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Poor Man’s
Digital Counter Using Pedometer
Aug 17, 2008
designed by David A. Johnson, P.E. |
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There are many occasions when you may want to count something electronically.
Perhaps it is car traffic on a street or items moving down an assembly line.
It might be the number of times a machine is activated or maybe you want to count
the number of people entering doorway. Commercial counting modules do exist
but if you want to use something cheaper, you can modify a pedometer to do much
the same thing. |
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You can usually find inexpensive digital pedometers near the
checkout stand in many stores. I have seen these things in drug stores, food
stores and even shoe stores. They cost about $5 and usually look like the
models shown below. They are clipped onto a belt and have a swinging
pendulum switch inside, which makes contact with each step taken.
There usually is a pushbutton switch, to set the mode of operation
and a second switch to reset the count to zero. Some models just have a single
reset button and only count steps. Most have at least 5 digits for a maximum
count of 99,999. They are usually powered by a single small 1.5v alkaline button
cell. |
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It is fairly easy to open up one of
these things and replace the mechanical pendulum switch with either an external
electronic transistor switch, controlled by some logic signal, or a simple mechanical
switch, such as a pushbutton. With a simple modification, this device can count
something other than footsteps. Since the device was originally used to count
footsteps, the electronics of the module restricts the counting rate about 3 counts
per second. If you are going to use this thing often, I would suggest removing
the small 1.5 volt button battery and replace it with a larger cell. A #357
silver oxide cell should keep the thing operating for years. I used a couple
small wires and some copper foil adhesive tape, to mount the large cell inside the
case. A bit of foam rubber will hold the cell in place, when the case back is
reinstalled. |
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To start the modification process,
first remove the back of the assembly. Usually two small screws hold the back
on. With the back removed, note the termination metal plate for the thin spring wire
attached to the pendulum weight. Also note the contact pad, which the pendulum
strikes, with each footstep |
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Next, remove the whole pendulum
assembly, including the thin spring wire. Usually only one screw holds the
assembly together.
Next, file a groove about 1/8”
wide and 1/16” deep on the edge of the plastic case, next to the silver battery
holder. The groove will be used to route two thin insulated wires through the
plastic case.
Next, solder a small gauge red
wire to the battery case and a similar black wire to the pendulum contact metal tab.
The two wires can be almost any length. These wires will be routed to either an
external mechanical switch or an electronic transistor switch. |
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After soldering the two wires, you
can then reinstall the back plastic case to the main assembly. Test the counting
unit by briefly touching the ends of red and black wires together. The count should
advance each time the stripped wire ends touch. |
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Pedometer Unit to Be Modified |
Pedometer Back Removed,
Note Pendulum Weight on Top |
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Pendulum Assembly Removed |
Slot Cut into Case for Two Switch Wires |
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Red and Black Wires Soldered to Switch Contacts
Routed Through Slotted Hole |
#357 Battery Cell Installed Using Copper Foil |
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Completed Counter Assembly |
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Click on Drawing Below to view PDF version of Schematic |
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