Author: Bryan Cockfield

1831 Articles

Ergonomic Keyboard Designed From The Ground Up

December 28, 2017 by 15 Comments

In 2011, [Fabio] had been working behind a keyboard for about a decade when he started noticing wrist pain. This is a common long-term injury for people at desk jobs, but rather than buy an ergonomic keyboard he decided that none of the commercial offerings had all of the features he needed. Instead, he set out on a five-year journey to build the perfect ergonomic keyboard.

Part of the problem with other solutions was that no keyboards could be left in Dvorak (a keyboard layout [Fabio] finds improves his typing speed) after rebooting the computer, and Arduino-based solutions would not make themselves available to the computer’s BIOS. Luckily he found the LUFA keyboard library, and then was able to salvage a PCB from another keyboard. From there, he programmed everything on a Teensy microcontroller, added an OLED screen, and soldered it all together (including a set of Cherry MX switches).

Of course, the build wasn’t truly complete until recently, when a custom two-part case was 3D printed. The build quality and attention to detail in this project is impressive, and if you want to roll out your own [Fabio] has made all of the CAD files and software available. Should you wish to incorporate some of his designs into other types of specialized keyboards, there are some ideas floating around that will surely improve your typing or workflow.

3D Printed Airplane Engine Runs On Air

December 27, 2017 by 13 Comments

One of the most important considerations when flying remote-controlled airplanes is weight. Especially if the airplane has a motor, this has a huge potential impact on weight. For this reason, [gzumwalt] embarked on his own self-imposed challenge to build an engine with the smallest weight and the lowest parts count possible, and came away with a 25-gram, 8-part engine.

The engine is based around a single piston and runs on compressed air. The reduced parts count is a result of using the propeller axle as a key component in the engine itself. There are flat surfaces on the engine end of the axle which allow it to act as a valve and control its own timing. [gzumwalt] notes that this particular engine was more of a thought experiment and might not actually produce enough thrust to run an airplane, but that it certainly will spark up some conversations among RC enthusiasts.

The build is also one of the first designs in what [gzumwalt] hopes will be a series of ever-improving engine designs. Perhaps he should join forces with this other air-powered design that we’ve just recently featured. Who else is working on air-powered planes? Who knew that this was a thing?

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Turn A Car Into A Game Controller

December 22, 2017 by 20 Comments

The CAN bus has become a staple of automotive engineering since it was introduced in the late ’80s, but in parallel with the spread of electronic devices almost every single piece of equipment inside a car has been put on the CAN bus. While there are opinions on whether or not this is a good thing, the reality is that enough data is gathered on this bus to turn an unmodified modern car into a video game controller with just a little bit of code.

The core of [Scott]’s project is a laptop and a Python program that scrapes information about the car from the car’s CAN bus, including positions of the pedals and the steering wheel. This information can be accessed by plugging an adapter into the OBD-II port (a standard for all cars made after 1995). From there, the laptop parses the CAN data into keyboard and mouse commands for your video game of choice.

This is an interesting investigation into the nitty-gritty of the CAN bus, but also a less dangerous demonstration of all of the data available from the car than some other cases we’ve seen. At least [Scott]’s Mazda (presumably) lacks any wireless attack vectors!

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DRM Workarounds Save Arcade Cabinet

December 19, 2017 by 32 Comments

DRM has become a four-letter word of late, with even media companies themselves abandoning the practice because of how ineffective it was. DRM wasn’t invented in the early 2000s for music, though. It’s been a practice on virtually everything where software is involved, including arcade cabinets. This is a problem for people who restore arcade machines, and [mon] has taken a swing at unraveling the DRM for a specific type of Konami cabinet.

The game in question, Reflec Beat, is a rhythm-based game released in 2010, and the security is pretty modern. Since the game comes with a HDD, a replacement drive can be ordered with a security dongle which acts to decrypt some of the contents on the HDD, including the game file and some other information. It’s not over yet, though. [mon] still needs to fuss with Windows DLL files and a few levels of decryption and filename obfuscation before getting the cabinet functional again.

The writeup on this cabinet is very detailed, and if you’re used to restoring older games, it’s a bit of a different animal to deal with than the embedded hardware security that older cabinets typically have. If you’ve ever wanted to own one of these more modern games, or you’re interested in security, be sure to check out the documentation on the project page. If your tastes are more Capcom and less Konami, check out an article on their security system in general, or in de-suiciding boards with failing backup batteries.

