An image of a desert with dramatically cloudy skies. In the middle of the image is a series of clay doorways with vertically-oriented wooden slats surrounding a central pole. These form the basis of a panemone windmill.

Help Wanted: Keep The World’s Oldest Windmills Turning

November 7, 2024 by Navarre Bartz 36 Comments

While the Netherlands is the country most known for its windmills, they were originally invented by the Persians. More surprisingly, some of them are still turning after 1,000 years.

The ancient world holds many wonders of technology, and some are only now coming back to the surface like the Antikythera Mechanism. Milling grain with wind power probably started around the 8th Century in Persia, but in Nashtifan, Iran they’ve been keeping the mills running generation-to-generation for over 1000 years. [Mohammed Etebari], the last windmill keeper is in need of an apprentice to keep them running though.

In a world where vertical axis wind turbines seem like a new-fangled fad, it’s interesting to see these panemone windmills are actually the original recipe. The high winds of the region mean that the timber and clay structure of the asbad structure housing the turbine is sufficient for their task without all the fabric or man-made composites of more modern designs. While drag-type turbines aren’t particularly efficient, we do wonder how some of the lessons of repairability might be used to enhance the longevity of modern wind turbines. Getting even 100 years out of a turbine would be some wicked ROI.

Wooden towers aren’t just a thing of the past either, with new wooden wind turbines soaring 100 m into the sky. Since you’ll probably be wanting to generate electricity and not mill grain if you made your own, how does that work anyway?

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Using AI To Help With Assembly

November 7, 2024 by Bryan Cockfield 30 Comments

Although generative AI and large language models have been pushed as direct replacements for certain kinds of workers, plenty of businesses actually doing this have found that using this new technology can cause more problems than it solves when it is given free reign over tasks. While this might not be true indefinitely, the real use case for these tools right now is as a kind of assistant to certain kinds of work. For this they can be incredibly powerful as [Ricardo] demonstrates here, using Amazon Q to help with game development on the Commodore 64.

The first step here was to generate code that would show a sprite moving across the screen. The AI first generated code in all caps, as was the style at the time of the C64, but in [Ricardo]’s development environment this caused some major problems, so the code was converted to lowercase. A more impressive conversion was done in the next steps, as the program needed to take advantage of the optimizations found in the Assembly language. With the code converted to 6502 Assembly that can run on the virtual Commodore, [Ricardo] was eventually able to show four sprites moving across the screen after several iterations with the AI, as well as change the style of the sprites to arbitrary designs.

Although the post is a bit over-optimistic on Amazon Q as a tool specifically for developers, it might have some benefits over other generative AIs especially if it’s capable at the chore of programming in Assembly language. We’d love to hear anyone with real-world experience with this and whether it is truly worth the extra cost over something like Copilot or GPT 4. For any of these generative AI models, though, it’s probably worth trying them out while they’re in their early stages. Keep in mind that there’s a lot more than programming that can be done with some of them as well.

DIY Lock Nuts

November 7, 2024 by Al Williams 19 Comments

If you have a metal lathe just looking for some work, why not make your own lock nuts? That’s what [my mechanics insight] did when faced with a peculiar lock nut that needed replacing in a car. We can’t decide what we enjoyed more in the video you can watch below: the cross-section cut of a lock nut or the oddly calming videos of the new nut being turned on a lathe.

The mystery of the lock nut, though, isn’t how it works. The nylon insert is just a little too small for the bolt, and the bolt, being harder than nylon, taps a very close-fitting hole in the nylon as you tighten it. The real mystery is how that nylon got in there to start with.

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Disposable Vape Batteries Power EBike

November 7, 2024 by Bryan Cockfield 15 Comments

There are a lot of things that get landfilled that have some marginal value, but generally if there’s not a huge amount of money to be made recycling things they won’t get recycled. It might not be surprising to most that this is true of almost all plastic, a substantial portion of glass, and even a lot of paper and metals, but what might come as a shock is that plenty of rechargeable lithium batteries are included in this list as well. It’s cheaper to build lithium batteries into one-time-use items like disposable vape pens and just throw them out after one (or less than one) charge cycle, but if you have some spare time these batteries are plenty useful.

