Design Constraints Bring Lockbox To Life

One of the most paradoxical aspects of creating art is the fact that constraints, whether arbitrary or real, and whether in space, time, materials, or rules, often cause creativity to flourish rather than to wither. Picasso’s blue period, Gadsby by Ernest Vincent Wright, Tetris, and even the Volkswagen Beetle are all famous examples of constraint-driven artistic brilliance. Similarly, in the world of electronics we can always reach for a microcontroller but this project from [Peter] has the constraint of only using passive components, and it is all the better for it.

The project is a lockbox, a small container that reveals a small keypad and the associated locking circuitry when opened. When the correct combination of push buttons is pressed, the box unlocks the hidden drawer. This works by setting a series of hidden switches in a certain way to program the combination. These switches are connected through various diodes to a series of relays, so that each correct press of a button activates the next relay. When the final correct button is pushed, power is applied to a solenoid which unlocks the drawer. An incorrect button push will disable a relay providing power to the rest of the relays, resetting the system back to the start.

The project uses a lot of clever tricks to do all of this without using a single microcontroller, including using capacitors that carefully provide timing to the relays to make them behave properly rather than all energizing at the same time. The woodworking is also notable as well, with the circuit components highlighted when the lid is opened (but importantly, hiding the combination switches). Using relays for logic is not a novel concept, though; they can be used for all kinds of complex tasks including replacing transistors in single-board computers.

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Custom Pneumatic Cylinders Lock This Monitor Arm In Place

Few consumer-grade PCs are what you’d categorize as built to last. Most office-grade machines are as likely as not to give up the ghost after ingesting a few too many dust bunnies, and the average laptop can barely handle a few drops of latte and some muffin crumbs before croaking. Sticking a machine like that in the shop, especially a metal shop, is pretty much a death sentence.

And yet, computers are so useful in the shop that [Lucas] from “Cranktown City” built this neat industrial-strength monitor arm. His design will look familiar to anyone with a swing-arm mic or desk light, although his home-brew parallelogram arm is far sturdier thanks to the weight of the monitor and sheet-metal enclosure it supports. All that weight exceeded the ability of the springs [Lucas] had on hand, which led to the most interesting aspect of the build — a pair of pneumatic locks. These were turned from a scrap of aluminum rod and an old flange-head bolt; when air pressure is applied, the bolt is drawn into the cylinder, which locks the arm in place. To make it easy to unlock the arm, a pneumatic solenoid releases the pressure on the system at the touch of a button. The video below has a full explanation and demonstration.

While we love the idea, there are a few potential problems with the design. The first is that this isn’t a fail-safe design, since pressure is needed to keep the arm locked. That means if the air pressure drops the arm could unlock, letting gravity do a number on your nice monitor. Second is the more serious problem [Lucas] alluded to when he mentioned not wanting to be in the line of fire of those locks should something fail and the piston comes flying out under pressure. That could be fixed with a slight design change to retain the piston in the event of a catastrophic failure.

Problems aside, this was a great build, and we always love [Lucas]’ seat-of-the-pants engineering and his obvious gift for fabrication, of which his wall-mount plasma cutter is a perfect example.

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This Robot Picks Locks, If You’re Very Patient

We all know the Hollywood trope of picking a lock with a paperclip, and while it certainly is doable, most reputable locks require slightly more sophisticated tools to pick effectively. That’s not to say that wire is off the table for locksports, though, as this cool lock-picking robot demonstrates.

The basics behind [Sparks and Code]’s design are pretty simple. Locks are picked by pushing pins up inside the cylinder until they line up with the shear plane, allowing the cylinder to turn. Normally this is done a pin at a time with a specialized tool and with a slight bit of torque on the cylinder. Here, tough, thin, stiff wires passing through tiny holes in a blade shaped to fit the keyway are used to push all the pins up at once, eliminating the need to keep tension on the cylinder to hold pins in place.

Sounds simple, but in practice, this looks like it was a nightmare. Getting five wires to fit into the keyway and guiding them to each pin wasn’t easy, nor was powering the linear actuators that slide the wires in and out. Applying torque to the lock was a chore too; even though tension isn’t needed to retain picked pins, the cylinder still needs to rotate, which means moving the whole picking assembly. But the biggest problem by far seems to be the fragility of the blade that goes into the keyway. SLA might not be the best choice here; perhaps the blade could be made from two thin pieces of aluminum with channels milled on their faces and then assembled face-to-face.

The robot works, albeit very slowly. This isn’t [Sparks and Code]’s first foray into robot lock picking. His previous version attempted to mimic how a human would pick a lock, so this is really thinking outside the box.

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