Author: Dan Maloney

3283 Articles

Good Lighting On A Budget With Cordless Tool Batteries

December 12, 2024 by 11 Comments

It’s perhaps not fair, but even if you have the best idea for a compelling video, few things will make people switch off than poor lighting. Good light and plenty of it is the order of the day when it comes to video production, and luckily there are many affordable options out there. Affordable, that is, right up to the point where you need batteries for remote shoots, in which case you’d better be ready to open the purse strings.

When [Dane Kouttron] ran into the battery problem with his video lighting setup, he fought back with these cheap and clever cordless tool battery pack adapters. His lights were designed to use Sony NP-F mount batteries, which are pretty common in the photography trade but unforgivably expensive, at least for Sony-branded packs. Having access to 20 volt DeWalt battery packs, he combined an off-the-shelf battery adapter with a 3D printed mount that slips right onto the light. Luckily, the lights have a built-in DC-DC converter that accepts up to 40 volts, so connecting the battery through a protection diode was a pretty simple exercise. The battery pack just slots right in and keeps the lights running for portable shoots.

Of course, if you don’t already have DeWalt batteries on hand, it might just be cheaper to buy the Sony batteries and be done with it. Then again, there are battery adapters for pretty much every cordless tool brand out there, so you should be able to adapt the design. We’ve also seen cross-brand battery adapters which might prove useful, too.

Unexpectedly Interesting Payphone Gives Up Its Secrets

December 11, 2024 by 7 Comments

Reverse engineering a payphone doesn’t sound like a very interesting project, at least in the United States, where payphones were little more than ruggedized versions of residential phones with a coin mechanism attached. Phones in other parts of the world were far more interesting, though, as this look at the mysteries of a payphone from Israel reveals (in Hebrew; English translation here.)

This is a project [Inbar Raz] worked on quite a while ago, but only got around to writing up recently. The payphone in question was sourced from the usual surplus market channels, and appears to have been removed from service by Israeli telecommunications company Bezeq only shortly before he found it. It was in pretty good shape, and was even still locked tight, making some amateur locksmithing the first order of the day. The internals of the phone are surprisingly complex, with a motherboard that looks more like something from a PC. Date codes on the chips and through-hole construction date the device to the early- to mid-1990s.

With physical access gained, [Inbar] turned to the firmware. An Atmel flash chip seemed a good place to look, and indeed he was able to pull code off the chip. That’s where things took a turn thanks to the CPU the code was written for — the CDP1806, a later version of the more popular but still fringe CDP1802. This required [Inbar] to fall down the rabbit hole of writing a new processor definition file for Ghidra so that the firmware could be reverse-engineered. This got him to the point of understanding 1806 assembly well enough that he was able to re-flash the phone to print debugging messages on the built-in 16×2 LCD screen, which allowed him to figure out which routines were being called under various error conditions.

It doesn’t appear that [Inbar] ever completed the reverse engineering project, but as he points out, what does that even mean? He got inside, took a look around, and made the phone do some cool things it couldn’t do before, and in the process made things easier for anyone working with 1806 processors in Ghidra. That’s a pretty complete win in our books.

Hackaday Links Column Banner

Hackaday Links: December 8, 2024

December 8, 2024 by 14 Comments

For some reason, we never tire of stories highlighting critical infrastructure that’s running outdated software, and all the better if it’s running on outdated hardware. So when we learned that part of the San Francisco transit system still runs on 5-1/4″ floppies, we sat up and took notice. The article is a bit stingy with the technical details, but the gist is that the Automatic Train Control System was installed in the Market Street subway station in 1998 and uses three floppy drives to load DOS and the associated custom software. If memory serves, MS-DOS as a standalone OS was pretty much done by about 1995 — Windows 95, right? — so the system was either obsolete before it was even installed, or the 1998 instance was an upgrade of an earlier system. Either way, the San Francisco Municipal Transportation Agency (SFMTA) says that the 1998 system due to be replaced originally had a 25-year lifespan, so they’re more or less on schedule. Replacement won’t be cheap, though; Hitachi Rail, the same outfit that builds systems that control things like the bullet train in Japan, is doing the job for the low, low price of $212 million.

Continue reading “Hackaday Links: December 8, 2024” →

Liquid Metal Ion Thrusters Aren’t Easy

December 7, 2024 by 10 Comments

What do scanning electron microscopes and satellites have in common? On the face of things, not much, but after seeing [Zachary Tong]’s latest video on liquid metal ion thrusters, we see that they seem to have a lot more in common than we’d initially thought.

As you’d expect with such a project, there were a lot of false starts and dead ends. [Zach] started with a porous-emitter array design, which uses a sintered glass plate with an array of tiny cones machined into it. The cones are coated in a liquid metal — [Zach] used Galinstan, an alloy of gallium, indium, and tin — and an high voltage is applied between the liquid metal and an extraction electrode. Ideally, the intense electric field causes the metal to ionize at the ultra-sharp tips of the cones and fling off toward the extraction electrode and into the vacuum beyond, generating thrust.

