Just a few days after Christmas last year AirAsia Flight 8051 traveling to Singapore tragically plummeted into the sea. Indonesia completed its investigation of the crash and just released the final report. Media coverage, especially in Asia is big. The stories are headlined by pilot error but,as technologists, there are lessons to be learned deeper in the report.
The Airbus A320 is a fly-by-wire system meaning there are no mechanical linkages between the pilots and the control surfaces. Everything is electronic and most of a flight is under automatic control. Unfortunately, this also means pilots don’t spend much time actually flying a plane, possibly less than a minute, according to one report.
Here’s the scenario laid out by the Indonesian report: A rudder travel limit computer system alarmed four times. The pilots cleared the alarms following normal procedures. After the fifth alarm, the plane rolled beyond 45 degrees, climbed rapidly, stalled, and fell.
[Proto G] built a small, desktop induction heater that is capable of making small castings, melting small amounts of metal, and functioning as one of the best solder pots we’ve ever seen.
The induction heater is built from a custom Zero Voltage Switching (ZVS) driver and powered by a small 48V, 1000W power supply. While this makes for an exceptionally small induction heater, it’s still very capable. In the video below, it only takes a few seconds to heat a screwdriver up to a temperature that will melt solder.
While an induction heating machine is essentially useless for irons unless you have a few antique, unpowered, blowtorch-powered soldering irons, it does make for a great solder pot. [Proto G] replaced the working coil in his induction heater with litz wire. The actual solder pot is made out of steel conduit wrapped with aerogel-infused fiberglass insulation. Compared to his old solder pot, this machine heats up instantly, and is more than capable of wetting a few wire connections.
The future plan for this inductive heater is to make a few more attachments for different metals, and a [Proto G] has a few aerogel blankets he could use to make some small metal castings.
Continue reading “A Small, 1000W Induction Heater”
Cordless soldering irons are, as a rule, terrible. A few months ago, you could pick up a cordless soldering iron from Radio Shack that was powered by AAA batteries. You can guess how well those worked. There are butane-fueled soldering irons out there that will heat up, but then you’re left without the requisite degree of temperature control.
[Xavier] didn’t want to compromise on a mobile soldering iron, so he made a desktop version portable. His mobile temperature controlled soldering iron uses the same electronics that are found in inexpensive Hakko clones, and is powered by a LiPo battery.
The soldering station controller comes directly from eBay, and a DC/DC boost converter accepts just about any DC power supply – including an XT60 connector for LiPo cells. A standard Hakko 907 iron plugs into the front, and a laser cut MDF enclosure makes everything look great. There were a few modifications to the soldering station controller that involved moving the buttons and temperature display, but this build really is as simple as wiring a few modules together.
With an off-the-shelf LiPo battery, the iron heats up fast, and it doesn’t have a long extension cord to trip over. With the right adapter, [Xavier] can use this soldering station directly from a car’s cigarette power port, a great feature that will be welcomed by anyone who has ever worked on the wiring in a car.
Continue reading “A DIY Mobile Soldering Iron”
For the last five years or so, Nintendo has been selling the 3DS, the latest in a long line of handheld consoles. Around two years ago, Nintendo announced the New Nintendo 3DS, with a faster processor and a few other refinements. The new 3DS comes in two sizes: normal and XL. You can buy the XL version anywhere in the world, but Nintendo fans in North America cannot buy the normal version.
[Stephen] didn’t want the jumbo-sized New 3DS XL, both because it’s too large for his pockets, and because there are no fancy cases for the XL. His solution? Creating a US non-XL 3DS with god-like soldering skills.
In manufacturing the XL and non-XL versions of the 3DS, Nintendo didn’t change much on the PCBs. Sure, the enclosure is different, but electronically there are really only two changes: the eMMC storage and the Nintendo processor. 3DS are region-locked, so simply swapping out the boards from a normal 3DS to an XL 3DS wouldn’t work; [Stephen] would also like to play US games on his modded console. That leaves only one option: desoldering two chips from a US XL and placing them on the board from a Japanese 3DS.
With a board preheater and heat gun, [Stephen] was able to desolder the eMMC chip off both boards. Of course this meant the BGA balls were completely destroyed in the process, which means reballing the package with solder bits only 0.3mm in diameter. With the US eMMC transplanted to the Japanese board, [Stephen] ended up with an error message that suggested the processor was reading the memory. Progress, at least.
