Hackaday Links: March 17, 2024

March 17, 2024 by Dan Maloney 16 Comments

A friend of ours once described computers as “high-speed idiots.” It was true in the 80s, and it appears that even with the recent explosion in AI, all computers have managed to do is become faster. Proof of that can be found in a story about using ASCII art to trick a chatbot into giving away the store. As anyone who has played with ChatGPT or its moral equivalent for more than five minutes has learned, there are certain boundary conditions that the LLM’s ~~creators~~ lawyers have put in place to prevent discussion surrounding sensitive topics. Ask a chatbot to deliver specific instructions on building a nuclear bomb, for instance, and you’ll be rebuffed. Same with asking for help counterfeiting currency, and wisely so. But, by minimally obfuscating your question by rendering the word “COUNTERFEIT” in ASCII art and asking the chatbot to first decode the word, you can slip the verboten word into a how-to question and get pretty explicit instructions. Yes, you have to give painfully detailed instructions on parsing the ASCII art characters, but that’s a small price to pay for forbidden knowledge that you could easily find out yourself by other means.

Continue reading “Hackaday Links: March 17, 2024” →

This ESP8266 Dev Board Has A Surprising Story Behind It

April 23, 2021 by Tom Nardi 24 Comments

If you’re looking to get started with the ESP8266, there’s no shortage of development boards out there to select from. But we don’t think you’ll find one with a more unique a backstory than the open source ME-ESP8266. That’s because Malouf, the company that makes the $20 USD board, is a home goods company better known for their pillows and bed frames.

So how do you go from mattress toppers to microcontrollers? Well, as unlikely as it might seem, the missing element is Toys R’ Us. Or more specifically, the liquidation of Toys R’ Us. A Texas distribution center Malouf purchased from the iconic toy retailer included an automated conveyor belt system to move product through the gargantuan building, but unfortunately, they couldn’t get it to work with their existing system. The company decided to use their in-house team of engineers to solve the problem, and the ME-ESP8266 was born.

It turns out that an ESP8266 board developed to move bedding around an old Toys R’ Us warehouse has a lot of useful features for hackers and makers. It’s got an integrated relay, 16 MB of flash storage, an IR receiver, beefy screw terminals, and a 2.54mm-pitch GPIO pin header. There’s even a MAX232 on the board so it can talk to RS-232 devices. The hardware is compatible with the standard Arduino IDE as a “Generic ESP8266 Module”, so you’ll have no problem using existing libraries and example code.

Now under normal circumstances, the public would never know about this sort of behind the scenes engineering. But instead of keeping their new ESP board to themselves, the team at Malouf got the go ahead from the company’s Chief Technology Officer (CTO) to release it as an open source project. Even more impressive, they got the company to put the board into production so it could be sold to the public. So today we not only learned that bedding companies have CTOs, but that they can be exceptionally open-minded.

Our hats off to the engineers at Malouf and the forward thinking brass that green lit production of the ME-ESP8266. It’s not the first interesting development to come from the liquidation of Geoffrey’s kingdom, but it just might be the most useful.

The 4-20 MA Current Loop

July 19, 2017 by Dan Maloney 114 Comments

The I/O capabilities built into most microcontrollers make it easy to measure the analog world. Say you want to build a data logger for temperature. All you need to do is get some kind of sensor that has a linear voltage output that represents the temperature range you need to monitor — zero to five volts representing 0° to 100°C, perhaps. Hook the sensor up to and analog input, whip up a little code, and you’re done. Easy stuff.

Now put a twist on it: you need to mount the sensor far from the microcontroller. The longer your wires, the bigger the voltage drop will be, until eventually your five-volt swing representing a 100° range is more like a one-volt swing. Plus your long sensor leads will act like a nice antenna to pick up all kinds of noise that’ll make digging a usable voltage signal off the line all the harder.

Luckily, industrial process engineers figured out how to deal with these problems a long time ago by using current loops for sensing and control. The most common standard is the 4-mA-to-20-mA current loop, and here we’ll take a look at how it came to be, how it works, and how you can leverage this basic process control technique for your microcontroller projects.

