resin printed pulsejet engine in operation

A Detonation Engine Prototyped Using Resin Printing

August 29, 2022 by Dave Rowntree 5 Comments

Over the years [Integza] has blown up or melted many types of jet engine, including the humble pulsejet. Earlier improvements revolved around pumping in more fuel, or forced air intakes, but now it’s time for a bit more refinement of the idea, and he takes a sidestep towards the more controllable detonation engine. His latest experiment (video, embedded below) attempts to dial-in the concept a little more. First he built a prototype from a set of resin printed parts, with associated tubing and gas control valves, and a long acrylic tube to send the exhaust down. Control of the butane and air injection, as well as triggering of the spark-ignition, are handled by an Arduino — although he could have just used a 555 timer — driving a few solid state relays. This provided some repeatable control of the pulse rate. This is a journey towards a very interesting engine design, known as the rotating detonation engine. This will be very interesting to see, if he can get it to work.

supersonic exhaust plume from a pulsejet engine — Supersonic exhaust plume with the characteristic ‘mushroom’ shape

Detonation engines operate due to the pressure part of the general thrust equation, where the action is in the detonative combustion. Detonative combustion takes place at constant pressure, which theoretically should lead to a greater efficiency than boring old deflagration, but the risks are somewhat higher. Apparently this is tricky to achieve with a fuel/air mix, as there just isn’t enough oomph in the mixture. [Integza] did try adding a Shchelkin spiral (we call them springs around here) which acts to slow down the combustion and shorten the time taken for it to transition from deflagration to detonation.

It sort of worked, but not well enough, so running with butane and pure oxygen was the way forward. This proved the basic idea worked, and the final step was to rebuild the whole thing in metal, with CNC machined end plates and some box section clamped with a few bolts. This appeared to work reasonably well at around 10 pulses/sec with some measurable thrust, but not a lot. More work to be done we think.

We hinted at earlier work on forced-air pulsejets, so here that is. Of course, whilst we’re on the subject of pulsejets, we can’t not mention [Colinfurze] and his pulsejet go kart.

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2022 Hackaday Prize: Boondock Echo Connects Your Radios With The Cloud

August 27, 2022 by Dave Rowntree 6 Comments

[Mark J Hughes] volunteers as a part of a local community fire watch which coordinates by radio. The La Habra Heights region of Los Angeles is an area of peaks and valleys, which makes direct radio connections challenging. Repeaters work well for range improvement, but in such areas, there is no good place to locate these. [Mark] says that during an emergency (such as a wildfire) the radio usage explodes, with him regularly tracking as many as eight radio frequencies and trying to make sense of it, whilst working out how to send the information on and to whom.

This led him together with collaborator [Kaushlesh Chandel] to create Project Boondock Echo, to help alleviate some of the stress of it all. The concept is to use a cheap Baofeng radio to feed into a gateway based around an ESP32 audio development kit. Mount this in a box with a LiPo based power supply, and you’ve got yourself a movable radio-to-cloud time-shift audio recorder.

By placing one or more of these units in the properties of several of the community group radio operators, all messages can be captured to an audio file, tagged with the radio frequency and time of transmission, and uploaded to a central server. From there they can be retrieved by anybody with access, no matter the physical location, only an internet connection is needed.

The next trick that can be performed, is to reverse the process and queue up previous recordings, and send it back over the cloud to remote locations for re-transmission via radio into the field. This is obviously a massive asset, because wherever there is some urbanization, there is likely an internet connection. With the addition of a Boondock Echo unit, anyone that has a receiver within a few miles can be fully connected with what’s going on outside the range of direct radio communications.

Source for the ESP32’s firmware as well as the web side of things can found on the project Boondock Echo GitHub, complete with some STLs for a 3D printed box to sit it in. Like always, there’s more than one way to solve a particular problem. Here’s an amateur radio repeater based using an RTL-SDR and a Raspberry Pi.

