Eric Weinhoffer has had plenty of experience in the product design arena, and this hard-earned knowledge is readily apparent in his mentor session for The Hackaday Prize. These serve to link up Prize entrants with industry experts in order to help them take their projects into production. You still have time to get in on the 2019 Hackaday Prize which is accepting entries until August 25th.
Eric’s work as a Prototype Engineer at Bolt stands him in good stead to deliver valuable advice on manufacturing techniques and prototyping. With projects as diverse as CNC milling machiness and ISS payloads under his belt, Eric was able to help out these entrants with a series of tricky problems that will be familiar to anyone who has tried to take a project out of the lab and into the market.
Let’s take a look at the projects and the advice that were shared during this session.
The year is 1894. You are designing a train system for a large city. Your boss informs you that the mayor’s office wants assurances that trains can’t have wrecks. The system will start small, but it is going to get big and complex over time with tracks crossing and switching. Remember, it is 1894, so computing and wireless tech are barely science fiction at this point. The answer — at least for the New York City subway system — is a clever system of signals and interlocks that make great use of the technology of the day. Bernard S. Greenberg does a great job of describing the system in great detail.
The subway began operation in 1904, well over 30 years since the above-ground trains began running. A clever system of signals and the tracks themselves worked together with some mechanical devices to make the subway very safe. Even if you tried to run two trains together, the safety systems would prevent it.
On the face of it, the system is very simple. There are lights that show red, yellow, and green. If you drive, you know what these mean. But what’s really interesting is the scheme used at the time to make them light.
Tired of risking his life every time he had to signal a turn using his hands while riding his bicycle in rainy Vancouver, [Simon Wong] decided he needed something a bit higher tech. But rather than buy something off the shelf, he decided to make it into his first serious Arduino project. Given the final results and the laundry list of features, we’d say he really knocked this one out of the park. If this is him getting started, we’re very keen to see where he goes from here.
So what makes these turn signals so special? Well for one, he wanted to make it so nobody would try to steal his setup. He wanted the main signal to be easily removable so he could take it inside, and the controls to be so well-integrated into the bike that they wouldn’t be obvious. In the end he managed to stuff a battery pack, Arduino Nano, and an HC-05 module inside the handlebars; with just a switch protruding from the very end to hint that everything wasn’t stock.
On the other side, a ATMEGA328P microcontroller along with another HC-05 drives two 8×8 LED matrices with MAX7219 controllers. Everything is powered by a 18650 lithium-ion battery with a 134N3P module to bring it up to 5 VDC. To make the device easily removable, as well as keep the elements out, all the hardware is enclosed in a commercial waterproof case. As a final touch, [Simon] added a Qi wireless charging receiver to the mix so he could just pull the signal off and drop it on a charging pad without needing to open it up.
Today the 2018 Hackaday Prize begins with a roar. This is our global engineering initiative with huge prizes for those hackers, designers, and engineers who want to use their skill and energy to build something that matters. This year, we challenge you to Build Hope. Show the world the amazing ways technology enriches humanity, and that its benefits can be shared by all.
There is over $200,000 in cash prizes headed to the most interesting hardware builds of the year. With plenty of room for great ideas, the top 100 entries will each receive a $1,000 cash prize and continue the build to final judging. The top five entries will be awarded a $50,000 Grand Prize, and $20,000, $15,000, $10,000, and $5,000 for 2nd through 5th places. We even have some additional seed funding set aside to help early entries to get started.
What is Building Hope?
It feels like there is a steady drumbeat of doom and gloom surrounding technology these days. We hear this foretold in many ways, things like robots rising up to enslave humanity, artificial intelligence and big data being used to manipulate people, and quantum computing on the horizon that will invalidate cryptographic security. Our challenge? Get in there and show the incredible good that technology can do in the world.
Design something that shows the benefits of using knowledge and creativity to solve a problem. Be the shining light that proves our future is full of hope because smart people care about what happens in the world and to the people who live here. It is our responsibility as those who understand powerful technologies to show the best ways they can be used to build up humanity. This is your chance.
