Dead UPS to DIY Spot welder

While i was looking for some spot welder ideas, i saw a project with some transformers of industrial UPS (Uninterrupted Power Supply). Then the old dead UPS lying around my room clicked to my mind and the transformer was huge as i hoped!

The rectification of the UPS was originally done by the diodes built into MOSFET’s used to drive the transformer from battery. To test the rig I used some 1mm copper wire and short circuited it, the result was quite good while the wire got very hot.

Playing more around the transformer showed that it had a center tap for the low voltage winding and a 40A fuse going to the battery. With some trouble, the centre tap got divided to separate coils and I connected them in parallel to increase the maximum current output (nearly doubling the initial amount). From the initial heated 1mm house wiring cable, I switched to multi stranded heaveier guage wire which got less heated and can melt the metal through it’s two connectors pretty easy.

My final conclusion was that using a dead UPS transformer is much easier than modifying a microwave as the risks are less, the coil needs minimal modifications and a nice casing!

Pinguino – PIC based Arduino-like board

For some time I’ve been looking for a microcontroller  development board for my projects so I can do the prototyping a lot easier. The first such system I met is arduino (an open source development board based on Atmel mircocontrollers), I started to search for something like it, but using PIC microcontrollers instead. In the current trend, serial ports are becoming obsolete from newer computers and almost none on laptops, therefore I looked for a USB based solution. Finally, an open source system so messing up with it is some fun!

After some googling, I found out about Pinguino which is based on 28 pin pic18F2550 and bigger version of it, pic18F4550 (40 pin) microcontrollers. Depending on the requirements, the user have choice for either for 2550 or 4550 and both are USB supported in hardware (not bit banging). Just as I had some 18F2550 with me, i made the “traditional 2550” version.

That’s the basic description! The board communicate with the computer as a HID (the microcontroller must be flashed with the firmware in pinguino site to make it the pinguino!) and the IDE given is a python based software which can communicate with the microcontroller. The language used in the IDE is SDCC that can be learnt pretty quickely after following the tutorial.

Overall I like the whole system as it’s very fast in communication (40 seconds in serial vs 2 seconds via pinguino) as well as it’s very responsive. Even though a boot loader usually affect a microcontroller’s performance, this didn’t do as I assumed.


“An Invention is something new and useful !”

Being one of the simplest definitions for inventions , it speaks out the most basic and required feature of an invention, being a new idea which is a solution for a problem while it serves the human kind in good or bad way. For most people inventions sounds like that they are one of the most exceptional things that exist in the earth, But for the surprise of many,  they are all around us !!!. From eraser attached pencil to ball point pen, from simplest carbon filament lamp to xenon discharge lamp or L.E.D. lamps and the first television with rotating disks to make the image to plasma projection televisions are just a handful of common inventions around us ! Therefore inventions are not exceptional or rare or something magical, but the idea of the invention is exceptional as without being exceptional that idea isn’t new and innovative.

The second important feature of an invention should be that it is serving us while it performs better than the previous technique, method or the system for the purpose. A good example is light bulb which revolutionized the human race by replacing dangerous and polluting kinds of flames from basic candle to gas lamp. Another example is the ball point pen. It stopped ink spills, usage of blotting paper and caused increased writing speeds.

While making the invention, the ability to be multi purpose will perform better as packing several things in one isn’t easy though the output is huge from such inventions. The swiss army knife or personal computer are two of the best examples for being multipurpose devices. Therefore being multipurpose is also a good feature of an invention though it is not compulsory.

People expect many things from an invention, including previously described features and marketing aspects, costs, etc. But I would like to point out a less discussed morally important aspect of an invention, “whether it helps the human to live better or destroy better”. The amazing thing is that both can be done from an invention while some are intended for one aspect. Still the invention can be used to help or destroy humans and environment. Therefore this is something not included in the idea of invention but way the user expect to use it. As an example rocket propulsion can be used for entertainment like fireworks and devastation like nuclear missiles. Therefore the biggest responsibility in using something is that it helps the human kind in a good way not the other way!.

Finally I think you can understand that inventions are things around us made for our ease. In addition they help us to perform our task better than we did earlier. But for inventors or creative thinkers, making one can be easy consuming several hours or difficult which even consuming our whole lifetime. Thats why Thomas Alva Edison who experimented more than 1000 types of materials for the best filament in making the electric bulb told,

“Genious if one percent inspiration, ninty-nine percent perspiration”.

