Safely Creating A Li-Ion Pack From Phone Cells

[Glen], at Maker Space Newcastle Upon Tyne, is refreshingly honest. As he puts it, he’s too cheap to buy a proper battery.

He needed a 1AH battery pack to power his quadcopter controller and FPV headset, and since inadequate discharge warnings had led him to damage lithium polymer cells with these devices, he wanted his pack to use lithium-ion cells. His requirements were that the cells be as cheap, lightweight, and small as possible, so to satisfy them he turned to a stack of mobile phone cells. Nokia BL-4U cells could be had for under a pound ($1.46) including delivery, so they certainly satisfied his requirement for cheapness.

It might seem a simple procedure, to put together a battery pack, and in terms of physical wiring it certainly is. But lithium-ion cells are not simply connected together in the way dry cells are, to avoid a significant fire risk they need to have the voltage of each individual cell monitored with a special balanced charger. Thus each cell junction needs to be brought out to another connector to the charger.

[Glen]’s write-up takes the reader through all the requirements of safe lithium-ion pack construction and charging, and is a useful read for any lithium-ion newbies. If nothing else it serves as a useful reminder that mobile phone cells can be surprisingly cheap.

Lithium cells have captured our attention before here at Hackaday. Our recent Hackaday Dictionary piece provides a comprehensive primer, we’ve featured another multi-cell build, and an interesting app note from Maxim for a battery manager chip.

Feeding The Cat, Reinventing The Wheel

There are few projects that we see as many iterations of as the pet feeder or the plant waterer. (What is it with you people? Are you all as forgetful as we are?) Still, the fun is in the details of the implementation. Or at least that’s the case with [Emmaanuel]’s cat feeder.

The writeup is split into three parts: the worm-drive, the electronics, and the housing (here in English: worm, electronics, housing). And of course, there’s a video inlined below.

The auger and motor housing make great use of PVC pipe and 3D printing, and the dispenser unit looks quite professional. There’s not all that much to say about the electronics — an Arduino clone, an LCD, and a cheap gear motor do just about what you’d expect.

The CNC’ed case with spring-fit tabs steals the show, however. It’s made out of MDF, which doesn’t take well to screwing or glueing. With carefully routed pins and tabs that have a little spring in them, [Emmaanuel] was able to take the pieces off the mill table and just snap them together. Awesome.

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Hackaday Prize Entry: You Know, For Kids

Like the fictitious invention of the Hula Hoop in Hudsucker Proxy, [David Spinden]’s big idea is small and obvious once you’ve seen it. And we’re not saying that’s a bad thing at all. What he’s done is to make a new kind of prototyping connector; one that hooks into a through-plated hole like a pogo pin, but in the horizontal direction.

9092981463539177581This means that your test-points can do double duty as header connectors, when you need to make something more permanent, or vice-versa. That’s a lot of flexibility for a little wire, and it takes one more (mildly annoying) step out of prototyping — populating headers.

[David] makes them out of readily available header pins that already have the desired spring-like profile, and simply cuts them out and connects them to a standard Dupont-style hookup wire. Great stuff.

When we opened up the “Anything Goes” category for the Hackaday Prize, we meant it. We’re excited to see people entering large and small ideas that improve the world, even if it’s just the world of hackers.

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Retrotechtacular: Fog Over Portland

In the early days of broadcast television, national spectrum regulators struggled to reconcile the relatively huge bandwidth required by the new medium with the limited radio spectrum that could be allocated for it. In the USA during the years immediately following World War Two there was only a 12-channel VHF allocation, which due to the constraints of avoiding interference between adjacent stations led to an insufficient number of possible transmitter sites to cover the entire country. This led the FCC in 1949 to impose a freeze on issuing licences for new transmitters, and left a significant number of American cities unable to catch their I Love Lucy or The Roy Rogers Show episodes.

