Rotary indexer’s are standard issue in most machine shops. These allow you to hold or chuck a work piece, and then a graduated handle lets you to rotate the workpiece. Useful when you want to drill or tap axial or radial features. A rack and pinion drive ensures that the workpiece does not move under machining load. Quite often, these indexers also have a manual lock to take care of gear backlash and play. Automating them is not too difficult either. You could use just a stepper motor (open loop) or servo+encoder (closed loop) to drive the turntable.

[smashedagainst] needed to drill six radial holes on a part. And he had to do it on 500 pieces for a total of 3000 holes. That was just for the first initial run, with more drilling likely in the future. The part in question was small and light weight. So instead of using a heavy duty, industrial grade unit, he built an all-electric rotary indexing jig using a stepper motor and an Arduino, giving him a sort of rotary 4th axis. His idea was to directly use the stepper motor to rotate the workpiece without any gearing, but he needed to build his own rig to do so.

His initial prototype used an Arduino Uno, which he swapped for a Pro Mini in the final version to save some space. The Arduino was connected to a Rugged Circuits motor driver. This was the only driver, out of the several that he tried that managed to hold the stepper motor with enough torque to prevent the workpiece from moving while drilling. The number of holes to be drilled is hard-coded in the Arduino, so all he needed was a single button. Each press of the button advanced the stepper motor through 60 degrees, giving him six, equally spaced holes. He used a NEMA-34 stepper motor, and that meant a beefy power supply. He scavenged a power supply from an old laser printer which conveniently had 24V DC as well as 5V outputs.

The next step was to work on the mechanical assembly. He machined an arbor that is attached to the shaft of the stepper motor. The face of the arbor is hexagonal and the workpiece wedges/locates over this. The motor assembly is fixed on one end of a base plate. The other end of the base plate has a clamping mechanism activated by a toggle clamp. It is also able to rotate (much like a live centre on a lathe). The workpiece is mated to the arbor, and the toggle clamp then locks the piece in place. During initial trials, some of the assembly fasteners worked loose, and there was some amount of chatter from the drill bit. He fixed these issues, and found it performed best when he set the spindle speed at 2400 rpm. Once he got it working, he was able to finish a hundred parts in under 2 hours. Drilling six holes in quick succession causes the part to get quite hot, so he first used some  pressurised air cooling. Later, he switched to a spray can based multi purpose penetrant lubricant. Watch his video of the indexing jig in action below.

“You can’t put new wine in old bottles” – so the saying goes. But you would if you’re a hacker stuck with a radio built in 2005, which looked like it was put together using technology from 1975. [Marcus Jenkins] did just that, pulling out the innards from his old radio and converting it to an Arduino FM radio.

His cheap, mains powered radio was pretty bad at tuning. It had trouble locating stations, and tended to drift. One look at the insides, and it was obvious that it was not well engineered at all, so any attempts at fixing it would be pointless. Instead, he drew up a simple schematic that used an Arduino Nano, an FM radio module based on the TEA5767, and an audio amplifier based on the LM386.

A single button on the Arduino helps cycle through a range of preset frequencies stored in memory. The Arduino connects to the FM radio module over I2C. The existing antenna was connected to the TEA5767 module. The radio module outputs stereo audio, but [Marcus] was content with using just a mono channel, as it would be used in his workshop. The audio amplifier is pretty straightforward, based on a typical application found in the data sheet. He put it all together on proto-board, although soldering the FM radio module was a bit tricky. The Arduino code is quite simple, and available for download (zip file).

He retained the original tuning knob, which is no longer functional. The AM-FM selector knob was fitted with a micro-switch connected to the Arduino for selecting the preset stations. Almost everything inside was held together with what [Marcus] calls “hot-snot” glue. The whole exercise cost him a few Euros, and parts scavenged from his parts bin. A good radio could probably be had for a few Euros from a yard sale and much less effort, but that wouldn’t be as cool as this.

Go deeper and explore how FM signals are modulated and demodulated for playback.

If you are from the 1960’s or 1970’s we know you would have enjoyed furiously punching the buttons of a pin ball machine back in the day. Installation artist [Niklas Roy] recently revisited this old classic game and built Galactic Dimension – a supersized pinball machine for Phæno – an amazing science center in the German city of Wolfsburg. The science centre was planning a big exhibition featuring thirty beautiful, classic pinball machines loaned from the Pacific Pinball Museum in Alameda, California.

The game machine was built on a steep ramp and has a gigantic play field measuring 3m x 6m (10’x20′). It features Sci-Fi game elements in the play field which blend perfectly with the futuristic building where it is housed. The game elements are built from repurposed everyday items like hair dryers and fans, giving visitors the motivation to build some of their own such contraptions.

The players operate the machine via a control desk, and a giant calculator is used to display the game score. The steep ramp had an incline of almost 30° which meant that he had to use a light ball to be able to propel it around the play field. The main user controls are the two flippers, and building giant ones was a big challenge. Solenoids or coils would not cut the ice, and he settled for pneumatic cylinders – easy to control, powerful, not too loud, and the museum already had a compressed air supply readily available. But it still took him three iterations before he could get it right. The plunger, which initially propels the ball, was built from PVC pipes and a hair dryer. Each play field element was built as a separate module to make assembly and maintenance easier. All featured a 220V AC supply, a sensor (either an IR distance sensor or a light barrier) to detect the ball, and an Arduino. Actuators were built from hair dryers and portable fans. Each of them have their own sound effects too – either a hacked toy or a speaker controlled by the Arduino. After everything was built, taken apart, transported, and reassembled at the site, the Galactic Dimension worked without a glitch, and without releasing any magic smoke. To top it off, Andreas Harre, who’s been the German pinball champion for several years in a row, also played the machine when he visited Phæno – and was totally excited about it!