Rits Super Science Fair 2009

This science fair was hosted by Ritsumeikan Senior high school and affiliated universities .For the first time Sri Lanka participated in the fair, and I’m one of the three participants.The fair was organized for the 7th consecutive year and we could see the organizing capabilities of the organizers.From the opening ceremony till closing ceremony, we could see the work done by everybody involved.The participants had to participate several activities which were chosen by the participants before. Science Zone, Science World can be considered as the best of the activities.In science world there are several choices, from biodiversity to robotics.In the robotics section we were first given a lecture whether artificial cultures exist or not, then we could interact with the Aibo, the robot dog manufactured by Sony (The production is stopped by the company).The aibo could show emotions based on the commands we give and it showed the complexity of the design.Later in the science Zone i chose robot zone which was on programming Lego Mindstorm NXT.In the latter part of the activity we had to make a robot which can navigate a dark line and the robot with shortest time was considered as the fastest.I lead the Team A consisting of four people and i did programming and some of the assembly of the robot.Only 3 teams of 9 could navigate the course and my team got the highest speed leading for victory !

Here is an image of the competition, I’m in the leftmost of the image while Mr.Kobeyashi of Ritsumeikan is in the middle.The robot is on the track running!

Image of receiving the award!

Ktechlab II

After I had the highest number of visits to the blog after original post on Ktechlab post as well as to comply some requests, I’m now going to talk on some more features and demo work in Ktechlab just after a new release of Ktechlab with some bug fixes.This time I’ll show some more work done in Ktechlab thanks to the bug fix which fixed the issue that cause Ktechlab crash when I add a PIC MCU as a component and give the assembly file.However this later release fixed it causing me to retry some experiments I had to stop.The first thing is that in circuit view you can give any assembly file written for a device supported in GPSIM which Ktechlab uses and also you can write programs in C with SDCC syntax (there are difference between C,C++ and SDCC in syntax and keywords) which is supported by SDCC.That compiled file can be converted to assembly and used in circuit view.But unfortunately the flow coding part lacks many MCU’s , it just support 3 MCU’s so I recommend to hard code rather than using flow coder because even without Ktechlab you can program.Just for your information, I didn’t know to code in C language in the time of writing the original post,but as i learnt some Java I hooked into a C++ tutorial and got some understanding in C++ causing hard coding easy and now I’m practising more to code in C so i can give up flow coder.Although I’m almost giving up flow coder, it may be the best way to start micro controller programming as it was my rescue for months!


This time I’m talking about a good Open Source software I found.When you come to electronics you eventually find micro controllers which have all the components in one chip which is in a computer,that means it has RAM,ROM ,etc.these chips become very useful when you are prototyping specially, as I found when I was designing my first robot in November 2008.But micro controllers need programming and it’s main language used to programming is assembly but currently many people use high level languages for it.However there are many brands,capabilities,types of micro controllers but i’m talking about Microchip PIC micro controllers..Although I was good in electronics I wasn’t good at programming and I was an absolute amature.Now Ktechlab come into my rescue as I was running out of time to the exibition I was planning to participate with the robot.

Ktechlab is an electronic simulator and a microcontroller IDE. Speciality of the IDE is that you can construct a program by flowcharts, and it can be converted to .asm Assembly, .c (C source code), microbe (a basic version for micro controllers) or to a hex file which can be directly programmed to the micro controller or upload the program to the micro controller.However the IDE currently support PIC micro controllers made by Microchip, however when you made the program you can simulate with the circuit simulator with the components in your design which is enebled by a component in electronic simulator called “PIC” and when you got it just load the program the box become to a chip with pins,then you can add other components to the circuit and I did my whole robot in Ktechab :),also I’ll add a new post about the robot as soon as I can.If you are good at programming then no worries, you can just ignore flowchart methord and you can debug a well as simulate the whole circuit with this!

