Heavy Engineering Hack Chat

September 13, 2022 by Dan Maloney 1 Comment

Join us on Wednesday, September 14 at noon Pacific for the Heavy Engineering Hack Chat with Andy Oliver!

Here at Hackaday, we focus mainly on engineering at the small end of the spectrum. Millimeter waves, nearly microscopic SMD components, nanoscale machines like MEMS accelerometers, and silicon chips with features that measure in the nanometer range. We’ve all become pretty good at wrapping our heads around problems at the wee end of the spectrum.

And while all that tiny stuff is great, there’s a whole, big world out there to explore, with big engineering to solve big problems. Think of things like dam spillways, lift bridges, and canal locks — big stuff that still has to move, and has to do it safely and efficiently. Those are problems that demand an entirely different way of thinking, and skills that not a lot of us have.

Andy Oliver works in the world of big, movable structures, designing control systems for them. He’ll drop by the Hack Chat to discuss the engineering that not only makes these structures work but also keeps them safe and reliable. If you’ve ever wondered how big things work, you won’t want to miss this one.

Our Hack Chats are live community events in the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Wednesday, September 14 at 12:00 PM Pacific time. If time zones have you tied up, we have a handy time zone converter.

Floppy Disk Sings: I’m Big In Japan

September 13, 2022 by Al Williams 66 Comments

The other day, a medical office needed my insurance card. I asked them where to e-mail it and they acted like I had offered them human flesh as an appetizer. “We don’t have e-mail! You have to bring it to us in person!” They finally admitted that they could take a fax and I then had to go figure out how to get a free one page fax sent over the Internet. Keep in mind, that I live in the fourth largest city in the United States — firmly in the top 100 largest cities in the world. I’m not out in the wilderness dealing with a country doctor.

I understand HIPAA and other legal and regulatory concerns probably inhibit them from taking e-mail, but other doctors and health care providers have apparently figured it out. But it turns out that the more regulations are involved in something, the more behind-the-times it is likely to be.

Continue reading “Floppy Disk Sings: I’m Big In Japan” →

Let Slip The Chips Of War

September 13, 2022 by Dave Rowntree 71 Comments

We’re going to go out on a limb and predict that future history books will note that the decision to invade a sovereign nation straight after a worldwide pandemic wasn’t exactly the best timing. Turns out the global electronics shortage the pandemic helped to catalyze isn’t just affecting those of us with peaceful intentions, as the Russian war machine is having a few supply issues with the parts needed to build modern weapons and their associated control equipment.

As you might expect, many of these parts are electronic in nature, and in some cases they come from the same suppliers folks like us use daily. This article from POLITICO includes an embedded spreadsheet, broken down by urgency, complete with part numbers, manufacturers, and even the price Moscow expects to pay!

Chips from US-based firms such as Texas Instruments are particularly hard for the Kremlin to source.

So what parts are we talking about anyway? The cheapest chip on the top priority list is the Marvell ‘Alaska’ 88E1322 which is a dual Gigabit Ethernet PHY costing a mere $7.10 USD according to Moscow. The most expensive is the 10M04DCF256I7G, which is an Altera (now Intel) Max-10 series FPGA, at $1,101 USD (or 66,815 Rubles, for those keeping score).

But it’s not just chips that are troubling them, mil-spec D-sub connectors by Airborn are unobtainable, as are all classes of basic passive parts, resistors, diodes, discrete transistors. Capacitors are especially problematic (aren’t they always). A whole slew of Analog Devices chips, as well as many from Maxim, Micrel and others. Even tiny logic chips from Nexperia.

Of course, part of this is by design. Tightened sanctions prevent Russia from purchasing many of these parts directly, which is intended to make continued aggression as economically unpleasant as possible. But as the POLITICO article points out, it’s difficult to prevent some intermediaries from ‘helping out’ without the West knowing. After all, once a part hits the general market, it is next to impossible to guarantee where it will eventually get soldered down.

Thanks to [Kim Tae] for the tip!

With A Little Heat, Printed Parts Handle Vacuum Duty

September 13, 2022 by Tom Nardi 40 Comments

We don’t have to tell the average Hackaday reader that desktop 3D printing has been transformative for our community, but what might not be as obvious is the impact the technology has had on the scientific community. As explained in Thermal Post-Processing of 3D Printed Polypropylene Parts for
Vacuum Systems by [Pierce Mayville], [Aliaksei Petsiuk], and [Joshua Pearce], the use of printed plastic parts, especially when based on open source designs, can lead to huge cost reductions in the production of scientific hardware.

More specifically, the authors wanted to examine the use of 3D printing components to be used in a vacuum. Parts produced with filament-based printers tend to be porous, and as such, are not suitable for fittings or adapters which need to be pumped down to below one atmosphere. The paper goes on to explain that there are coatings that can be used to seal the printed parts, but that they can outgas at negative pressures.

