Radio Apocalypse: HFGCS, The Backup Plan For Doomsday

To the extent that you have an opinion on something like high-frequency (HF) radio, you probably associate it with amateur radio operators, hunched over their gear late at night as they try to make contact with a random stranger across the globe to talk about the fact that they’re both doing the same thing at the same time. In a world where you can reach out to almost anyone else in an instant using flashy apps on the Internet, HF radio’s reputation as somewhat old and fuddy is well-earned.

Like the general population, modern militaries have largely switched to digital networks and satellite links, using them to coordinate and command their strategic forces on a global level. But while military nets are designed to be resilient to attack, there’s only so much damage they can absorb before becoming degraded to the point of uselessness. A backup plan makes good military sense, and the properties of radio waves between 3 MHz and 30 MHz, especially the ability to bounce off the ionosphere, make HF radio a perfect fit.

The United States Strategic Forces Command, essentially the people who “push the button” that starts a Very Bad Day™, built their backup plan around the unique properties of HF radio. Its current incarnation is called the High-Frequency Global Communications System, or HFGCS. As the hams like to say, “When all else fails, there’s radio,” and HFGCS takes advantage of that to make sure the end of the world can be conducted in an orderly fashion.

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Hackaday Links: August 4, 2024

Good news, bad news for Sun watchers this week, as our star launched a solar flare even bigger than the one back in May that gave us an amazing display of aurora that dipped down into pretty low latitudes. This was a big one; where the earlier outburst was only an X8.9 class, the one on July 23 was X14. That sure sounds powerful, but to put some numbers to it, the lower end of the X-class exceeds 10-4 W/m2 of soft X-rays. Numbers within the class designate a linear increase in power, so X2 is twice as powerful as X1. That means the recent X14 flare was about five times as powerful as the May flare that put on such a nice show for us. Of course, this all pales in comparison to the strongest flare of all time, a 2003 whopper that pegged the needle on satellite sensors at X17 but was later estimated at X45.

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Get Your Glitch On With A PicoEMP And A 3D Printer

We’re not sure what [Aaron Christophel] calls his automated chip glitching setup built from a 3D printer, but we’re going to go ahead and dub it the “Glitch-o-Matic 9000.” Has a nice ring to it.

Of course, this isn’t a commercial product, or even a rig that’s necessarily intended for repeated use. It’s more of a tactical build, which is still pretty cool if you ask us. It started with a proof-of-concept exploration, summarized in the first video below. That’s where [Aaron] assembled and tested the major pieces, which included a PicoEMP, the bit that actually generates the high-voltage pulses intended to scramble a running microcontroller temporarily, along with a ChipWhisperer and an oscilloscope.

The trouble with the POC setup was that glitching the target chip, an LPC2388 microcontroller, involved manually scanning the business end of the PicoEMP over the package. That’s a tedious and error-prone process, which is perfect for automation. In the second video below, [Aaron] has affixed the PicoEMP to his 3D printer, giving him three-axis control of the tip position. That let him build up a heat map of potential spots to glitch, which eventually led to a successful fault injection attack and a clean firmware dump.

It’s worth noting that the whole reason [Aaron] had to resort to such extreme measures in the first place was the resilience of the target chip against power supply-induced glitching attacks. You might not need to build something like the Glitch-o-Matic, but it’s good to keep in mind in case you run up against such a hard target. Continue reading “Get Your Glitch On With A PicoEMP And A 3D Printer”

Custom Hat Gives Vintage Mitutoyo Calipers A New Lease On Life

Metrology fans are usually at least a little bit in love with Mitutoyo, and rightfully so. The Japanese company has been making precision measuring instruments for the better part of 100 years, and users appreciate their precision almost as much as the silky smooth feel of their tools. If you can afford it, a Mitutoyo caliper is quite an addition to your toolbox.

As good as they are, though, they’re not perfect, which is what led to this clever Mitutoyo digital caliper hack by [turbanedengineer]. The calipers in question, a digital set from the early 1980s, happen to have a unique history with a tangential Hackaday angle — they belonged to [Dhaval], mechanical engineer and avid motorcyclist who happens to be the late elder brother of our own [Anool Mahidharia].

