A Homebrew Weller RT Soldering Station

January 6, 2020 by Tom Nardi 15 Comments

Like a number of hackers before him, [MarcelMG] was impressed with Weller’s RT soldering iron tips, but considerably less enthused about the high purchase price on the station they’re designed to go into. Inspired by similar projects, he decided to try his hand at building his own soldering station which reaps the benefits of these active tips without the sticker shock.

The station’s user interface was kept intentionally simple, with little more than a four digit LED display to show the temperature and a rotary encoder to set it. The display alternates between the current temperature and the set temperature every few seconds while the knob is being turned, and if you push it in, the set temperature will be saved as the default for next time.

[MarcelMG] also included a feature that drops the iron’s temperature when it’s sitting in the holder, reducing tip wear and energy consumption. He originally planned on using a Hall effect sensor to detect when the iron was holstered without needing to physically interface with it, but in the end he realized the easiest approach was to simply connect one of the input pins on the microcontroller to the metal holder. Since the tip is grounded, he could easily detect if it was in place with a couple lines of code.

Speaking of which, the station is powered by an ATtiny24A with firmware written in C using the Atmel Studio IDE. [MarcelMG] mentions that the limited storage on the 24A was a bit of a challenge to work around, and suggests that anyone looking to follow in his footsteps uses something with a bit more flash under the hood. The LED display is a very common TM1637 type, the rotary encoder was salvaged from a radio, and the power supply was from an old laptop. All told, this looks like a very economical build.

Depending on your needs, a DIY soldering station can either have features to rival the commercial models or be exceedingly simplistic. In either case, the advent of low-voltage irons and active tips have made self-built soldering stations much more approachable. Attempts without the use of these modern niceties tended to be somewhat less glamorous.

The Hacker History Of Music Technologies

January 6, 2020 by Lewin Day 7 Comments

Music throughout history has been inspired and changed by hackers and makers, and never moreso than in the 20th century. Helen Leigh is one such hacker, who brought a talk to Supercon to give us a crash course in the history of recording, electronics and music, and what the maker movement is doing in the music world today.

The tape recorder was an invention that kicked off a golden period of exploration in sound. Beginning in World War II, the Nazi propaganda machine cut and spliced recorded materials and disseminated them across broadcasting stations in Europe. To the astonishment of the Allies, certain German officials appeared to be making broadcasts from different studios at the same time, due to the high quality of the recording hardware. After the war, this technology was discovered by a group of Parisian recording artists who began to experiment with an art that became known as musique concrète, using tape hardware in weird and wonderful ways to create new sounds heretofore unheard in nature.

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Organic Audio: Putting Carrots As Audio Couplers To The Test

January 6, 2020 by Jenny List 34 Comments

[Boltz999]'s carrot interconnect. — [Boltz999]’s carrot interconnect.

If there’s one thing that gives us joy here at Hackaday it’s a story of audio silliness. There is a rich vein of dubious products aimed at audiophiles which just beg to be made fun of, and once in a while we oblige. But sometimes an odd piece of audio equipment emerges with another purpose. Take [Boltz999]’s interconnects for example, which were born of necessity when there were no female-to-female phono adapters to connect a set of cables. Taking a baby carrot and simply plugging the phonos into its flesh delivered an audio connectivity solution that worked.

Does this mean that our gold-nanoparticle-plated oxygen-free directional audio cables are junk, and we should be heading for the supermarket to pick up a bag of root vegetables instead? I set out to test this new material in the secret Hackaday audio lab, located on an anonymous 1970s industrial estate in Milton Keynes, UK.

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3D-Printed Tools Turn Bench Vise Into Expedient Press Brake

January 6, 2020 by Dan Maloney 33 Comments

Chances are pretty good that most of us have used a bench vise to do things far beyond its intended use. That’s understandable, as the vise may be the most powerful hand tool in many shops, capable of exerting tons of pressure with the twist of your wrist. Not taking advantage of that power wouldn’t make any sense, would it?

Still, the clamping power of the vise could sometimes use a little finesse, which is the thinking behind these 3D-printed press brake tools. [Brauns CNC] came up with these tools, which consist of a punch and a die with mating profiles. Mounted to the jaws of the vise with magnetic flanges, the punch is driven into the die using the vise, forming neat bends in the metal. [Braun] goes into useful detail on punch geometry and managing springback of the workpiece, and handling workpieces wider than the vise jaws. The tools are printed in standard PLA or PETG and are plenty strong, although he does mention using his steel-reinforced 3D-printing method for gooseneck punches and other tools that might need reinforcement. We’d imagine carbon-fiber reinforced filament would add to the strength as well.

