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migration.user — Fri, 01 Oct 2021 18:05:54 GMT

Current Revision posted to Documents by migration.user on 10/1/2021 6:05:54 PM

Community Feedback 03 - Power Safety Concerns!

tariq.ahmad — Fri, 18 Jan 2019 16:21:52 GMT

Current Revision posted to Documents by tariq.ahmad on 1/18/2019 4:21:52 PM

Join the Ben Heck team every week for amazing hacks! Watch them build and mod community-inspired projects using electronics!

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Community Feedback

Super Glue Gun

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Ben and Karen look through suggestions from anywhere on the element14 community on a segment called Community Feedback. This segment focuses on the Super Glue Gun Build after it just got started. Suggestions include putting a "do not try this at home" warning label when attempting to hook up mains to a breadboard in front of an audience, discussing different loads with their glue gun, and an excel sheet to deal with the non-linearity of thermistors.

Community Feedback comes from cherring , tm14 , and mr_widget !

Congratulations you win a Free Ben Heck T-Shirt!

cherring was concerned when the team attempted to hook mains up to a breadboard. Ben’s explanation is that he does not consider 120 volts to be that dangerous, when they did the test they made sure that everything was isolated, and that this was the fastest way to hook it up. Karen parses Ben’s explanation by letting the audience know that while it isn’t the safest method, it’s the fastest method, so don’t try this at home.

tm14 suggests that the team talks about different types of loads with their Super Glue Gun. The glue gun heater coils have low inductance and are mostly resistive. As they get hotter, their resistance changes. So measuring the cold resistance is not the same as the resistance when it is hot. As Ben explains to Karen, we can’t necessarily know what the current draw actually is. It probably won’t make a difference, since they’re using AC, but if the triac is rated lower than what they need, and they are actually drawing more current than they think they’re going to use, then they could blow out the triac. The real problem with electricity is when electricity has no stopping point.

In his designs, mr_widget typically uses 25C NTC thermistors as ambient sensors for oven controllers, while he uses a K thermocouple for the thermal enclosure. He was struck by the non-linearity of the thermistors so he made a spreadsheet, which he offers the team, to help calculate correction factors for Arduino controllers converting the ADC value to a calculated ambient temp.

Tags: communityfeedbacktbhs

Community Feedback 05: Super Glue Gun 2

tariq.ahmad — Fri, 18 Jan 2019 16:20:54 GMT

Current Revision posted to Documents by tariq.ahmad on 1/18/2019 4:20:54 PM

element14's The Ben Heck Show

Join the Ben Heck team every week for amazing hacks! Watch them build and mod community-inspired projects using electronics!

Back to The Ben Heck Show homepage

Community Feedback

Super Glue Gun

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www.youtube.com/watch

Comment below if you have feedback for Ben and Karen!

You'll get a free Ben Heck Shirt if you hear your name on Community Feedback!

Ben and Karen respond to feedback from Community Members give on their Super Glue Gun. Feedback includes using a 3D pen to see how it moves the filament, using a worm gear motor from a CD drive and replacing the trigger with a solenoid actuator, using a dremel saw as a gear, and replacing metal parts with a simple post and a sleeve.

Community Feedback comes from tm14 and 11treehugger11 !

Congratulations you win a Free Ben Heck T-Shirt!

tm14 recommended that they buy a 3D pen and see how it moves the filament. He suggests using a worm gear motor from a CD drive, keeping the original glue gun feeder, but replacing the trigger with a solenoid actuator using a hammering action. Ben doesn’t think there is enough power with this because worm gears are pretty wimpy as all they are used to do is move a read head back and forth. The idea of worm gear is good because you’d have a lot of constant pressure along the piece instead of just one contact point, although that’s more gearing that could get gummed up if there was a problem.