We have five challenge categories to choose from in the 2018 Hackaday Prize. The top twenty entries from each category will receive $1,000 and continue work in order to compete for the top prizes.
Open Hardware Design Challenge:
This is the challenge you should enter right now. Choose a challenge facing the world today and design the best plan possible for the boldest solution you can envision.
Over the years we’ve seen thousands of Hackaday Prize entries that take on farming, transportation, pollution, safety, scientific research, education, and assistive technologies like custom prosthetics, innovative wheelchairs, and braille interfaces for smartphones. There’s plenty in the world that needs solving and you have the talent to do it!
Robotics Module Challenge:
Build a module that makes it easier to put together advanced robots. Show your designs for the parts that others can build on.
Power Harvesting Challenge:
Build a module that harvests ambient power. Show how we can reduce or remove batteries from more devices.
Human Computer Interface Challenge:
Build an innovative interface for humans to talk to machines or machines to talk to humans. Break down more barriers to make devices more intuitive and natural to use.
Musical Instrument Challenge:
Be creative with this round and build a module, interface, or full instrument that evolves or goes far beyond modern music instrumentation.
Seed Funding For Early Entries
Itching to build something? Get a boost on your material budget by securing a bit of seed funding. Enter your design in the first challenge and pack it with as much information as possible. Each “like” that you get from the Hackaday.io community translates to $1 in seed funding. We have $4000 set aside with a max of $200 per entry. You can follow progress by checking the leaderboard on the Hackaday Prize page.
Incredible Judges
The Hackaday Prize has something really special in the judges that volunteer their time and talent to review the 100 finalists. They are accomplished engineers working, researching, and forging ahead to new frontiers in technology. Learn more about the judges on the Hackaday Prize page.
Get Started at World Create Day
This coming Saturday is Hackaday World Create Day, and the perfect time to get started with your Hackaday Prize entry. Stop by a meetup in your area (or host your own) and put your heads together and pick the design challenge you want to work on. We love seeing collaborative entries and this is a great chance to build your engineering dream team.
Five Years of Amazing Engineering
Thousands of entries have been submitted to the Hackaday Prize over the years. Founded in 2014 by Supplyframe CEO Steve Flagg, the Hackaday Prize is now in its fifth year. The challenges change each year, but the goal remains the same: to Build Something That Matters. We are consistently amazed both by the quality of the solutions, and the uncovering of new and interesting problems targeted by the entries.
Studying earth’s oceans is increasingly important be it due to climate change or pollution. Alex Williams was awarded the 2017 Hackaday Prize for his Open Source Underwater Glider, a suite of sensors built into a cleverly low-power underwater autonomous vehicle. In 2016, Alberto Molina took the top spot for DTTO, a modular robotics system made up of multiple single-hinge segments that can reorient themselves. A team working toward an eye-controlled electric wheelchair placed first in 2015 for Eyedriveomatic — a solution that improved life for two of the team members with Motor Neuron Disease, (also called ALS). And the recipients of the first Hackaday Prize were recognized for their team’s development of a network of satellite ground stations (SatNOGS) which anyone can build, add to the network, and share time on to communicate with satellites as they make their orbit. This is an important tool to make low-cost research for things like Cubesats possible, and the network has been growing ever since.
If you feel the need for more inspiration, take a few minutes to look over the Hackaday Prize hall of fame of all of the top finishers through the years.
These are impressive ideas that began with the basic question of how can we do better? A simple idea can change the world but only if you share that idea and work to make it grow. Enter yours in the Hackaday Prize now!
Safety is one of those topics that often elicits a less-than-serious response from some tool users. For these folks, they assume their elite skills will protect them and as long as they pay attention, they never will get hurt. This explains the prevalence of the nickname “Stubby” among this population. On the opposite end of the spectrum, safety is also one of those areas where people who don’t know a lot about tools can overreact. Imagine a whole table of kids wearing goggles as one of them gingerly melts some solder. You don’t want solder in your eye, but that’s just not going to happen under normal circumstances.
