johnridley: (555)
OK, got the switches in from an alternate supplier, and this evening I packaged up about 150 blinkies, so there are 190 kits in bags ready to roll in June. We'll be doing alternate colors but I may leave that until the convention. People liked the pink LEDs enough that we ordered more of them and will be charging a bit more (they're the most expensive LED I bought by a bit of a margin, so I didn't want to buy a LOT of them).

Also I want to do more patterns so I'm not burning the chips until within a few weeks of the convention, but they're all here and in the Duckon box.

VERY glad to have that all done.
johnridley: (555)
I had a package of switches coming from China burst open and most didn't arrive, and the seller never reshipped like he said. Finally got a refund and ordered from a supplier from Canada that I've used before.

I also ordered another 500 pink LEDs - they are super pretty and the people that saw them all agreed that people would be willing to pay a little more for them - they're twice the money as most of the other colors.

Anyway, once all that stuff arrives, I'll be able to complete packaging of the kits. Programming of the chips will wait until later since I still have plenty of room on the chips for more patterns, so I'll leave that until a couple of weeks before the convention.

2012-01-28

Jan. 28th, 2012 06:05 pm
johnridley: (Default)
Been trying to catch up on 3D printing today. I finally finished up all the prints that Tom asked me to do for his friends - switchblade combs in a variety of colors - teenage boys...

So now I'm actually printing the first batch of the 175 remaining battery holders I have to print to finish up the blinkie kits. I should be able to finish this weekend, it takes about 5 hours to print a set of 25 holders.

I got the assembly instructions for the blinkie complete and ready to print.

I sat down to make more patterns for the blinkie, and after a bunch of fruitless searching, finally resigned myself to the fact that AVR Studio must have saved the project on the C: drive, which I wiped a few days ago. Luckily I have a copy on Google Docs from a couple of weeks ago, so I just had to recreate the brightness control code, which took about 45 minutes since I'd already figured out how to do it.

I also had a bunch of software to install on the laptop post-reinstall to get AVR studio, the device programmer, the 3D printing software and some other stuff working.

I'm making changes in my recommended build for a 3D printer too. I think I've talked about them here before. The only parts that are the same as what I was using a month ago are the little bar clips, the frame corners and the Z motor holders. I'm even working on a replacement for the endstop holders and the X carriage.

I still have to create and copy a music CD to distribute to the choir tomorrow morning, for all the pieces we're going to be doing. Also the pianist is getting (another) arm surgery next week so we need music on CD for the foreseeable future so I have more CDs to burn for that. I suppose I should work on that now...

2012-01-26

Jan. 26th, 2012 07:03 pm
johnridley: (Default)
I've been falling behind on my personal journaling so I'll just do everything in this post.

Got the rest of the Duckon LEDs in today. Wow. The pink LEDs are PRETTY. We only got enough for 10 sets. They're a bit expensive at $1.20 per set instead of about 60 cents a set for the other colors. I think they're probably going to be gone pretty much instantly. I may change my mind and charge a little extra for them, though that involves bookkeeping that I'd just as soon not have to deal with. Most people seemed fine with just charging a flat rate regardless of color.

I somehow inflamed my left ankle about 4 weeks ago riding bike. It's been slowly getting better. I tried riding last Wednesday but it got a little worse as a result so I left off again. It's almost completely healed but I can still feel a bit of weirdness in there so with only one weekday left I'll wait until Monday to try again. I'm getting to where I've had QUITE enough of driving for a while.

I seem to have fallen behind on 3D printing again. Both machines running to try to catch up. Blinkie kit prep is stalled until I get black PLA loaded in one of the machines again. I do now have all of the LEDs counted out into the kit bags, the rest will only take an hour or so total. Need to write and print the instructions though.
johnridley: (Default)
The replacement (5mm) green LEDs came in today. I soldered up a green demo unit, completely prepped 23 blue kits, and counted out all of the LEDs for 100 blue kits, 55 green kits, 20 red kits, and 5 white kits. Pink, orange and yellow LEDs haven't arrived yet.

I need to print another 175 battery holders, but I need to load black PLA in a printer to do that and right now I have black ABS in one printer and red PLA in the other. Black tends to hang about in the hotend for a while so when I switch away from it I have to find something to print that color doesn't matter for, so I am shy of loading black in if I have any non-black stuff in the queue. Right now I've got some switchblade combs for my son's friends, they're amused by them so I'm running a few off in different colors.

I'll probably do the battery holders this weekend. I didn't do them before now because I wanted to assemble a few actual, final boards with them to be sure that the design was what I wanted it to be before making all 200 holders.

Counting out the LEDs is the real time consuming part and that's pretty much done. I do need to write the assembly instructions. I've already taken all the photos that I'll need.
johnridley: (555)
I assembled another demo of the new blinkie, this time with blue LEDs. Then I discovered that these blue LEDs are bright. I mean, they're really, really retina searingly bright.

So I spent the evening adding brightness control code to the firmware. I managed to work it in to the single-button control in a way that I hope is not too confusing.

As a bonus, the dimmer modes should really stretch the battery life - the dimmest mode with the blue LEDs is still reasonably bright, but the LEDs only run 1/255th of the time. For all I know the thing could run a few hundred hours on a set of batteries in that mode even wtih blue LEDs.
johnridley: (555)
Got an email from the board house just now. They've reviewed the files, found no problems, and scheduled production to be completed on Jan 21, so it'll beat Chinese New Year and definitely be here in time to make demos for Capricon.
johnridley: (555)
Ordered the tactile switches and poly bags from eBay. The CPUs, resistors and IC sockets are in the cart at Mouser but awaiting word whether to drop some more stuff into the basket.