11treehugger11 suggests flipping everything around. Instead of finding the perfect gear to fit on the perfect motor, put the gear on the idler shaft. The gear could be tensioned right against the shaft of the motor. He also suggests trying a dremel saw as a gear. It looked to him like they were smashing the glue instead of gripping it to feed. A sharper, thin saw or sanding blade might “bite” into the glue better. Ben thinks this could work if it went slowly because the teeth would bite into it and then push forward.

tm14 suggests that they reconsider the metal parts used on the Super Glue Gun because it may be overkill and that their weight would add to the shipping costs of the final product. Instead of bearing, he suggests using a simple post and a sleeve like they use to use in VCRs as tape guides. Ben thinks this is something they could try. The bearings simplified what they did the first time, but they could cost reduce further by taking a nylon spacer and putting it onto a steel post, and using that to push the stick in.

Tags: tbhs, super glue gun, karen corbeill, theheckwithkaren, ben heck, communityfeedbacktbhs

Episode 330: Super Glue Gun 12: Glue Gun Design with Fusion 360 Part 2

tariq.ahmad — Fri, 30 Mar 2018 13:39:06 GMT

Revision 1 posted to Documents by tariq.ahmad on 3/30/2018 1:39:06 PM

element14's The Ben Heck Show

Join the Ben Heck team every week for amazing hacks! Watch them build and mod community-inspired projects using electronics!

Back to The Ben Heck Show homepage

Super Glue Gun

Community Feedback

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www.youtube.com/watch

The Ben Heck Team has finally reached the conclusion of the Super Glue Gun project. Ben puts the finishing touches on the design using Autodesk Fusion 360, prints the parts, and does final assembly on a proof of concept. Does the super glue gun live up to his name? Does it have what it takes to make it on the consumer market? Let us know in the comments below!

Ben does some more design on the gun barrel using Autodesk Fusion 360. After getting a few pieces in place, along with front and rear wood to hold the barrel in place, he thinks he's found a way to get the wires through. He's made a few changes to the motor cap container such as putting a groove into the bottom of it. That should be enough to get the AC and temperature sensor wires out of the barrel. He'll need to make a place for the motor drive because wires take more space then you think. You have to be sure to account for them in your design, including any folds, loops or bends they might do. He does a section analysis to “peel back” the surface and ensure the design works with the motor driver. He’ll print the four halves separately, the two halves of the barrel along with the two halves of the barrel, and glue them together so they represent what a solid piece would look like.

On the front hot end of the gun, you have the AC barrel heater along with the temperature sensor. He’ll design it with assembly in mind rather than just glue and screw it together. Kapton tape is used to insulate the parts from heat as well as electricity. Everything fits together once assembled. This includes the AC wires, the sensor wires, and the motor drive wires coming out of the back. This will all go into the base of the handle where all the electronic controls are contained. Once he glues the halves together he’ll have a completed prototype. He’ll have to also make some adjustments to allow for an opening for the programming port. Once assembly is complete he’ll test make sure it works before completing the build. Ben does a motor test to ensure that everything is wired correctly. This is a proof of concept as the 3D printed plastic won’t last long under the heat. He’ll need to change the temperature profile. To do this he’ll re-extrude the glue, see what its temperature is, and then scale the thermistor settings to match that. After doing an extrude test, Ben presents the final reveal! Along the way to making a really cool glue gun they’ve gotten hands on experience with triacs, touch sensors, and new microcontrollers.

Disclaimer

Tags: autodesk fusion 360, super glue gun, prototype assembly, thermistor, sensor wires, kapton tape, motor drive wires, glue gun, proof of concept, extruder

Super Glue Gun 12: Glue Gun Design with Fusion 360 Part 2 -- Episode 330

Matt — Fri, 16 Feb 2018 08:24:00 GMT

Current Revision posted to Documents by Matt on 2/16/2018 8:24:00 AM

element14's The Ben Heck Show

Join the Ben Heck team every week for amazing hacks! Watch them build and mod community-inspired projects using electronics!