The solution proposed by the team is exceptionally simple: after printing their desired parts in polypropylene on a Lulzbot Taz 6, they simply hit them with a standard consumer heat gun. With the temperature set at ~400 °C, it took a little under a minute for the surface of take on a glossy appearance — the result reminds us of an ABS print smoothed with acetone vapor.

As the part is heated, the surface texture visibly changes. The smoothed parts performed far better in vacuum testing.

In addition to the heat treatment, the team also experimented with increasing degrees of infill overlap in the slicer settings. The end result is that parts printed with a high overlap and then heat treated were able to reliably handle pressures as low as 0.4 mTorr. While the paper admits that manually cooking your printed parts with a heat gun isn’t exactly the ideal solution for producing vacuum-capable components, it’s certainly a promising start and deserves further study.

Testing An Inexpensive CNC Spindle

September 12, 2022 by Bryan Cockfield 22 Comments

The old saying “you get what you pay for” is a cautionary cliché, but is directly contrary to several other common sayings. In the case of [Spikee]’s planned CNC machine build, he took the more adventurous idiom of “no risk, no reward” to heart when he purchased these spindles for the machine from AliExpress. While the delivered product seemed fine, there were some problems that needed investigations.

Upon delivery of the spindle, everything seemed to work correctly out-of-the-box. Even the variable frequency drive, which was programmed at the factory, was working properly. But at around 8000 rpm the machine would begin shaking. The suspected part causing the vibration was the tool holder, so after checking the machine’s runout and also using a specialized vibration sensor this was confirmed to be the case.

Luckily [Spikee] was able to get a refund on the tool holders since they were out of spec, but still has a quite capable spindle on his hands for an excellent price. Without some skills in troubleshooting he might have returned the entire machine unnecessarily. If you are looking for some other ideas in setting up an inexpensive CNC machine, you might also like to look at BLDC motors from a remote control vehicle.

Equalize Your Listening With HiFiScan

September 12, 2022 by Jenny List 28 Comments

Audiophiles will go to such extents to optimize the quality of their audio chain that they sometimes defy parody. But even though the law of diminishing returns eventually becomes a factor there is something in maintaining a good set of equipment. But what if your audio gear is a little flawed, can you fix it electronically? Enter HiFiScan, a piece of Python software to analyse audio performance by emitting a range of frequencies and measuring the result with a microphone.

This is hardly a new technique, and it’s one which PA engineers have used for a long time to tune out feedback resonances, but an easy tool bringing it to the domestic arena is well worth a look. HiFiScan is a measuring tool so it won’t magically correct any imperfections in your system, however it can export data in a format suitable for digital effects packages.

Naturally its utility is dependent on the quality of the hardware it’s used with, but the decent quality USB microphone used in the examples seems to give good enough results. We see it used in a variety of situations, of which perhaps the most surprising is a set of headphones that have completely different characteristics via Bluetooth as when wired.

If audio engineering interests you, remember we have an ongoing series: Know Audio.

Blue Origin Loses Rocket, Gains Abort System Test

September 12, 2022 by Tom Nardi 15 Comments

Even if you’re just making a brief hop over the Kármán line to gain a few minutes of weightlessness, getting to space is hard. Just in case any of their engineers were getting complacent, Blue Origin just got a big reminder of that fact this afternoon with the destruction of their New Shepard 3 (NS3) rocket during a suborbital research flight.

But while the rocket itself was lost, the New Shepard’s automated abort systems were able to push the capsule H. G. Wells away from the fireball, saving the dozens of scientific experiments which had been loaded onto the un-crewed vehicle. While there’s been no public word yet on the condition of these experiments, it’s reasonable to assume that at least some portion of them can be re-flown in the future — a fact that will likely come as a great relief to the researchers who designed them. It will be interesting to see who picks up the tab for the do-over flight; while launch insurance is a must-have for billion dollar satellites, it seems unlikely these small suborbital experiments would have been covered under a similar policy.

A spurt of flame can be seen in the otherwise invisible exhaust moments before engine failure.

We’re also still in the dark about what caused the in-flight breakup of NS3, other than the fact that the engine was clearly sputtering in the seconds before it blew apart. This could be a sign that the engine’s nominal fuel-to-oxidizer ratio was faltering, or perhaps even indicative of foreign debris becoming dislodged and burning in the combustion chamber. But really, without official word from Blue Origin, it’s impossible to say what happened.

This is especially true when you consider that we’re talking about a vehicle that’s pushing the envelope to begin with. Remember, the New Shepard is a reusable booster, and NS3 is specifically a veteran of eight flights — with all but one of them taking the booster above the 100 kilometer altitude, which is generally accepted to be the boundary of space.

For those worried that celebrities and assorted millionaires will no longer have access to space, fear not. Blue Origin’s crewed flights have flown exclusively on the newer NS4 and its associated capsule First Step. This does however mean that Blue Origin no longer has a spare booster on which to fly commercial payloads, potentially putting into jeopardy any semblance of scientific value the program may have had.

Continue reading “Blue Origin Loses Rocket, Gains Abort System Test” →