And then there are freak accidents, which are a reality. On September 20th, a leaking propane tank exploded at Sector67’s new workshop, severely injuring Chris Meyer. Far from a noob, Chris is one of the most experienced people in the shop and was a co-founder of the space. He has a long road of healing ahead of him, and as seems to be the sad necessity these days, he has a GoFundMe campaign to help both with his medical expenses and to help refurbish the workshop. The Foothills Community Workshop also burned to the ground recently, although fortunately no one was injured.
All in all, hackerspaces seem to be reasonably safe, particular considering the challenges they face — or more fairly, the risks associated with the typical hackerspace’s openness. Most hackerspaces allow anyone who pay dues to be a member. There is a wide range of backgrounds, competencies, and judgments represented with, how shall I put it, some unusual viewpoints that might hinder rule-following. And once the member has a fob or key, it’s open season on any kind of tool in the place right? Not everything can have a lock on it.
Here are a few simple rules that have emerged over the years, and may help your hackerspace navigate the twin dangers of complacency and paralyzed fear while preparing for the freak accidents that may simply come to pass.
To describe the constraints on developing consumer battery technology as ‘challenging’ is an enormous understatement. The ideal rechargeable battery has conflicting properties – it has to store large amounts of energy, safely release or absorb large amounts of it on demand, and must be unable to release that energy upon failure. It also has to be cheap, nontoxic, lightweight, and scalable.
As a result, consumer battery technologies represent a compromise between competing goals. Modern rechargeable lithium batteries are no exception, although overall they are a marvel of engineering. Mobile technology would not be anywhere near as good as it is today without them. We’re not saying you cannot have cellphones based on lead-acid batteries (in fact the Motorola 2600 ‘Bag Phone’ was one), but you had better have large pockets. Also a stout belt or… some type of harness? It turns out lead is heavy.
The Motorola 2600 ‘bag phone’, with a lead-acid battery. Image CC-BY-SA 3.0 source: Trent021
Rechargeable lithium cells have evolved tremendously over the years since their commercial release in 1991. Early on in their development, small grains plated with lithium metal were used, which had several disadvantages including loss of cell capacity over time, internal short circuits, and fairly high levels of heat generation. To solve these problems, there were two main approaches: the use of polymer electrolytes, and the use of graphite electrodes to contain the lithium ions rather than use lithium metal. From these two approaches, lithium-ion (Li-ion) and lithium-polymer (Li-Po) cells were developed (Vincent, 2009, p. 163). Since then, many different chemistries have been developed.
Traffic lights are so ubiquitous that we hardly give them a second thought, except to curse their existence when they impede us on our daily drive. But no matter how much it seems like traffic lights have the ability to read our minds and tell when we’re running late, they’re really not much more than a set of lights and a programmable controller. Simple in practice, but as usual, the devil is in the details, and for a system that needs to work as close to 100% of the time as possible, the details are important. Let’s explore the inner workings of traffic signals.
Electromechanical Timing
The traffic lights and crosswalk signals at an intersection are only the public user interface, of course. The interesting stuff is going on in the control box. There’s at least one at every intersection, usually a plain metal cabinet set back from the road, sometimes camouflaged with public bills or graffiti. But inside are the guts of what makes an intersection work and keeps vehicle and foot traffic moving smoothly and safely.
Unsurprisingly, most traffic signal controls started out as purely electromechanical devices. Cabinets were chock full of synchronous motors turning timing wheels with cams to cycle the intersection’s lights through the proper sequence. One old time controller that was common up until recently was made by Econolite, and the insides are a paragon of sturdy design.
Studying earth’s oceans is increasingly important be it due to climate change or pollution. Alex Williams was awarded the 2017 Hackaday Prize for his 
