Day: September 11, 2024

Lithium-Ion Battery Hotswapping, Polarity, Holders

September 11, 2024 by 28 Comments

Everyone loves, and should respect, lithium-ion batteries. They pack a ton of power and can make our projects work better. I’ve gathered a number of tips and tricks about using them over the years, based on my own hacking and also lessons I’ve learned from others.

This installment includes a grab-bag of LiIon tricks that will help you supercharge your battery use, avoid some mistakes, and make your circuits even safer. Plus, I have a wonderful project that I just have to share.

Hot-swapping Cells

When your device runs out of juice, you might not always want to chain yourself to a wall charger. Wouldn’t it be cool if you could just hot-swap cells? Indeed it is, I’ve been doing it for years, it’s dead simple to support, but you can also do it wrong. Let me show you how to do it right!

Recently, a new handheld has hit the hacker markets – the Hackberry Pi. With a Blackberry keyboard and a colour screen, it’s a pretty standard entry into the trend of handheld Pi Zero-backed computers with Blackberry keyboards. It’s not open-source and the author does not plan to open-source its hardware, so I want to make it absolutely clear I don’t consider it hacker-friendly or worth promoting. It did publish schematics, though, and these helped me find a dangerous mistake that the first revision made when trying to implement LiIon battery hot-swap. Continue reading “Lithium-Ion Battery Hotswapping, Polarity, Holders” →

Voyager 1 Completes Tricky Thruster Reconfiguration

September 11, 2024 by 35 Comments

After 47 years it’s little wonder that the hydrazine-powered thrusters of the Voyager 1, used to orient the spacecraft in such a way that its 3.7 meter (12 foot) diameter antenna always points back towards Earth, are getting somewhat clogged up. As a result, the team has now switched back to the thrusters which they originally retired back in 2018. The Voyager spacecraft each have three sets (branches) of thrusters. Two sets were originally intended for attitude propulsion, and one for trajectory correction maneuvers, but since leaving the Solar System many years ago, Voyager 1’s navigational needs have become more basic, allowing all three sets to be used effectively interchangeably.

The first set was used until 2002, when clogging of the fuel tubes was detected with silicon dioxide from an aging rubber diaphragm in the fuel tank. The second set of attitude propulsion thrusters was subsequently used until 2018, until clogging caused the team to switch to the third and final set. It is this last set that is now more clogged then the second set, with the fuel tube opening reduced from about 0.25 mm to 0.035 mm. Unlike a few decades ago, the spacecraft is much colder due energy-conserving methods, complicating the switching of thruster sets. Switching on a cold thruster set could damage it, so it had to be warmed up first with its thruster heaters.

The conundrum was where to temporarily borrow power from, as turning off one of the science instruments might be enough to not have it come back online. Ultimately a main heater was turned off for an hour, allowing the thruster swap to take place and allowing Voyager 1 to breathe a bit more freely for now.

Compared to the recent scare involving Voyager 1 where we thought that its computer systems might have died, this matter probably feels more routine to the team in charge, but with a spacecraft that’s the furthest removed man-made spacecraft in outer space, nothing is ever truly routine.

A Look Inside A DIY Rocket Motor

September 11, 2024 by 6 Comments

[Joe Barnard] made a solid propellant rocket motor, and as one does in such situations, he put it through its paces on the test stand. The video below is not about the test, nor is it about the motor’s construction. Rather, it’s a deconstruction of the remains of the motor in order to better understand its design, and it’s pretty interesting stuff.

Somewhere along the way, [Joe], aka “BPS.Space” on YouTube, transitioned from enthusiastic model rocketeer to full-fledged missile-man, and in the process stepped up his motor game considerably. The motor that goes under the knife — or rather, the bandsaw — in this video is his “Simplex V2,” a completely DIY build of [Joe]’s design. For scale, the casing is made from a 6″ (15 cm) diameter piece of aluminum tubing over a meter in length, with a machined aluminum forward closure and a composite nozzle assembly. This is a pretty serious piece of engineering.

The closure and the nozzle are the focus of the video, which makes sense since that’s where most of the action takes place. To understand what happened during the test, [Joe] lopped them off and cut them roughly in half longitudinally. The nozzle throat, which was machined from a slug of graphite, fared remarkably well during the test, accumulating only a little slag from the propellant, a combination of powdered aluminum, ammonium perchlorate, and HTBP resin. The lower part of the nozzle, made from phenolic-impregnated linen, did pretty well too, building up a pyrolyzed layer that acted much like a space capsule’s ablative heat shield would. The forward closure, whose sole job is to contain the inferno and direct the exhaust anywhere but up, took more of a beating but stood up to the challenge. Especially interesting was the state of the O-rings and the way that the igniter interfaced with the closure.

Post mortems like these are valuable teaching tools, and while it must be heartbreaking to destroy something you put so much work into, you can’t improve what you can’t measure. Hats off to [Joe] for the peek inside his world. Continue reading “A Look Inside A DIY Rocket Motor” →