Mechanical and Electromechanical Systems

Stupid Warning Labels, But Not The Kind You Think

Posted: May 6th, 2010 | Author: Tom Scarince | Filed under: Manufacturing | No Comments »

Warning Labels May Not Always Work

We’ve all seen the caution us not to do idiotic things or remind us of the obvious.  “Remove infant before folding stroller” and “Do not use toaster while bathing” are two examples that come to mind at random.  But what about warning labels that really do need to convey important, non-obvious information?  They can be stupid too. 

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How to Convert USB to Serial TTL Level Signals

Posted: April 20th, 2010 | Author: Tom Scarince | Filed under: Electronics | Tags: | No Comments »

If you’re designing a device that spends most or all of it’s time connected to a PC through a USB port, it is probably best to design USB connectivity right into the device.  However, if the device only needs to be connected occasionally to change settings or download data logs, it might be convenient to use a separate adapter that translates USB protocol to TTL level asynchronus serial signals that talk to the microcontroller’s UART.  Also, if you’re a hobbyist, you may not want to spend a lot of time understanding the details of USB interfacing hardware and protocols.  I recently stumbled upon an adapter that makes this easy.   

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Simple Thermal Heat Transfer Finite Element Analysis in Excel 2007

Posted: April 1st, 2010 | Author: Tom Scarince | Filed under: Energy | No Comments »

mainWhile some free finite element analysis software is available, the engineer or student can learn a lot about how FEA works by constructing a simple model from scratch in a commonly available spreadsheet program such as Excel.  The technique presented here can simulate a two dimensional flat plate of uniform thickness.  Each boundary element can be an arbitrary fixed-temperature or insulated.  The resultant temperature of each active element is iteratively calculated by simply averaging the temperatures of the adjacent cells.  Read the rest of this entry »


Prototypes and Short runs of a High-Volume Industrial Process

Posted: February 23rd, 2010 | Author: Tom Scarince | Filed under: Manufacturing | No Comments »

I recently saw a potential demand for a product that was essentially a seamless rectangular metal cup, about 1″ x 3″ on the open end and about 4″ deep.  This sounded like a job for a process called “deep drawing.”  In this process, a flat sheet of metal is punched through a die to form a cup shape. 

Great, all I need are a few prototypes to verify the design, then a few tens of pieces for some tentative test marketing, and finally perhaps a few thousand a year for production.  One problem: for a deep drawn part, a “short run” is considered “less than 60,000 pieces.”  I could find only one company that could actually deliver sample parts, but none of their standard sizes were close enough to what I needed. 

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Frosts Mora Swedish Knives Clipper vs. Craftsman Comparison

Posted: April 23rd, 2009 | Author: Tom Scarince | Filed under: Uncategorized | No Comments »

The town of Mora in Sweden is known for its traditional and utilitarian fixed-blade knives.  Many survival and bushcraft experts recommend these simple and very inexpensive knives, especially for beginners.  This article was originally posted by me on the Equipped to Survive Survival Forum.     

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Understanding Mixed Decay and the Allegro A3977 PFD Percent Fast Decay Feature

Posted: April 16th, 2009 | Author: Tom Scarince | Filed under: Stepper Motors | Tags: | No Comments »

This article explains why you might want to use mixed decay and how it is implemented in the A3977’s current chopper PWM scheme with the percent fast decay (PFD) pin. 

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Bidirectional PWM Motor Control

Posted: April 7th, 2009 | Author: Tom Scarince | Filed under: Motor Control | No Comments »

Once you understand unidirectional PWM of an inductive motor load, we can expand the concept to a bidirectional h-bridge PWM circuit.  Read the rest of this entry »


Unidirectional PWM Motor Control

Posted: April 2nd, 2009 | Author: Tom Scarince | Filed under: Motor Control | No Comments »

This article covers unidirectional Pulse Width Modulation (PWM) and how it can be used to control the power applied to a DC motor or the current in a stepper motor winding, for instance. While we eventually want to talk about doing bidirectional PWM with an h-bridge, we’ll start with a simple, one-direction control circuit.

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Intro to H-Bridge Motor Control Circuits

Posted: March 26th, 2009 | Author: Tom Scarince | Filed under: Motor Control | No Comments »

Simplified H-Bridge

An h-bridge is a bipolar driver circuit that is often used to control a load such as a brush type DC motor.  This article covers the most basic concepts of a simplified h-bridge circuit. Later articles dig deeper into the details of practical h-bridge operation and design.

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Waste Oil Furnace Secrets

Posted: March 20th, 2009 | Author: Tom Scarince | Filed under: Energy | No Comments »

This article explains the important points in converting a standard Beckett AFG oil burner to burn waste motor oil, used ATF, fryer grease or waste vegetable oil in your experimental furnace, heater or boiler.  Read the rest of this entry »