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Max's BADASS Display, Part 5

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Max The Magnificent
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A tempting tidbid...
Max The Magnificent   5/2/2014 6:00:50 PM
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Just to give you a taste of what's to come, one of the things I want to do is run my Arduino Mega, chipKIT Max32, and all of the LEDs in the BADASS display off a common 26A 5V highly-regulated supply.

However, the Arduino Mega requires a minimum of 7V (and preferably 9V or higher) from it's external supply. Meanwhile, the chipKIT Max32 does have the ability to bypass the main regulator and feed the 5V in directly, but there is a teeny-tiny gotcha if you also have the USB cable connected to a computer at the same time.

Fortunately, my on-site techno-weenie Ivan the Terrible (author of the "All About Batteries" blogs here on EE Times) has come up with cunning solutions to all of these issues.

Watch this space...

Rcurl
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Fresnel lens maybe...?
Rcurl   5/5/2014 11:57:30 AM
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How about using a fresnel lens for a 10mm led down the center of the cup washer instead of using the frosted mylar?  Look here: http://vcclite.com/_pdf/HMC-461-10mm-fresnel-thread-lens-drawing.pdf

If that doesn't do it, then a short light pipe might work.

Max The Magnificent
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Re: Fresnel lens maybe...?
Max The Magnificent   5/5/2014 12:04:41 PM
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@rcurl: How about uaing a fresnel lens for a 10mm led down the center of the cup washer instead of using the frosted mylar?  Look here: http://vcclite.com/_pdf/HMC-461-10mm-fresnel-thread-lens-drawing.pdf

Hmmm -- these do look tasty -- I'm afraid that the ymight be just a tad too wide - -I need to get my hands on one to check it out -- I'll order one today (the other thing is the cost -- remember tha tI need 250 of these little scamps)

Max The Magnificent
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Re: Fresnel lens maybe...?
Max The Magnificent   5/5/2014 12:08:37 PM
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@Rcurl: How about using a fresnel lens...

They are $1.58 each from Digi-key -- times 250 = tears rolling down my cheeks!!!

Rcurl
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Re: Fresnel lens maybe...?
Rcurl   5/5/2014 12:19:54 PM
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@Max: They are $1.58 each from Digi-key -- times 250 = tears rolling down my cheeks!!!


There wasn't anything in your specification about cost!  I can get these for 69 cents each.  In the meanwhile I'll look for a cheaper alternative.  

If you've got some acrylic rod and a chum at a machine shop then you could get some custom made lenses.

Max The Magnificent
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Re: Fresnel lens maybe...?
Max The Magnificent   5/5/2014 12:23:19 PM
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@rcurl: There wasn't anything in your specification about cost!

That doesn't mean I intend to have everything gold-plated LOL

Max The Magnificent
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Re: Fresnel lens maybe...?
Max The Magnificent   5/5/2014 12:24:54 PM
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@rcurl: I can get these for 69 cents each.  In the meanwhile I'll look for a cheaper alternative.

I just ordered one from Digi-Key -- just to see if it fits through the brass washer (if it doesn't, then this is a non-starter anyway).

Max The Magnificent
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Re: Fresnel lens maybe...?
Max The Magnificent   5/5/2014 12:26:37 PM
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@rcurl: If you've got some acrylic rod and a chum at a machine shop then you could get some custom made lenses.

It's one thing saying to the lads "can you whip me up a single XYZ" -- but it's a different kettle of fish when you want 250 of something...

perl_geek
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Re: Fresnel lens maybe...?
perl_geek   5/5/2014 2:25:27 PM
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Two thoughts for the mass-production; 3-D printer to create multiple copies at once, or a CNC machine to mill them. (Out of a large sheet, so lots created per loading.) At least the machine wouldn't get bored.

Max The Magnificent
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Re: Fresnel lens maybe...?
Max The Magnificent   5/5/2014 2:29:58 PM
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@perl_geek: Two thoughts for the mass-production...

I'm currently exploring a variety of options. I must admit that the Fresnel lenses do look rather tasty -- but it depends on (a) how they fit in the washers and (b) if I can find a really low-cost source.

I have one on order at the moment so we can check point (a) -- depending on the result we can decide what oiur next move shoudl be.

jstabler
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Re: Fresnel lens maybe...?
jstabler   5/5/2014 7:27:02 PM
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I suggest you make a filler disk with a center hole the same size as your brass washer.  It doesn't matter what material you use, could be another very cheap washer.  Glue your translucent disk to the filler disk.  Glue your new assembly to the brass washer.  Glue the final assembly to the surface of your project.  If you select your glue positions carefully, the glue should be hidden when you are done.

Max The Magnificent
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Re: Fresnel lens maybe...?
Max The Magnificent   5/6/2014 10:21:57 AM
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@jstabler: I suggest you make a filler disk with a center hole the same size as your brass washer...

This sounds like a good plan ... I'll add it into the mix ... I'm still looking at a variety of alternatives ... I'll be posting a follow-up blog when I make my final decision... watch this space :-)

jb0070
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Re: Fresnel lens maybe...?
jb0070   7/3/2014 4:30:28 PM
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The "filler disk" could asily be glue, or wood putty / paste (or something similar --- does not nned to be a washer / metal / "finished product"). Both harden and can be glued easily, and allow for clean up" before assembly. This can also be done to "mount" whatever lens you fit into the hole.

Max The Magnificent
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Re: Fresnel lens maybe...?
Max The Magnificent   7/3/2014 4:37:41 PM
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@jb0070: The "filler disk" could asily be glue, or wood putty / paste...

Thanks for the suggestion -- in fact I now know exactly which way I'm going to do this ... keep watching EE Times for my next blog on this topic...

slomobile
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Re: Fresnel lens maybe...?
slomobile   7/8/2014 6:43:43 PM
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Whichever way you go, you might consider using a 1 1/16" Forstner or anular bit (ideally spun by a cnc mill for accurate grid placement)on the face of the hardboard to positively locate each brass washer.  You can fine tune the depth to just barely capture the film/lens between washer and board eliminating the need for glue there.  A small bit of glue in the recess can unobtrusively secure the washer if needed.  The hole depth can also be used to adjust distance from LED to film/dissuser/lens.

Clive
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Re: Fresnel lens maybe...?
Clive "Max" Maxfield   7/9/2014 9:53:25 AM
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@slomobile: Whichever way you go, you might consider using a 1 1/16" Forstner or anular bit (ideally spun by a cnc mill for accurate grid placement)on the face of the hardboard to positively locate each brass washer.

That's not a bad idea -- I was already moving to using a CNC machine to drill the holes, because having them wander aroudn even a little will ruin the whole look of the thing.

AnSc.de
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Make the Film Disk bigger
AnSc.de   5/8/2014 1:22:29 AM
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Make the film disk as big as possible to fit under the washer.

Then you can glue it to the inside of the outer ring, so the unwanted glue on the inner ring is avoided.

Then you can use the space of the film disk below the washer to glue the washer in place without unwanted glue outside the washer. Or use here a ring of double sided adhesive film.

You still have to be careful with the amount of glue...

 

crude Inkscape sketch:

Washer with Disk and Glue

 

Max The Magnificent
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Re: Make the Film Disk bigger
Max The Magnificent   5/8/2014 9:47:57 AM
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@AnSc.de: Make the film disk as big as possible to fit under the washer...

This is a variation on one of the approaches I was considering -- but I think it's a better idea than mine ... let me look into this...

 

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