Axial Flux Motors For Electric Vehicles

October 10, 2021 by Al Williams 37 Comments

In the everything old is new again folder, [Lesics] has a good overview of axial flux motors. These are promising for electric vehicles, especially aircraft, since the motors should have high torque to weight ratio. The reason this is actually something old is that the early generators built by Faraday were actually of the axial flux type. Soon, though, radial flux generators and motors became the norm.

The simple explanation is that in a radial system, the magnetic flux lines are perpendicular to the axis of rotation. In the axial system, the flux lines are parallel to the axis of rotation. There’s more to it than just that of course, and the video below has nice animations showing how it all works.

While these are not very common, they do exist even today. The Lynch motor, for example, is a type of axial flux motor that dates back to 1979. Usually, the impetus for using an axial flux motor is the ease of construction, but with the right design, they can be quite efficient (up to 96% according to the video).

We’ve seen plenty of PCB motors and most of those are axial in design. Not all of them, though.

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Autonomous Ground Effect Vehicle Demonstrator Aims To Speed Up Maritime Shipping

October 10, 2021 by Danie Conradie 35 Comments

Ground effect vehicles, or ekranoplans, have the advantage of being more efficient than normal aircraft and faster than boats, but so far haven’t been developed beyond experimental prototypes. Fortunately, this doesn’t stop companies from trying, which has led to a collaboration between [ThinkFlight] and [rctestflight] to create a small-scale demonstrator for the Flying Ship Company.

The Flying Ship Company wants to use unmanned electric ekranoplans as high-speed marine cargo carriers that can use existing maritime infrastructure for loading and unloading. For the scale model, [rctestflight] was responsible for the electronics and software, while [ThinkFlight] built the airframe. As with his previous ekranoplan build, [ThinkFlight] designed it in XFLR5, cut the parts from foam using a CNC hot wire cutter (which we still want a better look at), and laminated it with Kevlar for strength. One of the challenges of ground effect vehicles is that the center of pressure will shift rearward as they leave a ground effect, causing them to pitch up. To maintain control when moving into and out of ground effect, these crafts often use a large horizontal stabilizer high up on the tail, out of ground effect.

A major feature of this demonstrator is automatic altitude control using a LIDAR sensor mounted on the bottom. This was developed by [rctestflight] using a simple foam board ekranoplan and [Think Flighs]’s previous airframe, with some custom code added to ArduPilot. It works very well on smooth, calm water, but waves introduce a lot of noise into the LIDAR data. It looks like they were able to overcome this challenge, and completed several successful test flights in calm and rough conditions.

The final product looks good, flies smoothly, and is easy to control since the pilot doesn’t need to worry about pitch or throttle control. It remains to be seen if The Flying Boat will overcome the challenges required to turn it into a successful commercial craft, and we will be following the project closely.

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1981 Called, Here’s Your Software

October 10, 2021 by Jenny List 53 Comments

How many of us who have a few decades of adulthood under our belts would like to talk to our 17 year old selves? “Hey kid, it’s all gonna be OK. Also, Duke Nukem Forever does come out eventually, but it’s not going to be pretty!” Being honest, exposure to the hot takes of one’s naive teenage self would almost certainly be as cringeworthy as the time-worn-but-familiar adult would be to the teenager, but there’s one way in which you can in a sense have a conversation with your teenage self. [Mad Ned] had this opportunity, when he discovered a printed BASIC listing for a game he’d written for the TRS-80 back in 1981. Could he make it run again, and what did it tell him about his teenage years?

Grizzled 8-bit veterans will tell you of countless hours spent typing poorly-reproduced listings found in magazines, and the inevitable pain that followed as all those mistypes were ironed out. [Ned] eschewed all that retro experience because this is the 21st century, and we now have much more powerful computers to do our bidding! The reality of incomplete OCR is one we’ll no doubt all be used to, and for 8-bit fans also the debugging that was needed to get the listing to run. Breaker Ball is an odd hybrid of Breakout and Space Invaders, and it’s his analysis of the teenage thinking that led to the game being the way it is that rounds off the piece. Sadly we’re not treated to the entire listing, but there’s a short gameplay video we’ve placed below the break.

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Borehole Camera Rig Makes Life Easier In Mining

October 9, 2021 by Lewin Day 11 Comments

Much of mining involves digging and drilling holes in the ground. Often, these holes need inspecting, but [Dean Harty] found that existing borehole inspection solutions weren’t up to snuff. Resolution was poor, and often live-view devices made recording footage a pain. Instead, he set about the development of the Sneaky Peaky, going through several revisions in the process.

The first revision was nothing more than a GoPro strapped to a small penny board, paired with a bright flashlight. The 4K resolution of the GoPro provided useful footage, and the assembly could be lowered into boreholes on a rope and retrieved easily. Rugged and water resistant, the gear worked well, and was remarkably cheap compared to more obscure mining industry hardware.

