Author: Dan Maloney

Battery Management Module Hacked for Lithium-Iron Battery Bank

September 14, 2017 by 36 Comments

In a departure from his usual repair and tear down fare, [Kerry Wong] has set out on a long-term project — building a whole-house battery bank. From the first look at the project, this will be one to watch.

To be fair, [Kerry] gave us a tease at this project a few months back with his DIY spot welder for battery tabs. Since then, he appears to have made a few crucial design decisions, not least of which is battery chemistry. Most battery banks designed for an inverter with enough power to run household appliances rely on lead-acid batteries, although lithium-ion has certainly made some inroads. [Kerry] is looking to run a fairly small 1000-watt inverter, and his analysis led him to lithium-iron cells. The video below shows what happens when an eBay pack of 80 32650 LiFePo4 cells meets his spot welder. But then the problem becomes one of sourcing a battery management system that’s up to the charge and discharge specs of his 4s battery pack. We won’t spoil the surprise for you, but suffice it to say that [Kerry] really lucked out that only minimal modifications were needed for his $9 off-the-shelf BMS module.

We’re looking forward to seeing where this build goes, not least because we’d like to build something similar too. For a more traditional AGM-based battery bank, check out this nicely-engineered solar-charged system.

Continue reading “Battery Management Module Hacked for Lithium-Iron Battery Bank” →

Hacked Headset Brings VR to the Commodore 64

September 14, 2017 by 4 Comments

The venerable Commodore 64 got a lot of people started in computers, and a hard core of aficionados keeps the platform very much alive to this day. But a C64 just doesn’t have the horsepower to do anything more than some retro 8-bit graphics games, right?

Not if [jim_64] has anything to say about it. He’s created a pair of virtual-reality goggles for the C64, and the results are pretty neat. Calling them VR is a bit of a stretch, since that would imply the headset is capable of sensing the wearer’s movements, which it’s not. With just a small LCD screen tucked into the slot normally occupied by a smartphone in the cheap VR goggles [jim64] used as a foundation for his build, this is really more of a 3D wearable display — so far. The display brings 3D-graphics to the C64, at least for the “Street Defender” game that [jim64] authored, a demo of which can be seen below. We’ll bet position sensing could be built into the goggles to control the game too. Even then it won’t be quite the immersive (and oft-times nauseating) experience that VR has become, but for a 35-year old platform, it’s not too shabby.

Looking for more C64 love? We’ve got a million of ’em — case mods, C64 laptops, tablets, even CPU upgrades.

Continue reading “Hacked Headset Brings VR to the Commodore 64” →

In-Band Signaling: Coded Squelch Systems

September 13, 2017 by 18 Comments

In the first part of our series on in-band signaling, we discussed one of the most common and easily recognizable forms of audio control, familiar to anyone who has dialed a phone in the last fifty years – dual-tone multifrequency (DTMF) dialing. Our second installment will look at an in-band signaling method that far fewer people have heard, precisely because it was designed to be sub-audible — coded squelch systems for public service and other radio services. Continue reading “In-Band Signaling: Coded Squelch Systems” →

Reed Organ MIDI Conversion Tickles All 88 Keys

September 13, 2017 by 9 Comments

What did you do in high school? Chances are it wasn’t anywhere near as cool as turning a reed organ into a MIDI device. And even if you managed to pull something like that off, did you do it by mechanically controlling all 88 keys? Didn’t think so.

A reed organ is a keyboard instrument that channels moving air over sets of tuned brass reeds to produce notes. Most are fairly complex affairs with multiple keyboards and extra controls, but the one that [Willem Hillier] scored for free looks almost the same as a piano. Even with the free instrument [Willem] is about $500 into this project. Almost half of the budget went to the solenoids and driver MOSFETs — there’s a solenoid for each key, after all. And each one required minor surgery to reduce the clicking and clacking sounds that don’t exactly contribute to the musical experience. [Willem] designed custom driver boards for the MOSFETs with 16 channels per board, and added in a couple of power supplies to feed all those hungry solenoids and the three Arduinos needed to run the show. The video below shows the organ being stress-tested with the peppy “Flight of the Bumblebee”; there’s nothing wrong with a little showing off.