Getting that working was very difficult, enough so that [Zach] gave up and switched to a slot thruster design. This was easier to machine, but alas, no easier to make work. The main problem was taming the high-voltage end of things, which seemed to find more ways to produce unwanted arcs than the desired thrust. This prompted a switch to a capillary emitter design, which uses a fine glass capillary tube to contain the liquid metal. This showed far more promise and allowed [Zach] to infer a thrust by measuring the tiny current created by the ejected ions. At 11.8 μN, it’s not much, but it’s something, and that’s the thing with ion thrusters — over time, they’re very efficient.

To be sure, [Zach]’s efforts here didn’t result in a practical ion thruster, but that wasn’t the point. We suspect the idea here was to explore the real-world applications for his interests in topics like electron beam lithography and microfabrication, and in that, we think he did a bang-up job with this project.

Continue reading “Liquid Metal Ion Thrusters Aren’t Easy” →

3D Printed Caliper Extensions Make Hole Measurement Easier

December 6, 2024 by 21 Comments

If there’s anything more frustrating than mounting holes that don’t line up with the thing you’re mounting, we don’t know what it could be. You measure as carefully as possible, you drill the holes, and yet at least one hole ends up being just out of place. Sometimes you can fudge it, but other times you’ve got to start over again. It’s maddening.

Getting solid measurements of the distance between holes would help, which is where these neat snap-on attachments for digital calipers come in. [Chris Long] came up with the 3D printed tools to make this common shop task a little easier, and they look promising. The extensions have cone-shaped tips that align perfectly with the inside edge of the caliper jaws, which lines the jaws up with the center of each hole. You read the center-to-center distance directly off the caliper display, easy peasy.

Of course, there’s also the old machinist’s trick (last item) about zeroing out the calipers after reading the diameter of one of the holes and then measuring the outside-to-outside distance between the two holes. That works great when you’ve got plenty of clearance, but the shorter inside jaws might make measuring something like a populated PCB with this method tricky. For the price of a little filament and some print time, these might be just the tool to get you out of a bind.

Continue reading “3D Printed Caliper Extensions Make Hole Measurement Easier” →

Hacked Ultrasonic Sensors Let You See With Sound

December 6, 2024 by 13 Comments

If you want to play with radar — and who could blame you — you can pretty easily get your hands on something like the automotive radar sensors used for collision avoidance and lane detection. But the “R” in radar still stands for “Radio,” and RF projects are always fraught, especially at microwave frequencies. What’s the radar enthusiast to do?

While it’s not radar, subbing in ultrasonic sensors is how [Dzl] built this sonar imaging system using a lot of radar principles. Initial experiments centered around the ubiquitous dual-transducer ultrasonic modules used in all sorts of ranging and detection project, with some slight modifications to tap into the received audio signal rather than just using the digital output of the sensor. An ESP32 and a 24-bit ADC were used to capture the echo signal, and a series of filters were implemented in code to clean up the audio and quantify the returns. [Dzl] also added a downsampling routine to bring the transmitted pings and resultant echoes down in the human-audible range; they sound more like honks than pings, but it’s still pretty cool.

To make the simple range sensor more radar-like, [Dzl] needed to narrow the beamwidth of the sensor and make the whole thing steerable. That required a switch to an automotive backup sensor, which uses a single transducer, and a 3D printed parabolic dish reflector that looks very much like a satellite TV dish. With this assembly stuck on a stepper motor to swivel it back and forth, [Dzl] was able to get pretty good images showing clear reflections of objects in the lab.

If you want to start seeing with sound, [Dzl]’s write-up has all the details you’ll need. If real radar is still your thing, though, we’ve got something for that too.

Thanks to [Vanessa] for the tip.

Non-Planar Fuzzy Skin Textures Improved, Plus A Paint-On Interface

December 6, 2024 by 4 Comments

If you’ve wanted to get in on the “fuzzy skin” action with 3D printing but held off because you didn’t want to fiddle with slicer post-processing, you need to check out the paint-on fuzzy skin generator detailed in the video below.

For those who haven’t had the pleasure, fuzzy skin is a texture that can be applied to the outer layers of a 3D print to add a little visual interest and make layer lines a little less obvious. Most slicers have it as an option, but limit the wiggling action of the print head needed to achieve it to the XY plane. Recently, [TenTech] released post-processing scripts for three popular slicers that enable non-planar fuzzy skin by wiggling the print head in the Z-axis, allowing you to texture upward-facing surfaces.

The first half of the video below goes through [TenTech]’s updates to that work that resulted in a single script that can be used with any of the slicers. That’s a pretty neat trick by itself, but not content to rest on his laurels, he decided to make applying a fuzzy skin texture to any aspect of a print easier through a WYSIWYG tool. All you have to do is open the slicer’s multi-material view and paint the areas of the print you want fuzzed. The demo print in the video is a hand grip with fuzzy skin applied to the surfaces that the fingers and palm will touch, along with a little bit on the top for good measure. The print looks fantastic with the texture, and we can see all sorts of possibilities for something like this.

Continue reading “Non-Planar Fuzzy Skin Textures Improved, Plus A Paint-On Interface” →