I did the tweaks I wanted to make on the battery holder design (wider slot to push the batteries out, moved the retention ridge down a little to make the batteries more snug, then printed out a few revs at different wall thickness and infill percentages. The final version is very tough, I had to really try pretty hard to break it. It won't break unless someone is trying to break it. I have the first 25 of those being made on the printer right now.

I also grabbed three more breadboards from one of the vendors. They were $9 for 3, what the heck. Mine are so old that the contacts are getting rather corroded and they're not particularly reliable anymore. I think the newest one is something like 25 years old now.
johnridley: (555)
Artwork and colors approved, boards ordered from China.
LEDs ordered. The rest of the stuff I'll get coming tomorrow.
Need to print 200 battery holders - I guess they're going to be boring old black.
It's good to have a phase behind me. It'll be even better to have them in the bag with instructions printed.
johnridley: (555)
Once again I'll be running the Blinkie room at Duckon 21.

I'm looking for GTers (or anyone qualified that I can grab) who will be there and can help out in running the room. Anything from an hour up would be helpful. Last year I spent from 8AM to 2AM in that room Friday and Saturday, and I'd like to get out of there a bit more. I have some programming I would like to present and can't do it if I can't get out of the room.

Ability to solder and debug blinkies is nice but not a prerequisite - by manning the front desk, taking money, etc, you can free up someone who can get on the floor and help people with their projects.

Usually the technical help is just helping people who don't really know how to solder, looking over a board carefully and finding bad solder joints, parts in backwards, etc.

The blinkie room will be running the same hours as last year, which is a bit less than in prior years. Friday 5PM to 10PM, Saturday 9AM to 7PM.

This is a fun gig, we get to help people make things. I saw a lot of Duckon 20 blinkies being worn around Windycon this year, so people really like them and Blinkies is often cited as one of the most fun parts of the convention. I'm happy to be able to help carry on this tradition. I may also have non-blinkie type things this year, I'm thinking about doing something like having "Useless Machine" kits, which are super easy to make and are pretty fun.

If you can help, please email me, if you have any idea when you'll be able to chip in, let me know that too. I want to get a handle on how much time I'll be able to get away from the room to do presentations. I know that this will be hard to coordinate since many people won't know when they'll be able to help until they see the program book, and I won't be able to say what programming I'll be able to do until I see who can help when.

I'm going to be checking out the new hotel this weekend, getting floor plans and taking pictures of the proposed room and trying to work out how many stations we'll be able to place. Last year we had 24 and that worked out pretty well.
johnridley: (555)
I'll be ordering blinkie boards as soon as the colors and artwork get approved. This is the current proposal based on the theme and the available colors for board and ink.

johnridley: (555)
The blinkie ran about 27 to 28 hours with blue LEDs. I think it'd probably run at least another 10 hours with red or green LEDs, maybe 5 more with yellow. Not because they draw less power, but because they will run on fewer volts. The chip will run on practically nothing, I think it'll keep running down to 1.2 volts or something like that, but blue LEDs need 3.2 volts or so to light up, whereas red LEDs will keep running down to I think a bit less than 2 volts.

27 hours with blue is acceptable to me. When I get the full kits in 3 or 4 weeks I'll assemble some with different colors and see how they do.
johnridley: (555)
Got 1000 LR44 cells for Duckon blinkies. Put 3 out of that package into the prototype. Test begins at 5:22 PM January 5, blinkie is set to rotate through all current patterns, and has blue LEDs (worst case scenario). Definitely way brighter than the cells I've been dinking with for the last few days, but those were half dead when I started.
johnridley: (555)
The 3D printer figured big in this year's blinkie design. Not only is the battery holder printed, but I used a gerber-to-gcode conversion script to enable me to use the RepRap to lay down the ink on the blank PCB to make the prototype, and by the time June rolls around I may have a printed sleeve to go on it that diffuses the LED light.

more yammering and a few photos after the cut )
johnridley: (555)
Today was a (hopefully last) day home with this cold. Since I'm supposed to have a prototype for the 2012 Duckon blinkie ready for the concom meeting and hopefully then the boards fabbed and a dozen copies ready to go for Capricon, I figured I'd better, you know, actually get started on it.

I had the design done, but only in my head.
I use most of the software; AVR C and EagleCAD, only once a year for this purpose, so I have to spend about 4 hours re-learning it all again every time.

Anyway, at the end of the day I'd accomplished everything I wanted to. I have a breadboarded running copy, with the control changes I wanted to make in place. I've done away with the power switch and instead use the "power down" mode of the AVR chip, which according to my DVM is drawing about 1 microamp, which would take 17 years to kill the battery, so that's OK.

This design needs to be thinner than last year's since I intend it to be a pendant, so the CR2032 cell was out. I am using three LR44 cells instead, and I had to design and print my own battery holders, I bashed that out this afternoon as well.

I got up to speed (enough) in EagleCAD to lay the schematic and board out. I intended to use the RepRap with a pen holder installed to draw ink onto a blank board but the HPGL to GCode software is causing me trouble. I'll work on that later.

I finally realized that it makes more sense to create the Charlieplex scan bits in the pattern design spreadsheet and store that rather than putting bits in the data section that represent the pattern and making the microcontroller do the Charlieplexing work. More complex spreadsheet formulas, but the firmware code goes from 80 lines to 2 lines and should draw less power.

Blinkie prototyping:


New battery holder (there's a slot on the other side to make it possible to get the cells out):

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