Back to The Ben Heck Show homepage

Super Glue Gun

Community Feedback

See All Episodes

www.youtube.com/watch

Disclaimer

Tags: autodesk fusion 360, super glue gun, prototype assembly, thermistor, sensor wires, kapton tape, motor drive wires, glue gun, proof of concept, extruder

Episode 319: Super Glue Gun 10: Time to Rack and Roll

tariq.ahmad — Fri, 08 Dec 2017 15:02:52 GMT

Revision 1 posted to Documents by tariq.ahmad on 12/8/2017 3:02:52 PM

element14's The Ben Heck Show

Join the Ben Heck team every week for amazing hacks! Watch them build and mod community-inspired projects using electronics!

Back to The Ben Heck Show homepage

Super Glue Gun

Community Feedback

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www.youtube.com/watch

In a previous episode, Ben and Karen worked on the auto stand mechanism only to discover they would need to redesign the entire upper portion of the gun. In this episode, they take apart some Glue Guns to come with some ideas and Ben works on the redesign in Autodesk Fusion 360.

Karen takes apart a mod podge gun that they never really got around to looking at. After taking it apart, she discovers that the heating elements and loader tube are about the length they are looking for. They’re trying to find a suitable heating element out of a glue gun. If it can be found to exist then they can probably find it for manufacture. The main thing this tells them is that they can actuate the glue far back and still get enough pressure to push it. Their goal is to lengthen the gun so they have room for the auto stand.

Earlier they were talking about locating the actuator under the barrel of the gun, like some sort of servo. But having the actuator for the auto stand in that position adds bulk and you lose the feel they are going for with the gun. Ben sketches up some ideas he has to get around this.

Ben gives an overhead view of his proposal for the auto stand. There’s a continuous rotation servo inside of the trigger guard area, a laser cut gear to fit onto it, and that gear will mesh with a rack. In a rack and pinion, the pinion is the part that rotates the gear and the rack is a linear set of teeth that intersect with the gear. When the gear rotates, linear motion is created.

Ben fires up Autodesk 360 and continues working on the redesign. Previously, he worked on a parametric extruder device that allows them to have account for variables, including the width of the glue stick and the distance, and parametrically change everything for them. He’s able to keep that in his design but he goes back to having a quarter inch glue stick.

Disclaimer

Tags: time to rack and roll, hack, super glue gun, auto stand, super_glue_gun, pinion, autodesk 360, servo, sub-micro continuous servo, motor, heck, ben, rack, episode 319: super glue gun 10:, tbhs_ep, hot end extruder

Super Glue Gun 10: Time to Rack and Roll -- Episode 319

Matt — Fri, 01 Dec 2017 08:24:00 GMT

Current Revision posted to Documents by Matt on 12/1/2017 8:24:00 AM

element14's The Ben Heck Show

Join the Ben Heck team every week for amazing hacks! Watch them build and mod community-inspired projects using electronics!

Back to The Ben Heck Show homepage

Super Glue Gun

Community Feedback

See All Episodes

www.youtube.com/watch

Disclaimer

Unique Glue Gun Uses

makerkaren — Mon, 07 Aug 2017 21:27:57 GMT

Current Revision posted to Documents by makerkaren on 8/7/2017 9:27:57 PM

element14's The Ben Heck Show

Join the Ben Heck team every week for amazing hacks! Watch them build and mod community-inspired projects using electronics!

Back to The Ben Heck Show homepage

Super Glue Gun

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Recently, I was building a case for a project for the show and I discovered I needed a very specific feature from my glue gun. I was adding a bracket to the inside of a case that ran the length of the case and was only an inch or two away from the side wall. I wanted to hot glue the brace of the bracket in place. My typical glue gun could fit into the space, but not at the angle I required to reach where the brace met the case. I ended up bodging it by using a heat gun to melt the end of a glue stick that I held with pliers and then smearing the hot glue where I wanted it. This resulted in more glue than necessary being used and was a bit messier than I would have preferred. Having a glue gun with a long, narrow nozzle would have worked great, or even possibly a flexible nozzle to reach that awkward angle.