The tool, in need of a little TLC, made its way to [turbanedengineer] who first restored the broken battery contacts. Once powered up again, it became apparent that while the caliper’s native metric measurements were spot on, the internal conversion to inches was considerably off. This led [turbanedengineer] to the data port on the tool, which is intended to send serial data to an external computer for logging measurements. After a little experimentation to nail down the data format, he prototyped a tiny circuit using an ATtiny85 and an OLED display that reads the caliper data, converts metric to inches, and displays both measurements on the screen. The prototype led to a more permanent version, which cleverly sits over the original display and taps into the data port without any free wires. The video below shows the very slick results.

Our hearts go out to [Anool] and his family for their loss, and we tip our hats to [turbanedengineer] for his thoughtful and respectful hack of a storied tool. We know that anthropomorphizing tools makes no rational sense, but we think it’s safe to say that a tool like this has a soul, and it’s probably happy to be back in the game.

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Over-molding Wires With Hot Glue And 3D Printed Molds

We’ve said it before and we’ll say it again: water always finds a way in. That’s particularly problematic for things like wire splices in damp environments, something that no amount of electrical tape is going to help. Heat shrink tubing might be your friend here, but for an electrically isolated and mechanically supported repair, you may want to give over-molding with a hot glue gun a try.

The inspiration for [Print Practical]’s foray into over-molding came from a video that’s making the rounds showing a commercially available tool for protecting spliced wires in the automotive repair trade. It consists of a machined aluminum mold that the spliced wires fit into and a more-or-less stock hot glue gun, which fills the mold with melted plastic. [Print Practical] thought it just might be possible to 3D print custom molds at home and do it himself.

His first attempt didn’t go so well. As it turns out, hot glue likes to stick to things — who knew? — including the PETG mold he designed. Trying to pry apart the mold after injection was a chore, and even once he got inside it was clear the glue much preferred to stay in the mold. Round two went much better — same wire, same mold, but now with a thin layer of vegetable oil to act as a release agent. That worked like a charm, with the over-mold standing up to a saltwater bath with no signs of leaking. [Print Practical] also repaired an iPhone cable that has seen better days, providing much-needed mechanical support for a badly frayed section.

This looks like a fantastic idea to file away for the future, and one that’s worth experimenting with. Other filament types might make a mold better able to stand up to the hot glue, and materials other than the ethylene-vinyl acetate copolymer found in most hot glue sticks might be explored. TPU over-molds, anyone? Or perhaps you can use a printer as an injector rather than the glue gun.

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Programming Tiny Blinkenlight Projects With Light

[mitxela] has a tiny problem, literally: some of his projects are so small as to defy easy programming. While most of us would probably solve the problem of having no physical space on a board to mount a connector with WiFi or Bluetooth, he took a different path and gave this clever light-based programming interface a go.

Part of the impetus for this approach comes from some of the LED-centric projects [mitxela] has tackled lately, particularly wearables such as his LED matrix earrings or these blinky industrial piercings. Since LEDs can serve as light sensors, albeit imperfect ones, he explored exactly how to make the scheme work.

For initial experiments he wisely chose his larger but still diminutive LED matrix badge, which sports a CH32V003 microcontroller, an 8×8 array of SMD LEDs, and not much else. The video below is a brief summary of the effort, while the link above provides a much more detailed account of the proceedings, which involved a couple of false starts and a lot of prototyping that eventually led to dividing the matrix in two and ganging all the LEDs in each half into separate sensors. This allows [mitxela] to connect each side of the array to the two inputs of an op-amp built into the CH32V003, making a differential sensor that’s less prone to interference from room light. A smartphone app alternately flashes two rectangles on and off with the matrix lying directly on the screen to send data to the badge — at a low bitrate, to be sure, but it’s more than enough to program the badge in a reasonable amount of time.

We find this to be an extremely clever way to leverage what’s already available and make a project even better than it was. Here’s hoping it spurs new and even smaller LED projects in the future.

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Undersea Cable Repair

The bottom of the sea is a mysterious and inaccessible place, and anything unfortunate enough to slip beneath the waves and into the briny depths might as well be on the Moon. But the bottom of the sea really isn’t all that far away. The average depth of the ocean is only about 3,600 meters, and even at its deepest, the bottom is only about 10 kilometers away, a distance almost anyone could walk in a couple of hours.

Of course, the problem is that the walk would be straight down into one of the most inhospitable environments our planet has to offer. Despite its harshness, that environment is home to hundreds of undersea cables, all of which are subject to wear and tear through accidents and natural causes. Fixing broken undersea cables quickly and efficiently is a highly specialized field, one that takes a lot of interesting engineering and some clever hacks to pull off.

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