Later revisions ditched the skateboard, replacing it with a pipe-style housing instead. Key to the design was that the device could readily be destroyed and flushed out of a borehole with an air blast in the event it got stuck.

Eventually, mining outfit Metrologi got involved, having worked with [Dean] on several borehole backfill operations. A 3D-printed chassis was developed to hold an action camera and twin torches, held together with plastic zip ties. These are attached to the pull rope, and if the camera becomes jammed, a sharp pull will snap the ties and cause the device to fall apart. Steel cable ties are then used to create flexible guides to center the assembly in a variety of pipe diameters.

It’s a great example of people on the ground hacking together the tools they need, combined with iterative design to integrate improvements over time. We don’t talk about boreholes much around here, but they can be musical if properly employed, as it turns out. If you’ve got your own great mining hacks, however, do drop us a line!

Dial A For Arduino

October 9, 2021 by Al Williams 19 Comments

A lot of phrases surrounding phones don’t make sense anymore. With a modern cellphone, you don’t really “hang up” and there’s certainly no “dial” to be had. However, with [jakeofalltrades’] project, you can read an old-fashioned phone dial using an Arduino.

The idea behind a phone dial is actually pretty simple. When you pull the dial back to the stop using one of the numbered holes and release it, it causes a switch to open and close the same number of times as the hole you selected. That is, if you pull back the 5 hole, you should get 5 switch closures. The duration of each switch event and the time between switch events is a function of the speed the dial moves because of its internal spring. The zero hole actually produces ten pulses.

There are standards for how precise the timing has to be, but — honestly — it’s pretty loose since these were not made to be read by precise microcontroller timers. In the United States, for example, the dial was supposed to produce between 9.5 and 10.5 pulses per second, but the equipment on the other end would tolerate anything from 8 to 11.

Even if you don’t want a rotary dial in your next project, the code has some good examples of using ATmega328 timers that you might find useful in another context. However, a dial would add a nice retro touch to any numeric input you might happen to need.

If you need project inspiration, how about a volume control? Or, why not a numeric keypad?

Single Event Upsets: High Energy Particles From Outer Space Flipping Bits

October 9, 2021 by Danie Conradie 13 Comments

Our world is constantly bombarded by high-energy particles from various sources, and if they hit in just the right spot on the sensitive electronics our modern world is built on, they can start flipping bits. Known as Single Event Upsets (SEU), their effect can range from unnoticeable to catastrophic, and [Veritasium] explores this phenomenon in the video after the break.

The existence of radiation has been known since the late 1800s, but the effect of low-level radiation on electronics was only recognized in the 1970s when trace amounts of radioactive material in the ceramic packaging of Intel DRAM chips started causing errors. The most energetic particles come from outer space and are known as cosmic rays. They originate from supernovas and black holes, and on earth they have been linked to an impossibly fast Super Mario 64 speedrun and a counting error in a Belgian election. It’s also possible to see their path using a cloud chamber you can build yourself. There are even research projects that use the camera sensors of smartphones as distributed cosmic ray detectors.

Earth’s magnetic field acts as a protective barrier against the majority of these cosmic rays, and there is a measurable increase in radiation as you gain altitude and enter space. In space, serious steps need to be taken to protect spacecraft, and it’s for this reason that the Perseverance rover that landed on Mars this year uses a 20-year-old main computer, the PowerPC RAD750. It has a proven track record of radiation resistance and has been used on more than a dozen spacecraft. Astronauts experience cosmic radiation in the form of flashes of light when they close their eyes and protecting their DNA from damaging effects is a serious concern for NASA.

It’s impossible to know the true impact of cosmic radiation on our world and even our history. Who knows, one of those impossible-to-replicate software bugs or the inspiration for your latest project might have originated in another galaxy. Continue reading “Single Event Upsets: High Energy Particles From Outer Space Flipping Bits” →

Drive High-Impedance Headphones With This Stylish USB DAC

October 9, 2021 by Jenny List 3 Comments

For anyone with an interest in building audio projects, it’s likely that an early project will be a headphone amplifier. They’re relatively easy to build from transistors, ICs, or tubes, and it’s possible to build one to a decent quality without being an electronic engineering genius. It’s not often though that we see one as miniaturized as [daumemo]’s USB-C DAC and headphone amplifier combo, that fits within a slightly elongated 3.5 mm jack cover as part of a small USB-to-headphone cable.

The DAC is an off-the-shelf board featuring an ALC4042 IC, it has a line-level output and a handy place to tap off a 5 volt line for the amplifier. This final part is a tiny PCB with two chips, a TPS65135 that produces clean +5 and -5 volt rails, and an INA1620 which is a high-quality audio amplifier set up for 2x gain. All this has been designed onto a very small PCB, which sits inside a 3D-printed housing along with the 3.5 mm earphone socket. The result is a very neat unit far better able do drive high-impedance headphones than the output from an unmodified DAC, but still looking as svelte as any commercial product. We like it.

This may be one of the most compact USB-to-headphone amplifiers we’ve seen, but it’s by no means the first.