Have you ever worked on a project that made you wish for a tool with an unconventional feature? Ever needed your glue gun to be able to do just a little bit more? Tell us your stories. Maybe there's even a solution already out there!

Tags: super glue gun, hot glue, theheckwithkaren, theheckwithkaren_glue_gun, glue, tools

Super Glue Gun: Ideas List

makerkaren — Mon, 07 Aug 2017 21:26:57 GMT

Current Revision posted to Documents by makerkaren on 8/7/2017 9:26:57 PM

element14's The Ben Heck Show

Join the Ben Heck team every week for amazing hacks! Watch them build and mod community-inspired projects using electronics!

Back to The Ben Heck Show homepage

Super Glue Gun

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The team at the Ben Heck Show values Community input. Here is the current plan for the super glue gun project. Leave any questions, comments, or recommendations in the comments below.

Overall Design:

Features:

Heats up quickly
Anti-drip retraction
Motorized extrusion w/ analog speed control
Automatic stand

Other Design Factors

Target audience: Serious crafters, makers, and craftsmen with LOTS of hot gluing to do.
COST: We are aiming for the sale cost of the glue gun to be around $99. This means that all parts should come to a cost of under about $30.

Components

Hot End Extruder

Design restrictions/considerations:
- Needs to reach a certain temperature (Low-temperature glue guns operate at approximately 120 °C (248 °F) and are well suited when high temperatures are undesirable, such as gluing lace and cloth. High-temperature guns operate at approximately 190–210 °C (374–410 °F) and produce a stronger bond.)
- Temperature falloffs
- Safety limitations
Ideas:
- Repurpose from another gun
- Find a stock part we can use
- Make our own? 3D printer parts?
- This is certainly something we could use help with.

Extruder Motor

Design restrictions/considerations:
- Size: must fit in case without inhibiting a comfortable grip.
- Power consumption limits
- Force required to extrude glue
Progress:
- We found a pancake shaped motor that runs at 50 RPM and 12 volts with a 5mm shaft.
- It has enough torque to extrude hot glue even at full speed.
- It's smaller so we could mount it sideways (not through the handle) giving us more room inside the handle for power supply, electronics and trigger.

Microcontroller

Design restrictions/considerations:
- Cheap
- Small
- Robust
- Fast boot
Progress
- Did much testing with Atmel ATTINY20
- It has plenty of IO including many ADC's for sensing temperature, control dials and trigger.
- Developing code with Atmel Studio.
- Using low-level hardware timer to drive PWM for motor.
- Could possibly use a pair of timers to control motor speeds in both directions.
- Decent amount of flash for program (a whopping kilobyte!) so we could include many speed and temp options.
- MCU allows us to use a cheaper/simpler motor controller, perhaps our own h-bridge if that's less than a dedicated IC.

Power Supply - THIS IS THE NEXT STEP

Design restrictions/considerations:
- 120VAC to 12VDC (motor) and 5VCD (logic)
- Should have an option to work at 220V 50Hz as well
- Must fit inside handle
- Must be cheap.
Ideas
- We have some sample packages with 5 and 12 volt lines, but the 12 volt current capacity is a bit under our spec and exceeding it browns out the 5VDC causing a MCU reset.
- Ultimately we want a single PCB in the handle with everything, but we can use existing supplies to mock up a target spec.

Trigger/controls

Design restrictions/considerations:
- Manufacturable. Final product will not be 3D printed.
- Capacitive touch to activate stand retraction
- Force required to extrude glue
Ideas
- TBD

Automatic Stand

Design restrictions/considerations:
- Need room for motor inside case
Ideas
- TBD

Case Design

Design restrictions/considerations:
- Ergonomic/comfortable to hold
Ideas
- Test design on 3D Printer
- Final product Injection molded

Tags: theheckwithkaren_glue_gun

Super Glue Gun Steps

tariq.ahmad — Thu, 13 Apr 2017 19:52:56 GMT

Current Revision posted to Documents by tariq.ahmad on 4/13/2017 7:52:56 PM

element14's The Ben Heck Show

Join the Ben Heck team every week for amazing hacks! Watch them build and mod community-inspired projects using electronics!