The solution sought by the FCC was found by releasing a large block of UHF frequencies between 470 and 890 MHz from their wartime military allocation, and thus creating the new channels 14 to 83. An experimental UHF pilot station was set up in Bridgeport, Connecticut in 1949, and by 1952 the FCC was ready to release the freeze on new licence applications. The first American UHF station to go on air was thus KPTV in Portland, Oregon, on September 18th of that year.

UHF TV was a very new technology in 1952, and was close to the edge of what could be achieved through early 1950s consumer electronics. Though the 525-line TV standard and thus the main part of the sets were the same as their VHF counterparts, the tuner designs of the time could not deliver the performance you might expect from more recent sets. Their noise levels, sensitivity, and image rejection characteristics meant that UHF TV reception  did not live up to some of its promise, and thus a fierce battle erupted between manufacturers all keen to demonstrate the inferiority of their competitors’ products over the new medium.

The video below the break delivers a fascinating insight into this world of claim and counter-claim in 1950s consumer electronics, as Zenith, one of the major players, fires salvos into the fray to demonstrate the superiority of their products over competing models or UHF converters for VHF sets. It’s very much from the view of one manufacturer and don’t blame us if it engenders in the viewer a curious desire to run out and buy a 1950s Zenith TV set, but it’s nonetheless worth watching.

A key plank of the Zenith argument concerns their turret tuner. The turret tuner was a channel selection device that switched the set’s RF front end between banks of coils and other components each preset to a particular TV channel. Zenith’s design had a unique selling point that it could be fitted with banks of components for UHF as well as VHF channels thus removing the need for a separate UHF tuner, and furthermore this system was compatible with older Zenith sets so existing owners had no need to upgrade. Particularly of its time in the video in light of today’s electronics is the section demonstrating the clear advantages of Zenith’s germanium mixer diode over its silicon equivalent. Undeniably true in that narrow application using the components of the day, but not something you hear often.

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Mechaduino- Closed Loop Stepper Servos For Everyone

Is it something in the water, or have there been a lot of really cool servo projects lately? Mechaduino is a board that sits on a regular stepper motor and turns it into a servo with a closed loop control of 0.1degree.

Whenever we post something about using cheap brushless motors for precision control, someone comments that a stepper is just a brushless motor with a lot of poles, why not just control it like one. That’s exactly what the Mechaduino does. They also hint at doing something very clever with a magnetic encoder on the board which allows them, after a calibration routine, to get the accuracy they’ve promised.

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Mind Control Cerebro Helmet Controls People

For the recent release of X-Men Apocalypse, YouTuber [Allen Pan] from “Sufficiently Advanced” decided to make a rather ambitious project — a working Cerebro Helmet. Wait what?

When worn, it allows you to steer the person wearing it to the left or right using a series of impulses to the brain. It’s actually a well-researched technique called Galvanic Vestibular Stimulation — basically if you zap a nerve in your ear it messes with your balance. If you’re trying to walk in a straight line and the electrodes trigger, it causes a sudden imbalance and you tend to lean in that direction — thus changing the direction you are walking. Kind of like remote control cockroaches — but… with people…

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How Did Pocket NC Survive And Thrive?

We had a chance to talk to Matthew Hertel of PocketNC at the Bay Area Maker Faire this year. During the conversation, he answered some questions I’d had about the project since I saw it on Kickstarter, and told a cool story while he was at it.

When the Pocket NC 5-axis Tabletop CNC Mill KickStarter came out, I immediately chocked it up as a failure out of the gate. I figured that there would never be a single delivered unit. It just seemed too impossible. The price was too low for a machine with that many large machined aluminum pieces. It had real linear guides. It had a real spindle and housed a beagle bone black running linuxCNC. It just couldn’t be that cheap. Ends up, I’m quite happy to be wrong. Pocket NC is doing well, delivering their first units, and taking new orders.

The CNC equivalent of a brag track on a hip-hop record.
The CNC equivalent of a brag track on a hip-hop record.

It’s easy to get jaded with the Kickstarter and IndieGoGo scams that are out there. Or even the disappointing behavior of projects that could be legitimate. People often do failure analysis of companies, but it is also worth investigating what people did right when they are successful.

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