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Chording Hybrid Keyboard

Based on experience with the previous chording keyboard, fully 3D printable version with two joysticks.

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The experience with the chording keyboard has been good so far. I use it now as my primary input method, for text writing, programming, and operating specialized software.The conventional arrow buttons seems a good addition to the chords. Three problems were uncovered:1. The thumbs operating three buttons each seem to be overloaded; two thumb buttons may work better;2. Right hand has to leave the keys to access the mouse.3. A keylogger program suggests Shift and Control are pressed way more often than many other keys, including the letters, thus adding separate keys for left fingers may be justified.

The keycaps' shape is inspired by Andrey Kalmatskiy project "32xe".

Not everyone can print rinse-away support structures, so for the best printing results and ease of post-processing the stems were separated from the tops. Each cap can be freed from the support structure with just two moves of a 6-mm wood chisel, then the stem is glued in place with a drop of Superglue.

For the buttons and the joystick caps, 0.1 mm step is used. With my printer, I saw no significant improvement by moving to 0.06 mm step, at the price of making the prints slower (and probably less robust).

Sabots_for_PCBs.zip

STL files for PCB "sabots". Print with .2 mm layer height.

x-zip-compressed - 71.25 kB - 12/24/2017 at 04:04

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sketch_keyjoy_mark4.ino

Software sketch. Compile with Arduino IDE.

ino - 27.93 kB - 12/24/2017 at 04:01

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03.zip

Thumb PCB files

x-zip-compressed - 9.71 kB - 12/18/2017 at 22:27

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02.zip

Left PCB files

x-zip-compressed - 8.13 kB - 12/18/2017 at 22:26

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01.zip

Right PCB files.

x-zip-compressed - 11.85 kB - 12/18/2017 at 22:26

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View all 18 files

  • 1 × Custom PCB -- board 1 See 01.zip
  • 1 × Custom PCB -- board 2 See 02.zip
  • 1 × Arduino Pro Micro
  • 2 × PSP joysticks Or optinally can have just one or none
  • 1 × Custom PCB -- board 3 See 03.zip

View all 16 components

  • Completed Top Covers

    ptrav03/08/2018 at 07:04 0 comments

    Designed and cut on a CNC the top covers for the prototype 2:

    The wrist rests were printed with 0.2 mm step (see the files attached)

    The right joystick is currently set as a mouse, and the left is a two-directional scroll.

  • Second Mechanical Prototype Completed

    ptrav01/28/2018 at 01:26 0 comments

    Fully assembled working keyboard less the top cover. Wooden wrist supports for testing.

  • Ballistic Mouse Algorithm

    ptrav12/26/2017 at 00:37 0 comments

    Upon experimenting with the mouse pointer, I discovered that control it not accurate at short distances.  If you need to move the mouse pointer by several pixels, have to be very careful with the joystick. The solution is to implement a "ballistic" algorithm, and give the mouse pointer some "virtual mass".

    #define _NULLMOUSE (signed char)0
        if( data < -10)
        {
          if( pot_Position[i] > 0) pot_Position[i] = _NULLMOUSE; 
          if( pot_Position[i] > -data*data/20) pot_Position[i]-=2; 
        }
        if( -10 <= data && data < -4) pot_Position[i] = (signed char)(-1);
        if( -4 <= data && data <= 4) pot_Position[i] = (signed char)0;
        if( 4 < data && data <= 10) pot_Position[i] = (signed char)1;
        if( 10 < data)
        {
          if( pot_Position[i] < 0) pot_Position[i] = _NULLMOUSE; 
          if( pot_Position[i] < data*data/20) pot_Position[i]+=2; 
        }
     

    Basically, if the joystick cap moves more than 1 mm, the pointer starts accelerating towards the maximum speed of 80 pix/dt and reaches the max after 40*50=2000 ms. If the cap is moved less than 1  mm, the pointer crawls at 1 pix/dt, providing accurate pointing. Releasing the joystick (position less than 0.4 mm) causes an instantaneous stop; -- well -- the joystick itself has some minor mechanical inertia.

    I left the dt=50 ms for now. 80 pix/dt is darn fast -- 1600 pix per second, so the mouse pointer flies from one end of a large monitor to the other in about a second, which is comparable to the classic mouse agility. After reaching the wanted screen corner, one just needs to release the joystick momentarily, and then precisely point the wanted pixel.
    The algorithm is fully integer-based and suitable for Arduino.

