Author: Dan Maloney

3283 Articles

3D Printed Hardware Sorter Keeps It Simple

November 2, 2024 by 8 Comments

If you’re like us, you’ve got at least one bin dedicated to keeping the random hardware you just can’t bear to part with. In our case it’s mostly populated with the nuts and bolts left over after finishing up a car repair, but however it gets filled, it’s a mess. The degree to which you can tolerate this mess will vary, but for [EmGi], even a moderately untidy pile of bolts was enough to spur this entirely 3D-printed mechanical bolt sorter.

The elements of this machine bear a strong resemblance to a lot of the sorting mechanisms we’ve seen used on automated manufacturing and assembly lines. The process starts with a hopper full of M3 cap head bolts of varying lengths, which are collated by a pair of elevating platforms. These line up the bolts and lift them onto a slotted feed ramp, which lets them dangle by their heads and pushes them into a fixture that moves them through a 90° arc and presents them to a long sorting ramp. The ramp has a series of increasingly longer slots; bolts roll right over the slots until they find the right slot, where they fall into a bin below. Nuts can also feed through the process and get sorted into their own bin.

What we like about [EmGi]’s design is its simplicity. There are no motors, bearings, springs, or other hardware — except for the hardware you’re sorting, of course. The entire machine is manually powered, so you can just grab a handful of hardware and start sorting. True, it can only sort M3 cap head bolts, but we suspect the design could be modified easily for other sizes and styles of fasteners. Check it out in action in the video below.

Just because it’s simple doesn’t mean we don’t like more complicated hardware sorters, like the ones [Christopher Helmke] builds.

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Fail Of The Week: Subscription EV Charger Becomes Standalone, Briefly

November 1, 2024 by 48 Comments

At this point in the tech dystopia cycle, it’s no surprise that the initial purchase price of a piece of technology is likely not the last payment you’ll make. Almost everything these days needs an ongoing subscription to do whatever you paid for it to do in the first place. It’s ridiculous, especially when all you want to do is charge your electric motorcycle with electricity you already pay for; why in the world would you need a subscription for that?

That was [Maarten]’s question when he picked up a used EVBox wall mount charger, which refused to charge his bike without signing up for a subscription. True, the subscription gave access to all kinds of gee-whiz features, none of which were necessary for the job of topping off the bike’s battery. A teardown revealed a well-built device with separate modules for mains supply and battery charging, plus a communications module with a cellular modem, obviously the bit that’s phoning home and keeping the charger from working without the subscription.

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Voyager 1 Fault Forces Switch To S-Band

October 31, 2024 by 70 Comments

We hate to admit it, but whenever we see an article about either Voyager spacecraft, our thoughts immediately turn to worst-case scenarios. One of these days, we’ll be forced to write obituaries for the plucky interstellar travelers, but today is not that day, even with news of yet another issue aboard Voyager 1 that threatens its ability to communicate with Earth.

According to NASA, the current problem began on October 16 when controllers sent a command to turn on one of the spacecraft’s heaters. Voyager 1, nearly a light-day distant from Earth, failed to respond as expected 46 hours later. After some searching, controllers picked up the spacecraft’s X-band downlink signal but at a much lower power than expected. This indicated that the spacecraft had gone into fault protection mode, likely in response to the command to turn on the heater. A day later, Voyager 1 stopped communicating altogether, suggesting that further fault protection trips disabled the powerful X-band transmitter and switched to the lower-powered S-band downlink.

This was potentially mission-ending; the S-band downlink had last been used in 1981 when the probe was still well within the confines of the solar system, and the fear was that the Deep Space Network would not be able to find the weak signal. But find it they did, and on October 22 they sent a command to confirm S-band communications. At this point, controllers can still receive engineering data and command the craft, but it remains to be seen what can be done to restore full communications. They haven’t tried to turn the X-band transmitter back on yet, wisely preferring to further evaluate what caused the fault protection error that kicked this whole thing off before committing to a step like that.

Following Voyager news these days feels a little morbid, like a death watch on an aging celebrity. Here’s hoping that this story turns out to have a happy ending and that we can push the inevitable off for another few years. While we wait, if you want to know a little more about the Voyager comms system, we’ve got a deep dive that should get you going.

Thanks to [Mark Stevens] for the tip.

Homebrew Sferics Receiver Lets You Tune Into Earth Music

October 30, 2024 by 10 Comments

It probably comes as little surprise that our planet is practically buzzing with radio waves. Most of it is of our own making, with cell phones, microwaves, WiFi, and broadcasts up and down the spectrum whizzing around all the time. But our transmissions aren’t the only RF show in town, as the Earth itself is more than capable of generating radio signals of its own, signals which you can explore with a simple sferics receiver like this one.

