Tesla Model S Battery Teardown

September 13, 2014 by Adam Fabio 84 Comments

Tesla Motors club user [wk057], a Tesla model S owner himself, wants to build an awesome solar storage system. He’s purchased a battery pack from a salvaged Tesla Model S, and is tearing it down. Thankfully he’s posting pictures for everyone to follow along at home. The closest thing we’ve seen to this was [Charles] tearing into a Ford Fusion battery. While the Ford battery is NiMH, the Tesla is a completely different animal. Comprised of over 7000 individual lithium-ion cells in 16 modules, the Tesla battery pack packs a punch. It’s rated capacity is 85kWh at 400VDC.

[wk057] found each cell connected by a thin wire to the module buses. These wires act as cell level fuses, contributing to the overall safety of the pack. He also found the water cooling loops were still charged with coolant, under a bit of pressure. [wk057] scanned and uploaded high res images of the Tesla battery management system PCBs (large image link). It is a bit difficult to read the individual part numbers due the conformal coating on the boards.

A second forum link shows images of [wk057] pulling the modules out of the pack. To do this he had to chip away the pack’s spine, which consisted of a 2/0 gauge wire potted in some sort of RTV rubber compound.

We’re sure Tesla doesn’t support hackers using their packs to power houses. Ironically this is exactly the sort of thing Elon Musk is working on over at Solar City.

Hacklet 15 – Arcade Fire

September 12, 2014 by Adam Fabio 8 Comments

This week’s Hacklet is dedicated to arcade games. The arcade parlors of the 80’s and early 90’s may have given way to today’s consoles and PC games, but the classic stand-up arcade cabinet lives on! Plenty of hackers have restored old arcade cabinets, or even built their own. We’re going to take a look at some of the best arcade game-related hacks on Hackaday.io!

[Brayden] starts things off with his Raspberry Pi Vintage Arcade. The Black Vortex is a tabletop arcade cabinet using a Raspberry Pi, an old monitor, and some nice carpentry skills. Black Vortex uses a Raspberry Pi B+. The extra GPIO pins make interfacing buttons and joystick switches easy. On the software side, [Brayden] is using the popular PiMame (now PiPlay) flavor of Linux built for gaming and emulation. Black Vortex’s shell is plywood. [Brayden] used a pocket hole jig to build a sturdy, cabinet without extra support blocks. A stain finish really works on this one!

Next up, [fredkono] blows our minds with the Arcade XY Monitor From Scratch. [fredkono] repairs classic Atari vector game PCBs. He needed a test monitor for his lab. The original Amplifone and WG6100 color XY monitors used in games like Tempest and Star Wars are becoming rather rare. Not a problem, as [fredkono] is building his own. Much like the WG6100, [fredkono] started with a standard color TV CRT. He removed and rewound the yoke for vector operation. The TV’s electronics were replaced with [fredkono’s] own deflection amplifier PCBs. [fredkono] was sure to include the all- important spot killer circuit, which shuts down the electron guns before a spot can burn-in the CRT.

[Rhys] keeps things rolling with a pair of projects dedicated to arcade controls. His TI Launchpad Arcade Control to USB Interface contains instructions and code to use a Texas Instruments Tiva C launchpad as a USB interface for arcade controls. [Rhys] puts all that to good use in his Arcade Control Panel. The control panel features MAME buttons, as well as the standard 2 player fighting game button layout. He finished off his panel with some slick graphics featuring red and blue dragons.

[Sarah and Raymond] hosted a Tron:Legacy release party back in 2010. An epic arcade movie calls for an epic arcade game, or in this case, games. 16 table top arcades to be exact. All 16 machines were built in just 6 days. 8 of the machines ran Armegatron Advanced, a networked version of the classic Tron lightcycle game. The others ran a mix of classic games like PacMan or modern bullet hell shooters like Tou-Hou. The cabinets were built from expanded PVC with wood blocks as a support structure. [Sarah and Raymond] custom painted each cabinet with UV black light paint. We love the custom artwork on their personal signature machines!

[Mike] takes us back to the 80’s with Just Another Arcade Machine. Under the hood, this machine uses the standard Raspberry Pi and PiMame (now PiPlay) suite. [Mike] even added a trackball so he could play Centipede. What makes this arcade special is the cabinet. [Mike] found an old wardrobe with that perfect 80’s style metallic strip cladding. [Mike] removed the cladding, and cut up the chipboard frame. He re-assembled things into a stand-up arcade cabinet that looks like it came right out of Sears’ Electronics department in 1985.