Continue reading “The 4-20 MA Current Loop” →

Modular Portable Conveyor Belt

February 9, 2017 by Anool Mahidharia 11 Comments

When teaching Industrial Automation to students, you need to give them access to the things they will encounter in industry. Most subjects can be taught using computer programs or simulators — for example topics covering PLC, DCS, SCADA or HMI. But to teach many other concepts, you need to have the actual hardware on hand to be able to understand the basics. For example, machine vision, conveyor belts, motor speed control, safety and interlock systems, sensors and peripherals all interface with the mentioned control systems and can be better understood by having hardware to play with. The team at [Absolutelyautomation] have published several projects that aim to help with this. One of these is the DIY conveyor belt with a motor speed control and display.

This is more of an initial, proof of concept project, and there is a lot of room for improvement. The build itself is straightforward. All the parts are standard, off the shelf items — stuff you can find in any store selling 3D printer parts. A few simple tools is all that’s required to put it together. The only tricky part of the build would likely be the conveyor belt itself. [Absolutelyautomation] offers a few suggestions, mentioning old car or truck tyres and elastic resistance bands used for therapy / exercise as options.

If you plan to replicate this, a few changes would be recommended. The 8 mm rollers could do with larger “drums” over them — about an inch or two in diameter. That helps prevent belt slippage and improves tension adjustment. It ought to be easy to 3D print the add-on drums. The belt might also need support plates between the rollers to prevent sag. The speed display needs to be in linear units — feet per minute or meters per minute, rather than motor rpm. And while the electronics includes a RS-485 interface, it would help to add RS-232, RS-422 and Ethernet in the mix.

While this is a simple build, it can form the basis for a series of add-ons and extensions to help students learn more about automation and control systems. Or maybe you want a conveyor belt in your basement, for some reason.

Continue reading “Modular Portable Conveyor Belt” →

Mod Your Camera With ModBus

December 31, 2016 by Lewin Day 7 Comments

Industrial hardware needs to be reliable, tough, and interoperable. For this reason, there are a series of standards used for command & control connections between equipment. One of the more widespread standards is ModBus, an open protocol using a master-slave architecture, usually delivered over RS-485 serial. It’s readily found being used with PLCs, HMIs, VFDs, and all manner of other industrial equipment that comes with a TLA (three letter acronym).

[Absolutelyautomation] decided to leverage ModBus to control garden variety digital cameras, of the type found cluttering up drawers now that smartphones have come so far. This involves getting old-school, by simply soldering wires to the buttons of the camera, and using an Arduino Nano to control the camera while talking to the ModBus network.

This system could prove handy for integrating a camera into an industrial production process to monitor for faults or defective parts. The article demonstrates simple control of the camera with off-the-shelf commercial PLC hardware. Generally, industrial cameras are very expensive, so this hack may be useful where there isn’t the budget for a proper solution. Will it stand up to industrial conditions for 10 years without missing a beat? No, but it could definitely save the day in the short term for a throwaway price. One shortfall is that the camera as installed will only save pictures to its local memory card. There’s a lot to be said for serving the images right to the engineer’s desk over a network.

We’ve seen [Absolutelyautomation]’s work before – check out this implementation of Pong on an industrial controller.

Industrial Automation In Action: Steam Controller Assembly

December 12, 2015 by Dan Maloney 63 Comments

Right up front, we’ll cop to the inevitable “not a hack” comments on this one. This video of the Steam Controller assembly plant is just two minutes of pure robotics porn, plain and simple.

From injection molding of the case parts through assembly, testing and final palletizing of packaged controllers for the trip to distributors, Valve’s video is amazingly detailed and very well made. We’d wager that the crane shots and the shots following product down conveyors were done with a drone. A grin was had with the Aperture Labs logo on the SCARA arms in the assembly and testing work cell, and that inexplicable puff of “steam” from the ceiling behind the pallet in the final shot was a nice touch too. We also enjoyed the all-too-brief time-lapse segment at around 00:16 that shows the empty space in Buffalo Grove, Illinois being fitted out.

This may seem like a frivolous video, but think about it: if you’re a hardware hacker, isn’t this where you want to see your idea end up? Think of it as inspiration to get your widget into production. You’ll want to get there in stages, of course, so make sure you check out [Zach Fredin]’s 2015 Hackaday Superconference talk on pilot-scale production.

Continue reading “Industrial Automation In Action: Steam Controller Assembly” →