The Miracle Of Injection Molding: How Does It Work?

December 17, 2017 by 18 Comments

Pretty much any household item nowadays has an involved, extremely well-thought-out manufacturing method to it, whether it’s a sheet of paper, an electrical outlet, a can of tuna, or even the house itself. Some of the stories of how these objects came to be are compelling, though, as one of the recent videos from [This Old Tony] shows as he takes a deep dive into a $5 ball valve, and uses it to talk about all of the cool things you can do with injection molding.

Injection molding is the process of casting molten plastic into more useful pieces of plastic. In this case it’s a plumbing valve which might seem simple on the surface, but turns out to be much more involved. These ball valves are extremely reliable but have a very small price tag, meaning that a lot of engineering must have gone into their design. What is unearthed in the video is that injection molding allows parts to be cast into the molds of other parts, and the means by which those parts don’t all melt together, and how seals can be created within the part itself. All of this happens with a minimal number of parts and zero interaction from a human, or from any robot that isn’t the injection mold itself.

The video goes into exceptional detail on these valves specifically but also expounds on various techniques in injection molding. Similar to the recognition the seemingly modest aluminum can deserves, the injection molded ball valve deserves a similar amount of respect. While [This Old Tony] usually focuses on metalworking, he often tackles other interesting topics like this and this video is definitely worth checking out.

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Modernizing Puerto Rico’s Grid

December 15, 2017 by 44 Comments

After two massive hurricanes impacted Puerto Rico three months ago, the island was left with extensive damage to its electrical infrastructure. Part of the problem was that the infrastructure was woefully inadequate to withstand a hurricane impact at all. It is possible to harden buildings and infrastructure against extreme weather, and a new plan to restore Puerto Rico’s power grid will address many of these changes that, frankly, should have been made long ago.

Among the upgrades to the power distribution system are improvements to SCADA systems. SCADA allows for remote monitoring and control of substations, switchgear, and other equipment which minimizes the need for crews to investigate problems and improves reliability. SCADA can also be used for automation on a large scale, in addition to the installation of other autonomous equipment meant to isolate faults and restore power quickly. The grid will get physical upgrades as well, including equipment like poles, wire, and substations that are designed and installed to a more rigorous standard in order to make them more wind- and flood-tolerant. Additional infrastructure will be placed underground as well, and a more aggressive tree trimming program will be put in place.

The plan also calls for some 21st-century improvements as well, including the implementation of “micro grids”. These micro grids reduce the power system’s reliance on centralized power plants by placing small generation facilities (generators, rooftop solar, etc) in critical areas, like at hospitals. Micro grids can also be used in remote areas to improve reliability where it is often impractical or uneconomical to service.

While hurricanes are inevitable in certain parts of the world, the damage that they cause is often exacerbated by poor design and bad planning. Especially in the mysterious world of power generation and distribution, a robust infrastructure is extremely important for the health, safety, and well-being of the people who rely on it. Hopefully these steps will improve Puerto Rico’s situation, especially since this won’t be the last time a major storm impacts the island.

Fully-functional Oscilloscope On A PIC

December 10, 2017 by 15 Comments

When troubleshooting circuits it’s handy to have an oscilloscope around, but often we aren’t in a lab setting with all of our fancy, expensive tools at our disposal. Luckily the price of some basic oscilloscopes has dropped considerably in the past several years, but if you want to roll out your own solution to the “portable oscilloscope” problem the electrical engineering students at Cornell produced an oscilloscope that only needs a few knobs, a PIC, and a small TV.

[Junpeng] and [Kevin] are taking their design class, and built this prototype to be inexpensive and portable while still maintaining a high sample rate and preserving all of the core functions of a traditional oscilloscope. The scope can function anywhere under 100 kHz, and outputs NTSC at 30 frames per second. The user can control the ground level, the voltage and time scales, and a trigger. The oscilloscope has one channel, but this could be expanded easily enough if it isn’t sufficient for a real field application.

All in all, this is a great demonstration of what you can accomplish with a microcontroller and (almost) an engineering degree. To that end, the students go into an incredible amount of detail about how the oscilloscope works since this is a design class. About twice a year we see a lot of these projects popping up, and it’s always interesting to see the new challenges facing students in these classes.

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