So if you are in that part of Germany anytime until September, do drop in and try to ring up a big score. For photos of his build log, check out the photo album. There’s also a fairly big block diagram (German) and the Arduino sketches (.zip file), if you’d like to take a stab at building an even bigger pinball machine. Check the video to see the machine in action. And if the name [Niklas] sounds familiar, it is because he loves building installations such as the Forbidden Fruit Machine, the Ball Sucking Machine, and another Ball Sucking Machine.

[Lewin] wrote in to tell us about a high speed library for Arduino Due that he helped develop which allows interfacing OLED displays that use the SSD1306 display controller, using DMA routines for faster display refresh time.

Typically, displays such as the Monochrome 1.3″ 128×64 OLED graphic display , are interfaced with an Arduino board via the SPI or I2C bus. The Adafruit_SSD1306 library written by [Limor Fried] makes it simple to use these displays with a variety of Arduinos, using either software or hardware SPI. With standard settings using hardware SPI, calls to display() take about 2ms on the Due.

[Lewin] wanted to make it faster, and the SAM3X8E on the Due seemed like it could deliver. He first did a search to find out if this was already done, but came up blank. He did find [Marek Buriak]’s library for ILI9341-based TFT screens. [Marek] used code from [William Greiman], who developed SD card libraries for the Arduino. [William] had taken advantage of the SAM3X8E’s DMA capabilities to enable faster SD card transfers, and [Marek] then adapted this code to allow faster writes to ILI9341-based screens. All [Lewin] had to do was to find the code that sent a buffer out over SPI using DMA in Marek’s code, and adapt that to the Adafruit library for the SSD1306.

There is a caveat though: using this library will likely cause trouble if you are also using SPI to interface to other hardware, since the regular SPI.h library will no longer work in tandem with [Lewin]’s library. He offers some tips on how to overcome these issues, and would welcome any feedback or testing to help improve the code. The speed improvement is substantial. Up to 4 times quicker using standard SPI clock, or 8 times if you increase SPI clock speed. The code is available on his Github repo.

It isn’t easy communicating when you have any form of speech impairment. In such cases, a Speech-generating device (SGD) becomes essential to help you talk to the world. When coupled with other ailments that limit body movement, the problem becomes worse. How do you type on a keyboard when you can’t move your hands, and how do you talk when your voice box doesn’t work. Well known Scientist Stephen Hawking has been battling this since 1985. Back then, it took a lot of hardware to build a text entry interface and a text to speech device allowing him to communicate.

But [Marquis de Geek] did a quick hack using just a few parts to make a Voice Box that sounds like Stephen Hawking. Using an arcade push button to act as a single button keyboard, an Arduino, a 74HC595 shift register, a 2-line LCD, and the SP0256 hooked to an audio amplifier / speaker, he built the stand-alone speech synthesizer which sounds just like the voice box that  Stephen Hawking uses. Although Dr. Hawking’s speech hardware is quite complex, [Marquis de Geek]’s hack shows that it’s possible to have similar results using off the shelf parts for a low cost solution.

There aren’t a lot of those SP0256-AL2 chips around. We found just a couple of retailers with small stock levels, so if you want to make one of these voice boxes, better grab those chips while they last. The character entry is not quick, requiring several button presses to get to the character you want to select. But it makes things easier for someone who cannot move their hands or use all fingers. A lot of kids grew up using Speak and Spell, but the hardware inside that box wasn’t the easiest to hack into. For a demo of [Marquis de Geek]’s homemade Hawking voice box, check the video below.

Sometimes it is a blessing to have some spare time on your hands, specially if you are a hacker with lots of ideas and skill to bring them to life. [Matt] was lucky enough to have all of that and recently completed an ambitious project 8 months in the making – a Non-Arduino powered by the giant of computing history – Intel’s 8086 processor. Luckily, [Matt] provides a link to describe what Non-Arduino actually means; it’s a board that is shield-compatible, but not Arduino IDE compatible.

He was driven by a desire to build a single board computer in the old style, specifically, one with a traditional local bus. In the early days, a System Development Kit for Intel’s emerging range of  microprocessors would have involved a fair bit of discrete hardware, and software tools which were not all too easy to use.

Back in his den, [Matt] was grappling with his own set of challenges. The 8086 is a microprocessor, not a microcontroller like the AVR, so the software side of things are quite different. He quickly found himself locking horns with complex concepts such as assembly bootstrapping routines, linker scripts, code relocation, memory maps, vectors and so on. The hardware side of things was also difficult. But his goal was learning so he did not take any short cuts along the way.

[Matt] documented his project in detail, listing out the various microprocessors that run on his 8OD board, describing the software that makes it all run, linking to the schematics and source code. There’s also an interesting section on running Soviet era (USSR) microprocessor clones on the 8OD. He is still contemplating if it is worthwhile building this board in quantities, considering it uses some not so easy to source parts. If you are interested in contributing to the project, you could get lucky. [Matt] has a few spares of the prototypes which he is willing to loan out to anyone who can can convince him that they could add some value to the project.

Thanks for the tip, [Garrett]