Back to The Ben Heck Show homepage

Super Glue Gun Build

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Super Glue Gun

1. GETTING STARTED

- Discuss original idea / episodes (use footage flashbacks)
- Talk about what we liked / didn’t like
- Why we believe it’s a good project
- Map out project goals / major design challenges
- Design drawing and sketches
- Decide major parts and begin sourcing:
  - Hot end extruder
  - Extruder motor
  - Power supply
  - Trigger/controls
  - Microcontroller
  - Automatic stand & casing

GOAL: Create product roadmap & design spec

2. EXTRUDER MOTOR

- Knowing what the hot end can do and what the PSU can supply, figure out the best way to mechanically move the glue through the device
- Source gear motors / knobbed extruder heads and work on a variety of 3D printed prototype tests.
- Find a motor that works within the constraints of the PSU.
- Isolate DC motor noise from the rest of the circuit. Work on stabilizing voltages.
- Test glue loading, idle wheel spring, and basically try and break the mechanism.

GOAL: Using a PWM controlled motor, extrude glue through the gun at both low, carefully controlled speeds and high “gushing” temperatures

3. HOT END EXTRUDER

- Discuss why we must decide this part first (certainly before PSU)
- Source and test multiple commodity extruder parts
- Do safety tests & find best / cheapest method of reliable temperature sensing & control
- Determine force required to extrude glue through gun and temperature falloffs
- Talk about solid state current control and PWM techniques
- Try and break it / burn it up to find the limits of safety

GOAL: Decide on a hot end and know all of its specs and how this will affect the rest of the project

4. POWER SUPPLY

- In this episode we figure out the best way to power our Super Glue Gun
- Decide between cord / battery powered (probably going to be AC cord)
- Test power supply with all conditions of the previously established Hot End
  - Figure out the cheapest way to provide (and control) high-voltage AC hot end power as well as stable 3.3v / 5v logic voltages
  - Find solutions that will provide the quickest path to UL/FCC certification

GOAL: Select the best switching control for hot end and logic circuits. Breadboard temperature sensor tests with MCU

5. TRIGGER / CONTROLS

- Figure out what controls and indicators the device needs and build prototypes
- Decide best way to get analog trigger input (potentiometer, hall effect, optical)
- Test the pros and cons of each method (ie, motor EMF could corrupt a hall effect sensor)
- Controls will influence product case design, so start narrowing down ideas for this and do sketches
- Begin initial tests / designs for an auto-deploying kickstand

GOAL: Translate analog trigger control to PWM DC motor driver / extruder, and see if capacitive trigger touch is affordable / easy to manufacture.

6. MICROCONTROLLER

- Decide what this MCU must do based off our mechanical tests thus far:
  - Temp sensing (be compatible with whatever we attached to hot end)
  - Analog trigger control
  - Capacitive touch sense – built in to save external circuitry?
  - Fewest external parts (crystals, PSU, EEPROM)
- Source and test multiple MCUs (well before episode films) create pro/con list
- Request help from vendors / supply side solutions?

GOAL: Select a MCU that is the cheapest possible thing that will support all of the features we’ve tested on the unit thus far (and has good availability / factory programming support)

7. CASING & AUTOSTAND

- Try and get an automatic deploy stand to work (controlled by capacitive touch trigger)
- Decide if this feature is economically feasible
- Using all previous parts, begin designing enclosures
- Fusion 360 / software collaboration?

GOAL: 3D print an enclosure that is in the ballpark of something that could be injection molded as a final product.

Tags: super_glue_gun, ben_heck