To be sure, no matter what tooling you throw at it, a bench vise is a poor substitute for a real press brake. Such machine tools are capable of working sheet metal and other stock into intricate shapes with as few setups as possible, and bring a level of power and precision that can’t be matched by an improvised setup. But the ability to make small bends in lighter materials with homemade tooling and elbow grease is a powerful tool in itself.

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Continuous Integration: What It Is And Why You Need It

January 6, 2020 by Ben James 35 Comments

If you write software, chances are you’ve come across Continuous Integration, or CI. You might never have heard of it – but you wonder what all the ticks, badges and mysterious status icons are on open-source repositories you find online. You might hear friends waxing lyrical about the merits of CI, or grumbling about how their pipeline has broken again.

Want to know what all the fuss is about? This article will explain the basic concepts of CI, but will focus on an example, since that’s the best way to understand it. Let’s dive in. Continue reading “Continuous Integration: What It Is And Why You Need It” →

Hackaday Belgrade: Call For Proposals

January 6, 2020 by Mike Szczys 3 Comments

Join Hackaday in Belgrade, Serbia on May 9th, 2020 for the Hackaday Belgrade conference! The biennial hardware conference is just seventeen weeks from now. Early Bird tickets will go on sale shortly, but beginning right now you can hack your way into the conference by submitting a talk proposal. Accepted speakers receive free admission, plus everyone who submits a quality talk proposal will be given priority when tickets go on sale.

Yes, I’m talking to you. Hackaday strives to include first-time speakers in the slate of presenters at our conferences. We’re looking for unique, cutting-edge, whimsical, crazy, formidable, or world-changing topics revolving around hardware creation. From learning new tools or techniques to fabrication adventures, from code-wrangling that firmware project to pulling off an art installation, and from forgotten hardware history to the impossible made possible on your own workbench, we need to hear your stories!

That project for which you went into the deep weeds and worked your way back out again? Everyone at a Hackaday conference wants to hear about it and in the greatest detail possible. After all, we’re your fellow hackers. In fact, you should probably bring the hardware along for the ride.

We Need You

None of this happens in a vacuum. This is the third Hackaday Belgrade conference, which have now settled into a tick-tock cadence of even-numbered years. The first two both sold out, this one will as well, and the result is always an action-packed, nearly 24-hour marathon sprint of talks, workshops, and hardware hacking. But the only reason this works is because amazing people just like you make it a priority in their life to be there.

So take the plunge, put together your talk proposal and submit it before March 2nd. But don’t stop there, pester your friends and your heros to do the same. Block out May 9th on your schedule (roughly 9 am-2 am) and take the day before off of work. While you’re at it, convince your boss and coworkers to come along with you. See you in Belgrade!

Steampunk Motorcycle Runs On Compressed Air, Is Pure Hacking Art

January 6, 2020 by Danie Conradie 27 Comments

Sometimes it’s ok to sacrifice some practicality for aesthetics, especially for passion projects. Falling solidly in this category is [Peter Forsberg]’s beautiful, barely functional steam punk motorcycle. If this isn’t hacker art, then we don’t know what is.

The most eye-catching part of the motorcycle is the engine and drive train, with most of the mechanical components visible. The cylinders are clear glass tubes with custom pistons, seals, valves and push rods. The crank mechanism is from an old Harley and is mounted inside a piece of stainless steel pipe. Because it runs on compressed air it cools down instead of heating up, so an oil system is not needed.

For steering, the entire front of the bike swings side to side on hinges in the middle of the frame, which is quite tricky to ride with a top speed that’s just above walking speed. It can run for about 3-5 minutes on a tank, so the [Peter] mounted a big three-minute hour glass in the frame. The engine is fed from an external air tank, which he wears on his back; he admits it’s borderline torture to carry the thing for any length of time. He plans to build a side-car to house a much larger tank to extend range and improve riding comfort.

[Peter] admits that it isn’t very good as a motorcycle, but the amount of creativity and resourcefulness required to make it functional at all is the mark of a true mechanical hacker. We look forward to seeing it in its final form.

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