[Stephen] then moved on to the processor. This was a nightmare of a 512 pin BGA package, with 512 pins that needed a tiny dot of solder placed on them. Here, sanity gave way and [Stephen] called up a local board and assembly house. They agreed to solder the chip onto the board and do an x-ray inspection. With the professional rework done, [Stephen] assembled his new US non-XL 3DS, and everything worked. It’s the only one in the world, and given the effort required to make these mods, we’re expecting it to remain the only one for a very long time.
The ESP8266 is an incredible piece of hardware; it’s a WiFi module controllable over a serial port, it’s five freaking dollars, and if that’s not enough, there’s a microcontroller on board. Until there’s a new radio standard, this is the Internet Of Things module.
The most common version of the ESP, the -01 version, only has a 2×4 row of pins for serial, power, configuration, and two lines of GPIO. It’s a shame that module only has two GPIOs, but if you’re good enough with a soldering iron you can get a few more. It took a lot of careful soldering, but [Hugatry] managed to break out two more GPIOs on this tiny module.
According to [Hugatry] a lot of patience to solder those wires onto those tiny pads, but after finishing this little proof of concept he discovered a Russian hacker managed to tap into four extra GPIOs on the ESP8266-01 module (Google Translatrix).
As a proof of concept, it’s great, but there’s more than one ESP module out there. If you’re looking for a cheap WiFi module, check out the ESP-03, -04, or -07; they have nice castellated pins that are exceptionally easy to solder to.
Continue reading “More GPIOs For The ESP8266”
For this week we’re veering away from our habit of giving away things to help with your build and giving away something fun. 20 Hackaday Prize entries will receive a Bulbdial Clock kit. Getting into the running is easy, start your project on Hackaday.io and make sure you officially submit it to the Hackaday Prize. Get it in by next Wednesday to be considered for this week’s prizes, and you’ll also be in the running each week after that as we work our way through $50,000 in prizes this summer before giving away the big stuff like a Trip into Space and $100,000 in cash.
The Bulbdial Clock has been a favorite of ours for years. Developed by Hackaday Prize Judges [Windell] and [Lenore] at Evil Mad Scientist Labs, it uses three rings of colored LEDs to cast shadows as clock hands. It’s a fun solder kit that will take time to assemble. In keeping with that ideal, your best bet at scoring one this week is to post a new project log showing off the solder work you’ve done on your prototype. If you don’t have one soldered yet, that’s okay too. Just post a new project log that talks about the component assembly you’ll be working on. This would be a great time to finally draw up a basic schematic, right?
Last Week’s 40 Winners of $50 Shapeways Gift Cards
Congratulations to these 40 projects who were selected as winners from last week. You will receive a $50 gift card from Shapeways so that you can get your custom parts 3D printed. We were on the lookout for projects that we thought would benefit most from custom parts. Some of these are far along in their development, some have just started, but all of them are awesome so browse the list and make sure to skull and follow the ones you like!
Each project creator will find info on redeeming their prize as a message on Hackaday.io.
After [Brian] starting selling his own Raspberry Pi expansion boards, he found himself with a need for a robot that could solder 40-pin headers for him. He first did what most people might do by looking up pre-built solutions. Unfortunately everything he found was either too slow, too big, or cost as much as a new car. That’s when he decided to just build his own soldering robot.
The robot looks similar to many 3D printer designs we’ve seen in the past, with several adjustments. The PCBs get mounted to a flat piece of aluminum dubbed the “PCB caddy”. The PCBs are mounted with custom-made pins that thread into the caddy. Once the PCBs are in place, they are clamped down with another small piece of aluminum. A computer slowly moves the caddy in one direction, moving the header’s pins along the path of the soldering irons one row at a time.
The machine has two soldering irons attached, allowing for two pins to be soldered simultaneously. The irons are retracted as the PCB caddy slides into place. They irons are then lowered onto the pins to apply heat. Two extruders then push the perfect amount of solder onto each pin. The solder melts upon contact with the hot pins, just as it would when soldered by hand.
The system was originally designed to be run on a Windows 8.1 tablet computer, but [Brian] found that the system’s internal battery would not charge while also acting like a USB host. Instead, they are running the Windows WPF application on full PC. All of the software and CAD files can be found on [Brian’s] github page. Also be sure to check out the demo video below. Continue reading “Open Source, DIY Soldering Robot”