Links for some photos,Due to my  busy life i’m unable to fix them to the post but hope you enjoy 🙂

Ktechlab snapshot 1

Ktechlab snapshot 2

Ktechlab snapshot 3

Ktechlab snapshot 4

Ktechlab snapshot 5

Ktechlab snapshot 6

Ktechlab snapshot7

Tux the Archer on Lap

About 3 weeks or a month ago I recieved a Toshiba L300-1AS laptop.See this page to get full list of specifications.After I got the laptop from in a morning first I just see work of the laptop and did some exploration.The most freaking part is that Windows Vista is worse than I expected as well as the OEM installation is full of bloatware (as i heard most people say) anyway after doing some work with it I was planning to install GNU/Linux which i had been planning even before the laptop’s arrival.So as Ubuntu is usually ok for easy installation ,etc I got a kubuntu CD (kubuntu has KDE instead of GNOME) and booted with it then for surprise X-server wasn’t working correctly,and I later found that it’s a problem with graphics driver which mean the configuring  tool didn’t got my graphics (intel) correctly so after several tries I gave up and then I got an Archlinux CD to install Archlinux which is my favourite GNU/Linux distro and installed Arch flawlessly within 15~ minutes (base installation) and I put the laptop to download the required things of me like KDE,etc and slept.On the next day’s morning I got the downloads done and configured X-server and started kde without any problem to my pleasure.On the same day I reinstalled arch but this time 64bit version which seems almost like 32bit version,however there are packages missing due to problems with the 64bit build of them ,anyhow I managed to get work done!Actually i didn’t knew that installing GNU/Linux in the laptop will be this ease as in laptops there are many manufacture specific things ,etc but i managed it! Now my laptop is free of Vista, a useless Operating System and I replaced the vista sticker with a sticker printed by me after finding the image of arch case sticker which you can buy from schwag of archlinux and did some gimping to get it to size I wanted and printed in photo quality to a sticker paper and did single side lamination.I managed to do quite impressive work with the laptop also I can prove big windows fans the power,flexibility and almost (I think no need of this)security invulnerebility of GNU/Linux!!!.Here i will add some images of the laptop when installing packages in Terminel (command line) of arch and some pictures after I got gui and I have latest snapshots which show the new release.

Before Vista removal!

After Vista removal and archlinux installed while downloading packages

After vista removal and on Archlinux

O/L is over but……

In this december i got rid of GCE (O/L) exam and I was happy these days after nonstop headaches and crazy days with one sad day on mathematics paper,(second part) and the crazy educational officers are holding the mathematics part two(second paper) again 😥 on 17th of January 2009 so the new year begins with horror.However I think the paper will be easier as the earlier paper gave us less time to work.


 I started using KDE 4.0 from about a week after it was released as i was fed up of kde 3 (vanilla,not kdemod) and those days KDE was full of bugs,including file conflicts ,library problems and many more.but after sometime (about 4 months) KDE was better and my opinion is now it can be used for daily work!

These are snapshots of my desktop , 


When switching from desktop (1st one ,it’s a rotating cube) to other using compiz-fusion!   (Zoom)                  


Some other effects. (Zoom)


Best Alt+Tab window switcher! (clearer than others)  (Zoom


When a window is clicked and hold (the window bar) the                                                                         transparency increase (Zoom)

My GNU/Linux usage timeline

I started using the computer really in grade 9 (2006)which had Win 98 after some time 98 got it’s file system damaged and i was a total geek those days and finally i was told that formatting the hard drive Will be the solution and i did in the geekiest way with imagined commands (most were success).Finally when i completed that i had to find drivers,in this way i changed to Xp and i got to know about Linux and i managed to find CDs and install Linux including OpenSuse,Ubuntu,Knoppix,etc.I didn’t have real understanding using GNU/Linux and I switched to windows until i got the ADSL Internet connection.Then I downloaded knoppix and Redhat.After that I installed redhat which unfortunately haven’t got good driver support 😦 .After this incident i was finding a person who know using GNU/Linux and found Yasith (his blog) and as a bonus I also met his twin brother Rajith (his Blog) Their suggesion was installing Debian.I installed Debian accepting their suggesion.Debian was easy to use than other distros.(when installing it in GUI) and was the most stable distro I ever met.After using debian for about 3 months (in last year) Yasith told me that he’s going to use Archlinux.After hearing that i immidiately downloaded Archlinux and started installing without a guide.That was the most craziest thing done when installing Archlinux.Finally i obtained the bginner’s guide (Beginner’s guide) and it was easy as a pie with a guide (got assistance from Yasith) still i’m running Archlinux.