Day: January 17, 2017

The Electrical Grid Demystified

January 17, 2017 by 80 Comments

Our society needs energy, and lots of it. If you’re reading this then the odds are astronomically good that you’re on a computer somewhere using energy, with the power cord plugged into the mysterious “black box” that is the electrical grid. The same is true if you’re reading this on a laptop or phone, which was charged from said black box even though it may not be connected at this moment. No matter where you are, you’re connected to some sort of energy source almost all the time. For almost every one of us, we have power lines leading up to our homes, which presumably connect to a power plant somewhere. This network of power lines, substations, even more power lines, and power plants is colloquially known as the electrical grid which we will be exploring in a series of articles.

While the electrical grid is a little over a century old, humanity has been using various energy sources since the agricultural revolution at least. While it started with animal fat for candles, wind for milling grain, and forests for building civilizations, it moved on to coal and steam during the industrial revolution and has ended up in a huge interconnected network of power lines connected to nuclear, natural gas, coal, solar, and wind sites around the world. Regardless of the energy source, though, there’s one reason that we settled on using electricity as the medium for transporting energy: it’s the easiest way we’ve found to move it from place to place.

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Servo-Controlled IoT Light Switches

January 17, 2017 by 27 Comments

The Internet of Things is fun to play with; there’s all manner of devices to automate and control remotely. It can be sketchy, though — make a mistake when coding your automatic plant watering system and you could flood your house. Make a mistake with a space heater and you could burn it down. Combine these risks with the fact that many people live in rental properties, and it can be a difficult proposition to bring the Internet of Things to your home.

[Suyash] came up with a way around this by building 3D printed light switch covers that add servo control. It’s a great solution that it doesn’t require the modification of any mains wiring, and interfaces with the standard switches in the normal way. It makes it a lot safer this way — there are municipal wiring codes for a reason. This is a great example of what you can do with a 3D printer, above and beyond printing out Yoda heads and keychains.

The backend of things is handled by the venerable ESP8266, with [Suyash]’s custom IoT library known as conduit doing the heavy lifting. The library is a way to quickly build IoT devices with web interfaces, and [Suyash] claims it’s possible to be blinking an LED from the cloud within 5 minutes using the tool.

For another take on an IoT light switch, check out this Hackaday Prize entry from 2016.

Shmoocon 2017: The Ins And Outs Of Manufacturing And Selling Hardware

January 17, 2017 by 29 Comments

Every day, we see people building things. Sometimes, useful things. Very rarely, this thing becomes a product, but even then we don’t hear much about the ins and outs of manufacturing a bunch of these things or the economics of actually selling them. This past weekend at Shmoocon, [Conor Patrick] gave the crowd the inside scoop on selling a few hundred two factor authentication tokens. What started as a hobby is now a legitimate business, thanks to good engineering and abusing Amazon’s distribution program.

The product in question is the U2F Zero, an open source U2F token for two-factor authentication. It’s built around the Atmel/Microchip ATECC508A crypto chip and is, by all accounts, secure enough. It’s also cheap at about $0.70 a piece, and the entire build comes to about $3 USD. All of this is hardware, and should be extremely familiar to the regular Hackaday reader. This isn’t the focus of [Conor]’s talk though. The real challenge is how to manufacture and sell these U2F dongles, a topic we looked in on back in September.

The circuit for this U2F key is basically just a crypto chip and a USB microcontroller, each of which needs to be programmed separately and ideally securely. The private key isn’t something [Conor] wants to give to an assembly house, which means he’s programming all these devices himself.

For a run of 1100 units, [Conor] spent $350 on PCB, $3600 for components and assembly, $190 on shipping and tariffs from China, and an additional $500 for packaging on Amazon. That last bit pushed the final price of the U2F key up nearly 30%, and packaging is something you have to watch if you ever want to sell things of your own.

For distribution, [Conor] chose Fulfillment By Amazon. This is fantastically cheap if you’re selling a product that already exists, but of course, [Conor]’s U2F Zero wasn’t already on Amazon. A new product needs brand approval, and Amazon would not initially recognize the U2F Zero brand. The solution to this was for [Conor] to send a letter to himself allowing him to use the U2F Zero brand and forward that letter to the automated Amazon brand bot. Is that stupid? Yes. Did it work? Also yes.

Sales were quiet until [Conor] submitted a tip to Hacker News and sold about 70 U2F Zeros in a day. After that, sales remained relatively steady. The U2F Zero is now a legitimate product. Even though [Conor] isn’t going to get rich by selling a dozen or so U2F keys a day, it’s still an amazing learning experience and we’re glad to have sat in on his story of bootstrapping a product, if only for the great tip on getting around Amazon’s fulfillment policies.