A black plastic trim piece from a vehicle interior. It has slight flecking in its texture. It is sitting on an off-white bench overlooking a workshop.

Can Car Parts Grow On Trees?

January 19, 2024 by Navarre Bartz 26 Comments

Cars don’t grow on trees, but Ford is designing car parts from olive tree cuttings. [via Electrek]

Ford is no stranger to designing parts from plants for their vehicles. Henry famously liked to beat on the Soy Bean Car with a blunted axe to tout the benefits of bioplastic panels. Researchers at Ford’s Cologne, Germany facility have detailed their work to use waste from olive orchards as part of a new biocomposite from the LIVE COMPOLIVE program.

Fibers from the olive tree cuttings are mixed with recycled plastic and injection molded to form panels. The video below features interior panels that are currently made with traditional plastics that could be swapped over to the new composite. Since these cuttings are a waste product from food production, there isn’t the tension akin to that presented via biofuels vs food. We’re curious what Precious Plastics could do with this, especially if the fibers are able to reinforce the matrix.

If you want to see some other unusual uses for waste wood, why not checkout a “paper” bottle or 3D printing with sawdust?

Continue reading “Can Car Parts Grow On Trees?” →

Tesla’s Plug Moves Another Step Closer To Dominance

December 21, 2023 by Navarre Bartz 46 Comments

Charging an EV currently means making sure you find a station with the right plug. SAE International has now published what could be the end to the mishmash of standards in North America with the J3400 North American Charging Standard.

The SAE J3400TM North American Charging Standard (NACS) Electric Vehicle Coupler Technical Information Report (TIR), which just rolls off the tongue, details the standard formerly only available on Tesla vehicles. We previously talked about the avalanche of support from other automakers this year for the connector, and now that the independent SAE standard has come through, the only major holdout is Stellantis.

Among the advantages of the NACS standard over the Combined Charging System (CCS) or CHAdeMO is a smaller number of conductors given the plug’s ability to carry DC or AC over the same wires. Another benefit is the standard using 277 V which means that three separate Level 2 chargers can be placed on a single 3-phase commercial line with no additional step down required. Street parkers can also rejoice, as the standard includes provisions for lampost-based charger installations with a charge receptacle plug instead of the attached cable required by J1772 which leads to maintenance, clutter, and ADA concerns.

Now that J3400/NACS is no longer under the purview of a single company, the Federal Highway Administration has announced that it will be looking into amending the requirements for federal charger installation subsidies. Current rules require CCS plugs be part of the installation to qualify for funds from the Bipartisan Infrastructure Bill.

If you want to see how to spice up charging an EV at home, how about this charging robot or maybe try fast charging an e-bike from an electric car plug?

An image of the inside of a vehicle wheel. An outer ring gear is attached to two articulated sets of three small helical gears attached to a central sun gear. A shaft from the right side enters into the sun gear.

A Revolution In Vehicle Drivetrains?

December 6, 2023 by Navarre Bartz 47 Comments

Power delivery in passenger vehicle drivetrains hasn’t changed much since the introduction of the constant velocity (CV) joint in the 1930s. Most electric vehicles still deliver power via the same system used by internal combustion cars. Hyundai/Kia has now revealed a system they think will provide a new paradigm with their Universal Wheel Drive System (Uni Wheel). [via Electrek]

What appears at first to be a hub motor is in fact a geared wheel that keeps the motor close without the problem of high unsprung weight. Power is fed into a sun gear which can move independently of the wheel allowing the system to maintain a more consistent driveline and avoid power variability over the range of suspension travel like you’d find in a CV joint experiencing high deflection.

We have some concerns about the durability of such a system when compared with the KISS and long development history of CV joints, but we can’t deny that moving the motors of an electric vehicle out to the corners would allow more packaging flexibility for the cargo and passenger areas. We’re also excited to see open source replicas make their way into smaller robotics projects now that the images have been released. If you’ve already made one in CAD, send us a tip at tips@hackaday.com.

Looking for more interesting innovations in electric cars? How about an off-grid camper van? If you think automakers are overcomplicating something that should be simple, read the Minimal Motoring Manifesto.

Continue reading “A Revolution In Vehicle Drivetrains?” →

A 555 Can Even Make Your Car Indicator More Visible

November 25, 2023 by Lewin Day 42 Comments

Modern cars often come with white marker lights or daytime running lights that are on all the time, as a supplement to the primary headlights. The problem is that in some vehicle designs, these additional lights tend to make it harder to see the indicators when they’re on. [nibbler] had this very problem, and decided to solve it with a special interrupter circuit that cuts the daytime running light when the indicator is on. Even better, they used a 555 to do it!