Bit-Banged Ethernet On The Raspberry Pi Pico

August 26, 2022 by Dave Rowntree 29 Comments

Whilst the Raspberry Pi RP2040 is quite a capable little chip, on the whole it’s nothing really special compared to the big brand offerings. But, the PIO peripheral is a bit special, and its inclusion was clearly a masterstroke of foresight, because it has bestowed the platform all kinds of capabilities that would be really hard to do any other way, especially for the price.

Our focus this time is on Ethernet, utilizing the PIO as a simple serialiser to push out a pre-formatted bitstream. [kingyo] so far has managed to implement the Pico-10BASE-T providing the bare minimum of UDP transmission (GitHub project) using only a handful of resistors as a proof of concept. For a safer implementation it is more usual to couple such a thing magnetically, and [kingyo] does show construction of a rudimentary pulse transformer, although off the shelf parts are obviously available for this. For the sake of completeness, it is also possible to capacitively couple Ethernet hardware (checkout this Micrel app note for starters) but it isn’t done all that much in practice.

UDP is a simple Ethernet protocol for transferring application data. Being connection-less, payload data are simply formatted into a packet buffer up front. This is all fine, until you realize that the packets are pretty long and the bitrate can be quite high for a low-cost uC, which is why devices with dedicated Ethernet MAC functionality have a specific hardware serialiser-deserialiser (SERDES) block just for this function.

Like many small uC devices, the RP2040 does not have a MAC function built in, but it does have the PIO, and that can easily be programmed to perform the SERDES function in only a handful of lines of code, albeit only currently operating at 10 MBit/sec. This will cause some connectivity problems for modern switch hardware, as they will likely no longer support this low speed, but that’s easily solved by snagging some older switch hardware off eBay.

As for the UDP receive, that is promised for the future, but for getting data out of a remote device over a wired network, Pico-10BASE-T is a pretty good starting point. We’ve seen a few projects before that utilize the PIO to generate high speed signals, such as DVI, albeit with a heavy dose of overclocking needed. If you want a bit more of an intro to all things Pico, you could do worse than check out this video series we highlighted a while back.

Integrated Circuit Manufacturing At Bell Labs In 1983

August 23, 2022 by Dave Rowntree 13 Comments

With the never ending march of technological progress, arguably the most complex technologies become so close to magic as to be impenetrable to those outside the industry in which they operate. We’ve seen walkthrough video snapshots of just a small part of the operation of modern semiconductor fabs, but let’s face it, everything you see is pretty guarded, hidden away inside large sealed boxes for environmental control reasons, among others, and it’s hard to really see what’s going on inside.

Let’s step back in time a few decades to 1983, with an interesting tour of the IC manufacturing facility at Bell Labs at Murray Hill (video, embedded below) and you can get a bit more of an idea of how the process works, albeit at a time when chips hosted mere tens of thousands of active devices, compared with the countless billions of today. This fab operates on three inch wafers, producing about 100 die each, with every one handled and processed by hand whereas modern wafers are much bigger, die often much smaller with the total die per wafer in the thousands and are never handled by a filthy human.

Particle counts of 100 per cubic foot might seem laughable by modern standards, but device geometries back then were comparatively large and the defect rate due to it was not so serious. We did chuckle somewhat seeing the operator staff all climb into their protective over suits, but open-faced with beards-a-plenty poking out into the breeze. Quite simply, full-on bunny suits were simply not necessary. Anyway, whilst the over suits were mostly for the environment, we did spot the occasional shot of an operator wearing some proper protective face shielding when performing some of the higher risk tasks, such as wafer cleaning, after all as the narrator says “these acids are strong enough to eat through the skin” and that would certainly ruin your afternoon.

No story about integrated circuit processing would be complete without mentioning the progress of [Sam Zeloof] and his DIY approach to making chips, and whilst he’s only managing device counts in the hundreds, this can only improve given time.

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Is This The Oldest Open Source HVAC Project In Existence?