If you’ve never heard of sferics and other natural radio phenomena, we have a primer to get you started. Briefly, sferics, short for “atmospherics,” are RF signals in the VLF range generated by the millions of lightning discharges that strike the Earth daily. Tuning into them is a pretty simple proposition, as [DX Explorer]’s receiver demonstrates. His circuit, which is based on a design by [K8TND], is just a single JFET surrounded by a few caps and resistors, plus a simple trap to filter out the strong AM broadcast signals in his area. The output of the RF amplifier goes directly into an audio amp, which could be anything you have handy — but you risk breaking [Elliot]’s heart if you don’t use his beloved LM386.

This is definitely a “nothing fancy” build, with the RF section built ugly style on a scrap of PCB and a simple telescopic whip used for an antenna. Tuning into the Earth’s radio signals does take some care, though. Getting far away from power lines is important, to limit AC interference. [DX Explorer] also found how he held the receiver was important; unless he was touching the ground plane of the receiver, the receiver started self-oscillating. But the pips, crackles, and pings came in loud and clear on his rig; check out the video below for the VLF action.

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Making PCB Strip Filter Design Easy To Understand

October 28, 2024 by 4 Comments

We’ve always been fascinated by things that perform complex electronic functions merely by virtue of their shapes. Waveguides come to mind, but so do active elements like filters made from nothing but PCB traces, which is the subject of this interesting video by [FesZ].

Of course, it’s not quite that simple. A PCB is more than just copper, of course, and the properties of the substrate have to be taken into account when designing these elements. To demonstrate this, [FesZ] used an online tool to design a bandpass filter for ADS-B signals. He designed two filters, one using standard FR4 substrate and the other using the more exotic PTFE.

He put both filters to the test, first on the spectrum analyzer. The center frequencies were a bit off, but he took care of that by shortening the traces slightly with a knife. The thing that really stood out to us was the difference in insertion loss between the two substrates, with the PTFE being much less lossy. The PTFE filter was also much more selective, with a tighter pass band than the FR4. PTFE was also much more thermostable than FR4, which had a larger shift in center frequency and increased loss after heating than the PTFE. [FesZ] also did a more real-world test and found that both filters did a good job damping down RF signals across the spectrum, even the tricky and pervasive FM broadcast signals that bedevil ADS-B experimenters.

Although we would have liked a better explanation of design details such as via stitching and trace finish selection, we always enjoy these lessons by [FesZ]. He has a knack for explaining abstract concepts through concrete examples; anyone who can make coax stubs and cavity filters understandable has our seal of approval.

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Lock-In Thermography On A Cheap IR Camera

October 28, 2024 by 17 Comments

Seeing the unseen is one of the great things about using an infrared (IR) camera, and even the cheap-ish ones that plug into a smartphone can dramatically improve your hardware debugging game. But even fancy and expensive IR cameras have their limits, and may miss subtle temperature changes that indicate a problem. Luckily, there’s a trick that improves the thermal resolution of even the lowliest IR camera, and all it takes is a little tweak to the device under test and some simple math.

According to [Dmytro], “lock-in thermography” is so simple that his exploration of the topic was just a side quest in a larger project that delved into the innards of a Xinfrared Xtherm II T2S+ camera. The idea is to periodically modulate the heat produced by the device under test, typically by ramping the power supply voltage up and down. IR images are taken in synch with the modulation, with each frame having a sine and cosine scaling factor applied to each pixel. The frames are averaged together over an integration period to create both in-phase and out-of-phase images, which can reveal thermal details that were previously unseen.

With some primary literature in hand, [Dmytro] cobbled together some simple code to automate the entire lock-in process. His first test subject was a de-capped AD9042 ADC, with power to the chip modulated by a MOSFET attached to a Raspberry Pi Pico. Integrating the images over just ten seconds provided remarkably detailed images of the die of the chip, far more detailed than the live view. He also pointed the camera at the Pico itself, programmed it to blink the LED slowly, and was clearly able to see heating in the LED and onboard DC-DC converter.

The potential of lock-in thermography for die-level debugging is pretty exciting, especially given how accessible it seems to be. The process reminds us a little of other “seeing the unseeable” techniques, like those neat acoustic cameras that make diagnosing machine vibrations easier, or even measuring blood pressure by watching the subtle change in color of someone’s skin as the capillaries fill.

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Hackaday Links: October 27, 2024

October 27, 2024 by 14 Comments

Problem solved? If the problem is supplying enough lithium to build batteries for all the electric vehicles that will be needed by 2030, then a new lithium deposit in Arkansas might be a resounding “Yes!” The discovery involves the Smackover Formation — and we’ll be honest here that half the reason we chose to feature this story was to be able to write “Smackover Formation” — which is a limestone aquifer covering a vast arc from the Rio Grande River in Texas through to the western tip of the Florida panhandle. Parts of the aquifer, including the bit that bulges up into southern Arkansas, bear a brine rich in lithium salts, far more so than any of the brines currently commercially exploited for lithium metal production elsewhere in the world. Given the measured concentration and estimated volume of brine in the formation, there could be between 5 million and 19 million tons of lithium in the formation; even at the lower end of the range, that’s enough to build nine times the number of EV batteries needed.

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