  • Code Modification Completed

    ptrav12/24/2017 at 04:17 0 comments

    Added the code for joystick support. Currently the left joystick scrolls like a mouse wheel, the right one -- controls the mouse pointer. The joystick sensitivity is as shown:

    The joystick is checked every dt=50 ms.  The "dead zone" is .4 mm, then 1 pixel/dt till .7 mm, then 2 pix/dt till 1 mm, then a quadratic function to the maximum speed of 80 pix/dt.

  • PCBs Arrived and Soldered

    ptrav12/20/2017 at 10:26 0 comments

    PCB arrived!

    I've decided replacing the large joysticks with small PSP clone version. For that, needed to print a stand:

    PSP joysticks soldered in place:

    And the rest of the boards:

  • Completed PCB Design

    ptrav12/18/2017 at 22:23 0 comments

    Boards were designed in KiCAD and ordered on AllPCB. The schematics were as following:

    Currently it uses all available ports on Nano Pro board:

    D2 (pin5) – right fingers WRITE

    D3 (pin6) – left fingers WRITE

    D4 (pin7) – arrows WRITE

    D5 (pin8) – service buttons WRITE

    D6 (pin9) – left thumb WRITE

    D7 (pin10) – right thumb WRITE

    D8 (pin11) – left LED

    D9 (pin12) – right LED

    D10 (pin24) – READ 8

    D16 (pin23) – READ 4

    D14 (pin22) – READ 2

    D15 (pin21) – READ 1

    A0 (pin20) – left joystick RL

    A1 (pin19) – left joystick UD

    A2 (pin18) – right joystick RL

    A3 (pin17) – right joystick UD

    The KiCAD outputs are uploaded here.

  • Mechanical prototype completed

    ptrav08/26/2017 at 08:35 0 comments

    Cut the base on CNC and assembled buttons and joysticks. Tested mouse operation with a breadboard.

    Everything looks sturdy, the plastic parts are solid and have zero play. The wrist pads felt too thin for my hands, so 3-mm inserts were printed -- note the blue inserts between the base and the wrist pads.  The STL files have been modified for the extra thickness.  I have also made the files which combine the wrist pads and the switch slots for printing in one go.

    The original plan was to print the joystick caps from a semi-transparent filament to make them glow in the dark (both joystick boards have LEDs).  Well, no filament for now, may replace later.

  • Joystick boards and thumb keys

    ptrav07/09/2017 at 11:17 0 comments

    The joystick boards and thumb keys have been designed and built.

    For the prototype, a prototyping board is sufficient; sometimes in the future can do traces :)

    The body parts have been printed. Everything fits so far.

  • Initial Mockups Done

    ptrav06/11/2017 at 02:18 0 comments

    I've completed three initial mockups using cardboard, junk prints, and hot glue. The dimensions were progressively fed into the Blender model and actual components printed.

    Iteration 1. Initial layout with 3 thumb buttons.

    At this point, decided to drop one thumb button from design: one joystick plus three buttons is a bit cumbersome to handle.

    Iteration 2. Initial layout with 2 thumb buttons and approximate positions for wristpads and joysticks. Actual joystick caps and key caps are used.

    Iteration 3. The thumb layout is now final. Experimenting with the joystick offsets and finger buttons.

    The same layout ported to Blender:


  • Figured out the button printing

    ptrav06/10/2017 at 09:54 0 comments

    After experimenting with support structures, decided to use separate prints for top and bottom and glue together.

    Top row: experiments. Bottom row: final version. For the latter, the switch slots require no cleaning and look way more accurate.

    "Gravity is not just a good idea. It's the law."

    Parts completed so far:

View all 10 project logs

  • 1
    Print the body parts

    In order to accommodate the smaller printers, the body is composed of 6 parts: 2 wrist supports, 2 key holders, 1 center cover, and 1 base. On a 200x200 printer, each wrist support - key holder pair may be printed simultaneously, I will eventually release a combined STL, yet to be tested.

    The current files have been tested using Cocoon Create PLA filament. I used the step of 0.2 mm, which produced satisfactory results with no filing. Instead of using epoxy for coating, the prototype have been coated twice with the White Knight charcoal paint (it has nice glitter in it and hides dust, which will eventually settles on any keyboard). The third coating was a clear gloss.


  • 2
    Print and assemble buttons

    The project requires two joystick caps and 24 key caps. The technique is pretty much the same for all.

    1. Print the cap, studs and painting sticks

    2. Remove supports with 6 mm chisel

    3. Polish caps with 150 and then 600 sandpaper

    4. Glue studs

    5. Glue painting sticks to some used popsicle or ice cream sticks

    6. Spray paint.  I used 3 layers of transparent coating.

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