Author: Bryan Cockfield

1760 Articles

A Guide For Heat-Treating Steel At Home

December 28, 2023 by 37 Comments

A lot of colloquial words that we might use when describing something’s durability take on extremely specific meanings when a materials scientist or blacksmith uses them. Things like “strength”, “toughness”, “hardness”, and “resilience” all have different meanings when working in a laboratory or industrial setting than most people might otherwise think.

For the beginner metalworker, this can be a little bit confusing at first but some hands-on practice will help. To that end, this beginner lesson in heat-treating steel from [Blondihacks] demonstrates why it can be beneficial to trade some of the metal’s toughness for improved hardness and just how to accomplish it on your own.

The first part of the lesson is to make sure the steel is high-carbon steel, since most other steels aren’t able to be heat treated. It will also have a specific method for its quenching, either in oil, water, or some other medium. But beyond that the only other thing required for this process is a torch of some sort. [Blondihacks] is using a MAP-Pro torch to get the steel up to temperature, which is recognizable when it turns a specific orange color. From there all that’s needed is to quench the hot metal in whatever fluid is called for. At this point the metal can also be tempered, which restores some of its toughness while maintaining a certain amount of hardness.

While the process doesn’t require specialized tools, [Blondihacks] does have a hardness tester, a fairly expensive piece of instrumentation that measures how deeply the metal can be indented by a force. By measuring the size of the indentation made by the tool, the hardness can be determined. As it’s many thousands of dollars this is mostly for demonstration and not necessary for most of us, but does go a long way to demonstrate the effectiveness of heat treating and tempering in an otherwise simple environment. If you’re looking for excuses to start heat treating and tempering metal, here’s a great project which creates a knife nearly from scratch.

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Old Prius Gets Upgraded Batteries

December 18, 2023 by 24 Comments

So many of the batteries made today are lithium batteries of some sort, from mobile phones, laptops, and drones to electric cars and grid storage solutions. But this technology is relatively new; even as late as the 90s and early 00s the only widely-available batteries for things like power tools or the new hybrid vehicles coming on the market were nickel-metal hydride (NiMH). While it was good for the time, they don’t hold up to all of the advantages lithium has. There’s still plenty of hybrid vehicles on the road using these batteries, so if you’re driving an older Prius and want to give it a modern refresh, there’s a quick option to swap your old batteries.

Despite lithium technology being available for several decades, the switch to lithium for the Toyota Prius wasn’t instant, with many variants still using NiMH batteries as late as the 2020s largely because the NiMH batteries are less expensive and less maintenance-intensive than lithium batteries are. As these batteries lose capacity, the cars are still driveable but the advantages of the hybrid drivetrain won’t be as accessible anymore. The upgrade, from a company called Project Lithium, replaces these batteries with modern lithium technology that can improve the efficiency and performance of these cars even above their original capabilities since lithium batteries have more power density.

With the Toyota Prius being among the most reliable vehicles on the road thanks to the electric motor in the hybrid drivetrain taking a lot of stress off of the internal combustion engine, it’s often worth upgrading these old batteries to modern ones to squeeze every last mile from these workhorses as possible. With many of the replacement processes being almost as simple as lifting out an old battery and placing a new one in, it can be a no-brainer if that’s the only issue with the vehicle otherwise. This is also true of all-electric vehicles as well, although the process to replace the battery can be a little more involved.

Thanks to [JohnU] for the tip!

Renewable Energy: Beyond Electricity

December 18, 2023 by 72 Comments

Perhaps the most-cited downside of renewable energy is that wind or sunlight might not always be available when the electrical grid demands it. As they say in the industry, it’s not “dispatchable”. A large enough grid can mitigate this somewhat by moving energy long distances or by using various existing storage methods like pumped storage, but for the time being some amount of dispatchable power generation like nuclear, fossil, or hydro power is often needed to backstop the fundamental nature of nature. As prices for wind and solar drop precipitously, though, the economics of finding other grid storage solutions get better. While the current focus is almost exclusively dedicated to batteries, another way of solving these problems may be using renewables to generate hydrogen both as a fuel and as a means of grid storage. Continue reading “Renewable Energy: Beyond Electricity” →

The Geometry Of Transistors

December 13, 2023 by 10 Comments

Building things in a lab is easy, at least when compared to scaling up for mass production. That’s why there are so many articles about fusion being right around the corner, or battery technology that’ll allow aviation to switch away from fossil fuels, or any number of other miraculous solutions that never come into being. They simply don’t scale or can’t be manufactured in a cost effective way. But even when they are miraculous and can be produced on a massive scale, as is the case for things like transistors, there are some oddities that come up as a result of the process of making so many. This video goes into some of the intricacies of a bipolar junction transistor (BJT) and why it looks the way it does.

The BJT in this video is a fairly standard NPN type, with three layers of silicon acting as emitter, base, and collector. Typically when learning about electronics devices the drawings of them are simplified two-dimensional block diagrams, but under a microscope this transistor at first appears nothing like the models shown in the textbook. Instead it resembles more of a bird’s foot with a few small wires attached. The bird’s foot shape is a result of attempting to lower the undesirable resistances of the device and improve its performance, and some of its other quirks are due to the manufacturing process. That process starts with a much larger layer of doped silicon that will eventually become the collector, and then the other two, much smaller, layers of the transistor deposited on top of the collector. This also explains while it looks like there are only two layers upon first glance, and also shows that the horizontal diagram used to model the device is actually positioned vertically in the real world.

