Low-Tech Fix Saves Expensive, High-Tech TV From Junk Pile

October 27, 2020 by 67 Comments
Wiggling this connector caused the backlight to turn off and on.

[Tweepy]’s TV stopped working, and the experience is a brief reminder that if a modern appliance fails, it is worth taking a look inside because the failure might be something simple. In this case, the dead TV was actually a dead LED backlight, and the fix was so embarrassingly simple that [Tweepy] is tempted to chalk it up to negligently poor DFM (design for manufacture) at best, or even some kind of effort at planned obsolescence at worst.

What happened is this: the TV appeared to stop working, but one could still make out screen content while shining a bright light on the screen. Seeing this, [Tweepy] deduced that the backlight had failed, and opened up the device to see if it could be repaired. However, the reason for the backlight failure was a surprise. It was not the power supply, nor even any of the LEDs themselves; the whole backlight wouldn’t turn on because of a cheap little PCB-to-PCB connector, and the two small spring contacts inside that had failed.

The failed connector, once cut open, showed contacts in poor condition (click to enlarge). It was ditched for a soldered connection, and the TV lived again.

From the outside things looked okay, but wiggling the connector made the backlight turn on and off, so the connection was clearly bad. Investigating further, [Tweepy] saw that the contact points of the PCBs and the two little conductors inside the connector showed clear signs of arcing and oxidation, leading to a poor connection that eventually failed, resulting in a useless TV. The fix wasn’t to clean the contacts; the correct fix was to replace the connector with a soldered connection.

Using that cheap little connector doubtlessly saved some assembly time at the factory, but it also led to failure within a fairly short amount of time. Had [Tweepy] not been handy with a screwdriver (or not bothered to investigate) the otherwise working TV would doubtlessly have ended up in a landfill.

It serves as a good reminder to make some time to investigate failures of appliances, even if one’s repair skills are limited, because the problem might be a simple one. Planned obsolescence is a tempting doorstep upon which to dump failures like this, but a good case can be made that planned obsolescence isn’t really a thing, even if manufacturers compromising products in one way or another certainly is.

Getting Rid Of All The Space Junk In Earth’s Backyard

October 15, 2020 by 85 Comments

Space, as the name suggests, is mostly empty. However, since the first satellite launch in 1957, mankind began to populate the Earth orbit with all kinds of spacecraft. On the downside, space also became more and more cluttered with trash from defunct or broken up rocket stages and satellites. Moving at speeds of nearly 30,000 km/h, even the tiniest object can pierce a hole through your spacecraft. Therefore, space junk poses a real threat for both manned and unmanned spacecraft and that is why space agencies are increasing their efforts into tracking, avoiding, and getting rid of it.
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Russia’s Newest Weather Satellite May Have Been Killed By Space Junk

December 27, 2019 by 27 Comments

For humans and satellites alike, making a living in space is hard. First, there’s the problem of surviving the brief but energetic and failure-prone ride there, after which you get to alternately roast and freeze as you zip around the planet at 20 times the speed of sound. The latter fact is made all the more dangerous by the swarm of space debris, both natural and man-made, that whizzes away up there along with you, waiting to cause an accident.

One such accident has apparently led to the early demise of a Russian weather satellite. Just a few months after launch, Meteor-M 2-2 suffered a sudden orbital anomaly (link to Russian story; English translation). Analysis of the data makes it pretty clear what happened: the satellite was struck by something, and despite some ground-controller heroics which appear to have stabilized the spacecraft, the odds are that Meteor-M 2-2 will eventually succumb to its wounds.

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A Stunning Ray Gun Built From Junk

December 12, 2019 by 11 Comments

If ever there was a quintessential weapon of science fiction, it would have to be the ray gun. [lonesoulsurfer] built this one-of-a-kind stunner from his impressive collection of junk. It’s centered around a vintage Bakelite soldering gun, a vacuum tube, and a portable stove burner, all of which contribute to the fantastic mid-century look.

Inside is a slightly modified version of a ray gun sound effects circuit from MAKE: that squeezes square waves from a lo-fi synth builder’s favorite IC, the 40106 hex inverting Schmitt trigger. [lonesoulsurfer] was able to reuse the soldering gun’s trigger to start the pew-pew-pew, and he can adjust the death ray’s output with potentiometers. The gun is powered by an old cell phone battery and a combo Li-ion charger/step-up module from the world’s largest virtual auction house. Blast past the break to watch the build video.

If one little green LED isn’t enough for you, maybe you’d prefer this light painting gun.

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Flex PCB Saves Lens From The Junk Pile

May 31, 2019 by 16 Comments

There’s a piece of tech that many of us own, but very few of us have dissected. This is strange, given our community’s propensity for wielding the screwdriver, but how many of you have taken apart a camera lens. Even though many of us have a decent camera, almost none of us will have taken a lens to pieces because let’s face it, camera lenses are expensive!

[Anthony Kouttron] has taken that particular plunge though, because in cleaning his Olympus lens he tore its internal ribbon cable  from the camera connector to the PCB. Modern lenses are not merely optics in a metal tube, their autofocus systems are masterpieces of miniaturised electronics that penetrate the entire assembly.

In normal circumstances this would turn the lens from a valued photographic accessory into so much junk, but his solution was to take the bold path of re-creating the torn cable in KiCad and have it made as a flexible PCB, and to carefully solder  it back on to both connector and autofocus PCB. We applaud both the quality of his work, and thank him for the unusual glimpse into a modern lens system.

Lens repairs may be thin on the ground here, but we’ve had another in 2015 with this Nikon aperture fix.

Junkbox MIDI

April 27, 2019 by No comments

Do you ever peer into the void…of your hardware scrap box? It may be a wonderland of parts with near-infinite potential, and they just need to be assembled and depending on what you hoard, programmed. Access to a laser engraver doesn’t hurt either. The stuff in [Mr. Sobolak]’s bin is cooler than average, at least by Hackaday writer standards. His sound palette project is a wild mixture of interfaces, hardware, channels, and color. There are arcade pushbuttons, slider potentiometers, rotary potentiometers, miniature laser harp, touch piano, and drum pads which earns the title of junk box build extraordinaire.

Under the hood, we find the usual copper tape, wire and solder connecting operators to a Teensy 3.2. In the more esoteric part of the BOM, we find some fancy SoftPots which look like great fun to play. All the code is linked in the Instructable, but there is absolutely no reason to make an exact copy. MIDI is from the 80s and libraries abound for this protocol so the building may be the hardest part of making an interface that fits your character. Some of the techniques in the Instructable may help you, like how to connect a piezo element so it can read something lighter than a wrecking ball or the laser harp roughly the size of your palm.

We are not short of MIDI interfaces if you are thinking of making your own or be truly random.

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Component Shelf Life: How To Use All That Old Junk

April 23, 2019 by 31 Comments

There are two types of Hackaday readers: those that have a huge stock of parts they’ve collected over the years (in other words, an enormous pile of junk) and those that will have one a couple of decades from now. It’s easy to end up with a lot of stuff, especially items that you’re likely to use in more than one design; the price breakpoints at quantities of 10 or 100 of something can be pretty tempting, and having a personal stock definitely speeds the hacking process now that local parts shops have gone the way of the dinosaur. This isn’t a perfect solution, though, because some components do have shelf-lives, and will degrade in some way or another over time.

If your stash includes older electronic components, you may find that they haven’t aged well, but sometimes this can be fixed. Let’s have a look at shelf life of common parts, how it can be extended, and what you can do if they need a bit of rejuvenation.

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