[Willem]’s build adds yet another instrument to the MIDI fold. We’ve covered plenty before, from accordions to harmonicas and even a really annoying siren.

Continue reading “Reed Organ MIDI Conversion Tickles All 88 Keys” →

Doppler Module Teardown Reveals the Weird World of Microwave Electronics

September 11, 2017 by 16 Comments

Oscillators with components that aren’t electrically connected to anything? PCB traces that function as passive components based solely on their shape? Slots and holes in the board with specific functions? Welcome to the weird and wonderful world of microwave electronics, brought to you through this teardown and analysis of a Doppler microwave transceiver module.

We’ve always been fascinated by the way conventional electronic rules break down as frequency increases. The Doppler module that [Kerry Wong] chose to pop open, a Microsemi X-band transceiver that goes for about $10 on eBay right now, has vanishingly few components inside. One transistor for the local oscillator, one for the mixer, and about three other passives are the whole BOM. That the LO is tuned by a barium titanate slug that acts as a dielectric resonator is just fascinating, as is the fact that PB traces can form a complete filter network just by virtue of their size and shape. Antennas that are coupled to the transceiver through an air gap via slots in the board are a neat trick too.

[Kerry] analyzes all this in the video below and shows how the module can be used as a sensor. If you need a little more detail on putting these modules to work, we’ve got some basic circuits you can check out.

Continue reading “Doppler Module Teardown Reveals the Weird World of Microwave Electronics” →

A Ham Radio Go-Box Packed with Functionality

September 9, 2017 by 15 Comments

“When all else fails, there’s ham radio.” With Hurricane Harvey just wrapping up, and Irma queued up to clobber Florida this weekend, hams are gearing up to pitch in with disaster communications for areas that won’t have any communications infrastructure left. And the perfect thing for the ham on the go is this ham shack in a box.

Go-boxes, as they are known, have been a staple of amateur radio field operations for as long as there have been hams. The go-box that [Fuzz (KC3JGB)] came up with is absolutely packed with goodies that would make it a perfect EmComm platform. The video tour below is all we have to go on, but we can see a tri-band transceiver, an RTL-SDR dongle and a Raspberry Pi with a TFT screen for tracking satellites. The Pi and SDR might also be part of a NOAA satellite receiver like the one [Fuzz] describes in a separate video; such a setup would be very valuable in natural disaster responses. Everything is powered by a 12-volt battery which can be charged from a small solar panel.

[Fuzz] is ready for action, and while we genuinely hope he and other hams won’t be needed in Florida, it doesn’t seem likely at this point. You can read more about the public service face of ham radio, or about an even more capable go-box.

Continue reading “A Ham Radio Go-Box Packed with Functionality” →

Your Work Won’t Move with a Magnetic Drill Press Vise

September 8, 2017 by 32 Comments

Setting up your workpiece is often the hardest part of any machining operation. The goal is to secure the workpiece so it can’t move during machining in such a way that nothing gets in the way of the tooling. Magnetic chucks are a great choice for securely and flexibly holding down workpieces, as this simple shop-built electromagnetic vise shows.

It looks like [Make It Extreme] learned a thing or two about converting microwave oven transformers to electromagnets when they built a material handling crane for the shop. Their magnetic vise, designed for a drill press but probably a great choice for securing work to a milling machine, grinder, or even a CNC router, has a simple but sturdy steel frame. Two separate platforms slide on the bed of the vise, each containing two decapitated MOTs. Wired to mains power separately for selective control and potted in epoxy, the magnets really seem to do the job. The video below shows a very thick piece of steel plate cantilevered out over one magnet while having a hole cut; that’s a lot of down force, but the workpiece doesn’t move.

Like the idea of a shop-made vise but would rather go the old-fashioned way? Check out [Make It Extreme]’s laminated bench vise, which also makes an appearance in this video.

Continue reading “Your Work Won’t Move with a Magnetic Drill Press Vise” →