The circuit is a simple monostable 555 circuit with an active low output. It’s triggered by the indicator signal. When the indicator is on, the circuit drives a relay to switch off the power to the daytime running light. Two copies of the circuit were built, one for the left side, and one for the right side of the car. This means that when the orange indicator is lit, it’s not being overwhelmed by the white daytime running light next to it. In fact, many automakers now program this behavior into their lighting by default.

It’s a nifty hack with a real positive safety impact. We’ve featured some other neat indicator hacks of late, like these tidy sequential indicators. Meanwhile, if you’re hacking on your own automotive lighting solutions, don’t hesitate to let us know!

ESP32 Used As Wireless CAN Bus Reader

November 22, 2023 by Lewin Day 34 Comments

The CAN bus, accessible through the OBD-II port, is the channel that holds all the secrets of the modern automobile. If you want to display those for your own perusal, you might consider this nifty tool from [EQMOD].

Yes, it’s an OBD-II dongle that you can build using an ESP32 WROVER module. It’s designed to read a car’s CAN bus communications and display them on a self-hosted web page, accessible over WiFi. The build relies on the dual-core nature of the ESP32, with the first core handling CAN bus duties via the SN65HVD230 CAN bus transceiver chip. The second core is responsible for hosting the web page. Data received via the CAN bus is pushed to the web user interface roughly every 60 to 100 milliseconds or so for information like RPM and speed. Less time-critical data, like temperatures and voltages, are updated every second.

It’s a neat little thing, and unlike a lot of dongles you might buy online, you don’t need to install some dodgy phone app to use it. You can just look at the ESP32’s web page for the data you seek. The graphics may be a little garish, but they do the job of telling you what’s going on inside your car. Plus, you can always update them yourself.

Getting to grips with the CAN bus is key if you want to diagnose or modify modern vehicles. Meanwhile, if you’ve been cooking up your own electronic vehicular hacks, don’t hesitate to drop us a line!

Keeping A Mazda’s Radio On After The Engine Shuts Off

November 22, 2023 by Lewin Day 51 Comments

Have you ever pulled into a car park with your favorite song blaring, only to lament the fact that the music cut out when you stopped the engine? Some modern cars are smart enough to keep the radio on until you open the door. [ssh16] decided to hack that very functionality into their Mazda MX-5.

The device uses a microcontroller to read the CAN bus of the vehicle. The microcontroller also has the ability to keep the vehicle’s ACC (accessory) relay energized at will. Thus, when the engine is turned off, the microcontroller keeps the ACC relay on, maintaining power to the stereo and infotainment system. Then, after ten minutes, or when it receives a CAN message that the driver’s door has been opened, it cuts power to the relay, shutting the accessories off. It’s a simple build, but one that [ssh16] executed cleanly. By putting the microcontroller on a neat PCB with a harness that can clip into the stock Mazda one, it’s possible to install the hack without needing to cut any wires. Plus, with a small modification, it was even possible to use the same hack with a Mazda CX-5.

Whether you’re jamming out to a cool song, or you just want to finish a phone call over Bluetooth, it’s a nifty feature to have in a vehicle. We’ve seen some other neat infotainment hacks before, too. Video after the break.

Continue reading “Keeping A Mazda’s Radio On After The Engine Shuts Off” →

Building An Animated Turn Signal For The Mazda MX-5

November 21, 2023 by Lewin Day 37 Comments

Turn signals in most of the world are mandated to be a flashing orange light, distinct from other bulbs on a vehicle. However, there has been a trend in the modern era to go for fancier animated turn signals using great numbers of LEDs. [ssh16] decided to whip up a set of their own to suit their late-model Mazda MX-5.

Fully lit, the replacement is brighter than the original bulb by some margin.

While many builds go down the route of using addressable LEDs, [ssh16] instead went for garden variety OSRAM yellow LEDs in a 3×12 array, driven via a shift register. A small PIC microcontroller is then used to command the shift register to light the rows of LEDs in turn, generating the sequential lighting effect that sweeps from one side to the other. The LEDs are are installed on a 4″ board designed to install in place of the Mazda’s standard indicator bulb, with the animation spreading from the centerline of the vehicle out towards the direction of the turn.

It’s a fun build that modernizes the rear turn signals of the Mazda. We’ve seen some other neat turn signal builds before, too; it almost seems to be a trend amongst Mazda enthusiasts. Meanwhile, if you’ve built your own automotive lighting mods, don’t hesitate to send them in to the tipsline.