Ok folks, that’s it for another episode of The Hacklet. As always, see you next week. Same hack time, same hack channel, bringing you the best of Hackaday.io!

Global Radiation Monitoring Network Update

September 11, 2014 by Adam Fabio 30 Comments

Things have been busy at Global Radiation Monitoring Network Central Command. As a semifinalist in the Hackaday Prize, project creator [Radu Motisan] has quite a bit of work to do. He’s not slacking off either. With 33 project logs (and counting), [Radu] has been keeping us up to date with his monitoring network and progress on uRADMonitor , the actual monitoring hardware.

[Radu’s] latest news is that he’s ready to go into production with model A of the uRADMonitor. Moving from project to production can be an incredible amount of work due to sourcing parts, setting up assembly houses, and dealing with any snags that come up along the way. We’re sure [Radu] can handle it, though.

The network of uRADMonitors is also growing. A new monitor was just installed in Prescott, Arizona. This is the 10th unit in the USA. You can view the map, data, and graphs of global radiation live on the uRADMonitor website.

The project featured in this post is a semifinalist in The Hackaday Prize.

DIY Powder Coating Oven Gets Things Cooking

September 9, 2014 by Adam Fabio 54 Comments

[Bob] needed an oven for powder coating metal parts. Commercial ovens can cost thousands of dollars, which [Bob] didn’t have. He did have an rusty old file cabinet though. And thus, a plan was born. The file cabinet’s steel shell would make a perfect oven body. He just had to remove all the drawers, sliders, and anything combustible. A few minutes with an angle grinder made quick work of the sheet metal. The drawer fronts we re-attached with hinges, allowing the newly fashioned door to swing out-of-the-way while parts are loaded into the oven.

The oven’s heating elements are two converted electric space heaters. The heating elements can be individually switched off to vary power to the oven. When all the elements are running, the oven pulls around 2000 watts, though full power is only used for pre-heating.

[Bob] used a lot of pop rivets in while building this oven, and plenty of them went into attaching sheet metal guards to protect the outside of the heating units. To complete the electrical equipment, a small fan was placed on top of the oven to circulate the air inside.

The most important part of the build was insulation. The entire inside of the oven was coated with aluminum foil and sealed with heat proof aluminum tape. On top of that went two layers of fiberglass matting. Metal strips kept the fiberglass in place, and the stays were held down with rivets. One last layer of aluminum foil was laid down on top of the fiberglass. Curing powder coating produces some nasty gasses, so [Bob] sealed the gaps of the oven with rolled fiberglass matting covered by aluminum foil and tape.

[Bob] was a bit worried about the outside of the oven getting hot enough to start a fire. There were no such problems though. The fiberglass matting makes for an extremely good insulator. So good that the oven goes from room temperature to 400 °F in just 5 minutes. After an hour of operation, the oven skin is just warm to the touch.

If you need to find [Bob], he’ll be out in his workshop – cooking up some fresh powder coated parts.

A Tale Of Two Ring Boxes

September 8, 2014 by Adam Fabio 17 Comments

This is a tale of two hearts, two engagements, and two ring boxes. About a couple of years ago, [curtisabrina] proposed to his girlfriend. Rather than just hand her the ring, he placed it in a locking ring box [imgur link] he custom-made. The box seems normal at first glance, but lifting up the first drawer reveals a complex and ornate gear system. The gears can only be turned by a pair of interlocking heart-shaped keys – a gift [curtisabrina] had given her months earlier. The mechanism is nothing short of stunning – planetary reductions drive a spring-loaded iris which opens to reveal an engagement ring.

[curtisabrina] built his ring box after hours at his signmaking job. The job gave him access to some incredible tools, such as the MultiCam 3000 series CNC. The box turned out great, and he showed his work off in a Reddit thread.

Fast forward two years. [joetemus] was getting ready to propose to his girlfriend, and wanted to do something similar. He didn’t have access to high-end shop tools, but he did have a Shapeoko 2. Using the original box as inspiration, [joetemus] started designing. Over time, trial, and error, a second ring box emerged [imgur link]. Like the original box, [joetemus] started with a rough cut board. Nearly every part, including the aluminum gears, was cut on the Shapeoko 2. [joetemus] also celebrated his accomplishment with a Reddit thread.

[joetemus’s] ring box isn’t quite as complex or polished as [curtisabrina’s], but he was working with a machine that cost much less than the equipment [curtisabrina] was using. We think both of them are great, and are happy to report that both of their girlfriends said, “Yes!”

