog for TinyTrak – inline DE9 adapter

Last update: 1st September, 2019, 1:42 PM

Basic programming jig for STC15F104E and STC15F204E chips #3

The STC15Fx chips use a simple TTL/CMOS async programming interface that is suited to the common USB-RS232(TTL) adapters. This article describes a low cost programmer that also allows the programming application to Vcc (so initiating the boot loader automatically).

Above is the programmer ($2.50 on eBay) and a small adapter that plugs into the top row of the 2×5 header on the programmer.

DIP-28 are located carefully so that the pins 10-18 are in the socket, the same connections are used for both chip sizes for STC15F104E and STC15F204E. Continue reading Basic programming jig for STC15F104E and STC15F204E chips #3

Last update: 18th August, 2019, 7:57 PM