August 22, 2022 by Dave Rowntree 19 Comments

Homebrew HVAC systems are one of those projects that take such a big investment of time, effort and money that you’ve got to be a really dedicated (ideally home-owning) hacker with a wide variety of multidisciplinary skills to pull off an implementation that can work in reality. One such HVAC hacker is [Vadim Tkachenko] with his multi-zone Home Climate Control (HCC) project that we covered first back in 2007. We now have rare opportunity to look at the improvements fifteen years of part-time development can produce, when a project is used all day, all year round in their own home. At the start, things were simple, just opening and closing ventilators with none of those modern MQTT-driven cloud computing stuff. Continue reading “Is This The Oldest Open Source HVAC Project In Existence?” →

Building A Spot Welder From 500 Junk Capacitors

August 20, 2022 by Dave Rowntree 5 Comments

[Kasyan TV] over on YouTube was given a pile of spare parts in reasonably large quantities, some of which were useful and allocated to specific projects, but given the given the kind of electronics they’re interested in, they couldn’t find a use for a bag of 500 or so low specification 470uF capacitors. These were not low ESR types, nor high capacitance, so unsuitable for power supply use individually. But, what about stacking them all in parallel? (video, embedded below) After a few quick calculations [Kasyan] determined that the total capacitance of all 500 should be around 0.23 Farads with an ESR of around 0.4 to 0.5 mΩ at 16V and packing a theoretical energy total of about 30 joules. That is enough to pack a punch in the right situation.

A PCB was constructed to wire 168 of the little cans in parallel, with hefty wide traces, reinforced with multiple strands of 1.8mm diameter copper wire and a big thick layer of solder over the top. Three such PCBs were wired in parallel with the same copper wire, in order to keep the total resistance as low as possible. Such a thing has a few practical uses, since the super low measured ESR of 0.6mΩ and large capacitance makes it ideal for smoothing power supplies in many applications, but could it be used to make a spot welder? Well, yes and no. When combined with one of the those cheap Chinese ‘spot welder’ controllers, it does indeed produce some welds on a LiPo cell with a thin nickel plated battery strip, but blows straight through it with little penetration. [Kasyan] found that the capacitor bank could be used in parallel with a decent LiPo cell giving a potentially ideal combination — a huge initial punch from the capacitors to blow through the strip and get the weld started and the LiPo following through with a lower (but still huge) current for a little longer to assist with the penetration into the battery terminal, finishing off the weld.

[Kaysan] goes into some measurements of the peak current delivery and the profile thereof, showing that even a pile of pretty mundane parts can, with a little care, be turned into something useful. How does such an assembly compare with a single supercapacitor? We talked about supercaps and LiPo batteries a little while ago, which was an interesting discussion, and in case you’re still interested, graphene-based hybrid supercapacitors are a thing too!

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(Re)designing The LumenPnP Tape Feeder

August 15, 2022 by Dave Rowntree 9 Comments

Many of the hardware orientated hackers among us will likely have been following along with the story of [Stephen Hawes] and the Lumen pick-and-place project but kind of waiting a bit for the project to mature some more before maybe taking the plunge and ordering a kit. One reason for this might be that whilst the basic machine design is there and working, the tape feeders did need a fair bit of work, and a lack of usable feeders does not make a great PnP machine. [Stephen] has been working on a newer design that addresses some of the identified shortcomings, and has started documenting his progress (video, embedded below) along the way.

Gone is the PCB-based ‘case’, reverting back to a 3D printable affair and a much smaller PCB. After flip-flopping a bit between different geared DC motors, [Stephen] settled back on the original, smaller unit, which after a wee spot of hacking, was convinced to accept an optical encoder stripped from another unit, and this proved that it was indeed more than up to the tape-advancement duty. The reason for this change was physical size — the original motor resulted in an assembly 38mm wide — this limited the number for feeders on the front rail to barely eleven units. This is not really enough, but with the narrower assembly, the width is reduced to 15.5mm allowing 27 feeders to snuggle together on the rail, and that should make the machine much more usable.

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