Continue reading “A Tale Of Two Ring Boxes” →

THP Semifinalist: Secure Your Internets With Web Security Everywhere

September 6, 2014 by Adam Fabio 50 Comments

[Arcadia Labs] has created a great little device in Web Security Everywhere, a semifinalist in The Hackaday Prize. At the center of it all is UnJailPi, a Raspberry Pi device which can act as a secure router between a protected network and the unprotected internet. UnJailPi can create OpenVPN and Tor connections on the fly from its touch screen interface. The full details are right up on [Arcadia’s] Hackaday.io project page.

One of the most amazing things about the project is its creator, [Arcadia Labs]. [Arcadia] started from square one learning python just 1 year ago. Since then he’s become a proficient python coder, and created UnJailPi’s entire user interface with pygame.

[Arcadia] is also working with simple hand tools. He has no access to the CNC routers, 3D printers, or milling machines used in many of the projects we see here on Hackaday. All the work on UnJailPi’s acrylic case was done with a handsaw, a file, and a heck of a lot of patience.

Currently [Arcadia’s] biggest hurdle is finding a good power supply for his project. UnJailPi is designed to work both on AC or an internal battery. His current power circuit throws off enough heat that the Raspberry Pi resets while the battery is charging.

We’re sure [Arcadia] will figure out his power issues, but if you have any suggestions, leave a comment here, or head over to the project page and let him know!

The project featured in this post is a semifinalist in The Hackaday Prize.

Hacklet 14 – Hacks Around The House

September 5, 2014 by Adam Fabio 25 Comments

In this weeks Hacklet we’re looking at household hacks. Not necessarily globally connected home automation hacks, but task specific hacks that we want in our lives yesterday!

We’ve all had it happen, you’re burning the midnight oil on a project when you realize it’s garbage night. The mad dash to collect empty anti-static bags, last night’s Chinese food, and the rest of the trash before actually venturing outside in the dark.

[Mehmet-cileli] doesn’t have to deal with any of that, thanks to My Bins, his automated trash and recycling can moving system. Normally the bins are stationed near the house. Each garbage night, the system springs into action. The cans and their platform pivots 90 degrees. The entire system then rolls along a track to the curb. Once the cans have been collected, everything rolls back ready for more trash. We just hope [Mehmet’s] garbage men are nice enough to put the bins back on their platform!

Next we have the perfect cup of tea. [Marcel] kept forgetting his tea while it was steeping. After ending up with ink a few times, he built this Automatic Tea Timer. A button starts the timer, and after a few minutes, the tea bag is automatically lifted and a light illuminates to let you know your tea is ready. [Marcel] used a ~~Raspberry Pi~~ ~~Arduino~~ ~~555~~ simple R-C timer circuit to create his delay. The lift arm is a discarded hard drive read arm. The light bulb limits current through the voice coils.

[Juan Sandu] always has veggies with his Smart Small Greenhouse. [Juan] has created a desktop sized greenhouse that gives plants what they crave. No, not Brawndo, we’re talking water, warmth, and light. An Arduino Uno uses sensors to monitor humidity, temperature, light, and moisture. Based upon one of two pre-set plant types, the system determines when to water, turn on lights, or even power up a fan to keep temperatures plant friendly. [Juan] is still working on his greenhouse, but his code is already up on Github.

Next up is [nerwal] with his entry in The Hackaday Prize, GrillUp. GrillUp is a remote grill temperature monitoring system with a cooling spray. Up to 6 food grade thermometers provide GrillUp with its temperature data. If things are getting a bit too hot, Grillup cools the situation down by spraying water, beer, or your favorite marinade. The system is controlled over Bluetooth Low Energy from an android smart phone. A laser pointer helps to aim the water spray. Once the cooling zones are set up, the system runs automatically. It even has a sprinkler mode, where it sprays everything down.

Every hacker’s house needs some Sci-fi mood lights, right? [spetku and maehem] round out this weeks Hacklet with their Fifth Element Stone Mood Lighting. Originally an entry in the Hackaday Sci-fi contest, these mood lights are based on the elemental stones in everyone’s favorite Bruce Willis movie. The lights are 3D printed in sections which stack over foamboard cores. The actual light comes from a trio of RGB LEDs. LED control is from the same brain board which controls the team’s Robot Army. The lights are designed to open up just like the ones in the movie, though fire, earth, wind, and water are not required. The servos [spetku and maehem] selected weren’t quite up to the task, but they mention this will be remedied in a future revision.