For most of the processes in our daily lives, the transistor has largely been abstracted away. We don’t have to think about them in a computer that much anymore, and unless work is being done on high-wattage power electronics devices, radios, or audio amplifiers it’s not likely that an average person will run into a transistor. But this video goes a long way to explaining the basics of one of the fundamental building blocks of the modern world for those willing to take a dive into the physics. Take a look at this video as well for an intuitive explanation of the close cousin of the BJT, the field-effect transistor.

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Bluetooth As Proxy For Occupancy

December 13, 2023 by 59 Comments

During [Matt]’s first year of college, he found in a roundabout way that he could avoid crowds in the dining hall by accessing publicly available occupancy data that the dining hall collected. Presumably this was data for the dining hall to use internally, but with the right API calls anyone could use the information to figure out the best times to eat. But when the dining hall switched providers, this information feed disappeared. Instead of resigning himself to live in a world without real-time data on the state of the dining hall, he recreated the way the original provider counted occupancy: by using Bluetooth as a proxy for occupancy.

Bluetooth devices like smartphones, fitness sensors, and other peripherals often send out advertising packets into the aether, to alert other devices to their presence and help initiate connections between devices. By sniffing these advertising packets, it’s possible to get a rough estimate of the number of people in one particular place, assuming most people in the area will be carrying a smartphone or something of that nature. [Matt]’s Bluetooth-sniffing device is based on the ESP32 set up to simply count the number of unique devices it finds. He had some trouble with large crowds, though, as the first ESP32 device he chose didn’t have enough RAM to store more than a few hundred IDs and would crash once the memory filled. Switching to a more robust module seems to have solved that issue, and with a few rounds of testing he has a workable prototype that can run for long periods and log at least as many Bluetooth devices passing by as there are within its range.

While [Matt] hasn’t deployed this to the dining hall yet, with this framework in place most of the work has been done that, at least in theory, one of these modules could be easily placed anywhere someone was interested in collecting occupancy data. He has plans to submit his project to the university, to research the topic further, and potentially sell these to businesses interested in that kind of data. This isn’t an idea limited to the ESP32, either. We’ve seen similar projects built using the Raspberry Pi’s wireless capabilities that perform similar tasks as this one.

Thanks to [Adrian] for the tip!

A Ham Radio Answering Machine

December 8, 2023 by 15 Comments

For those who grew up with a cell phone in their hand, it might be difficult to imagine a time where the phone wasn’t fully integrated with voicemail. It sounds like a fantastical past, yet at one point a separate machine needed to be attached to the phone to record messages if no one was home to answer. Not only that, but a third device, a cassette tape, was generally needed as a storage device to hold the messages. In many ways we live in a much simpler world now, but in the amateur radio world one group is looking to bring this esoteric technology to the airwaves and [saveitforparts] is demonstrating one as part of a beta test.

The device is called the Boondock Echo, and while at its core it’s an ESP32 there’s a lot going on behind the scenes. It has an audio interface which is capable of connecting to a radio given the correct patch cable; in this case with a simple Baofeng handheld unit. The answering machine can record any sounds that come in. However, with a network connection the recordings are analyzed with an AI which can transcribe what it hears and even listen for specific call signs, then take actions such as sending emails when it hears triggers like that. Boondock also plans for this device to be capable of responding as well, but [saveitforparts] was not able to get this working during this beta test.

While an answering machine might seem like a step backwards technologically, an answering machine like this, especially when paired with Google Voice-like capabilities from an AI, has a lot of promise for ham radio operators. Even during this test, [saveitforparts] lost a radio and a kind stranger keyed it up when it was found, which was recorded by the Boondock Echo and used to eventually recover the radio. Certainly there are plenty of other applications as well, such as using AI instead of something like an Arduino to do Morse decoding.

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One Less Binary Blob

December 7, 2023 by 36 Comments

Open-source software has gone a long way into making modern technology the way it is today. The Linux kernel alone is almost single-handedly holding up the entire Internet, and various other open-source projects allow for more access to computing resources not just because the software is often free, but because it’s possible to look under the hood and modify it for specific needs. Without open-source software available we often run into problems both expected, such as software licensing costs, and unexpected, which often come up because a developer can’t or won’t fix issues or add features. To that end, a group at Ghent University in Belgium are attempting to rectify a problem with the ESP32 by eliminating one of its binary blobs and replacing it with an open source driver.

The ESP32 is famously a low-cost microcontroller with on-board wireless capabilities, but its Wi-Fi functionality currently relies on closed-source software from Espressif. The team is currently working on building a fully working open-source networking stack with the hopes of enabling greater flexibility of these devices but also making things like security auditing possible. The other major goal is to improve low-cost mesh networking which is currently not available with the proprietary driver. Reverse engineering is the name of the game here, both from a hardware and a software level, but current versions of the software already able to send and receive packets.

The source code for the project is available on the team’s GitHub page for any open-source aficionados to take a look at. We certainly hope the project gains some steam, as any new open source project helps all of us using the platform. Open source projects frequently get stymied by a single or small handful of binary blobs too, often with little hope for recourse. Examples include Android being an open-source operating system but generally using the closed-source Google Play suite in practice, or Firefox including support for Adobe Flash. Another great example is that even computers running 100% open-source code once they boot their operating systems, there’s still some black boxes running in the background few of us think about.

Thanks to [Crote] for the tip!