[Chris Doel] found over a hundred disposable vape pens after a local music festival and collected them all to build into a battery powerful enough for an ebike. Granted, this involves a lot of work disassembling each vape which is full of some fairly toxic compounds and which also generally tend to have some sensitive electronics, but once each pen was disassembled the real work of building a battery gets going. He starts with testing each cell and charging them to the same voltage, grouping cells with similar internal resistances. From there he assembles them into a 48V pack with a battery management system and custom 3D printed cell holders to accommodate the wide range of cell sizes. A 3D printed enclosure with charge/discharge ports, a power switch, and a status display round out the build.

With the battery bank completed he straps it to his existing ebike and hits the trails, easily traveling 20 miles with barely any pedal input. These cells are only rated for 300 charge-discharge cycles which is on par for plenty of similar 18650 cells, making this an impressive build for essentially free materials minus the costs of filament, a few parts, and the sweat equity that went into sourcing the cells. If you want to take an ebike to the next level of low-cost, we’d recommend pairing this battery with the drivetrain from the Spin Cycle.\

Thanks to [Anton] for the tip!

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2023 Hackaday Supercon: One Year Of Progress For Project Boondock Echo

November 7, 2024 by Lewin Day 2 Comments

Do you remember the fourth-place winner in the 2022 Hackaday Prize? If it’s slipped your mind, that’s okay—it was Boondock Echo. It was a radio project that aimed to make it easy to record and playback conversations from two-way radio communications. The project was entered via Hackaday.io, the judges dug it, and it was one of the top projects of that year’s competition.

The project was the brainchild of Mark Hughes and Kaushlesh Chandel. At the 2023 Hackaday Supercon, Mark and Kaushlesh (KC) came back to tell us all about the project, and how far it had come one year after its success in the 2022 Hackaday Prize.

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Hear A Vintage Sound Chip Mimic The Real World

November 7, 2024 by Donald Papp 12 Comments

Sound chips from back in the day were capable of much more than a few beeps and boops, and [InazumaDenki] proves it in a video recreating recognizable real-world sounds with the AY-3-8910, a chip that was in everything from arcade games to home computers. Results are a bit mixed but it’s surprising how versatile a vintage sound chip that first came out in the late 70s is capable of, with the right configuration.

Recreating a sound begins by analyzing a spectrograph.

Chips like the AY-3-8910 work at a low level, and rely on being driven with the right inputs to generate something useful. It can generate up to three independent square-wave tones, but with the right approach and setup that’s enough to get outputs of varying recognizability for a pedestrian signal, bird call, jackhammer, and referee’s whistle.

To recreate a sound [InazumaDenki] begins by analyzing a recording with a spectrogram, which is a visual representation of frequency changes over time. Because real-world sounds consist of more than just one frequency (and the AY-3-8910 can only do three at once), this is how [InazumaDenki] chooses what frequencies to play, and when. The limitations make it an imperfect reproduction, but as you can hear for yourself, it can certainly be enough to do the job.

How does one go about actually programming the AY-3-8910? Happily there’s a handy Arduino AY3891x library by [Andreas Taylor] that makes it about as simple as can be to explore this part’s capabilities for yourself.

If you think retro-styled sound synthesis might fit into your next project, keep in mind that just about any modern microcontrollers has more than enough capability to do things like 80s-style speech synthesis entirely in software.

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Mechanisms: Tension Control Bolts

November 7, 2024 by Dan Maloney 54 Comments

If there’s an enduring image of how large steel structures used to be made, it’s probably the hot riveting process. You’ve probably seen grainy old black-and-white films of a riveting gang — universally men in bib overalls with no more safety equipment than a cigarette, heating rivets to red heat in a forge and tossing them up to the riveters with a pair of tongs. There, the rivet is caught with a metal funnel or even a gloved hand, slipped into a waiting hole in a flange connecting a beam to a column, and beaten into submission by a pair of men with pneumatic hammers.

Dirty, hot, and dangerous though the work was, hot riveted joints were a practical and proven way to join members together in steel structures, and chances are good that any commercial building that dates from before the 1960s or so has at least some riveted joints. But times change and technology marches on, and riveted joints largely fell out of fashion in the construction trades in favor of bolted connections. Riveting crews of three or more men were replaced by a single ironworker making hundreds of predictable and precisely tensioned connections, resulting in better joints at lower costs.

Bolted joints being torqued to specs with an electric wrench might not have the flair of red-hot rivets flying around the job site, but they certainly have a lot of engineering behind them. And as it turns out, the secret to turning bolting into a one-person job is mostly in the bolt itself.

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