Author: Dan Maloney

3373 Articles

A French Cleat Twist On Electronics Bench Organization

May 18, 2020 by 38 Comments

For some of us, our workbench is where organization goes to die. Getting ready to tackle a new project means sweeping away a pile of old projects, exposing exactly as much bench space needed to plop down the new parts. On the other end of the spectrum lie those for whom organization isn’t a means to an end, but an end itself. Their benches are spotless, ready to take on a new project at a moment’s notice.

[Eric Gunnerson]’s new French-cleat electronics bench is somewhere in between those two extremes, although nowhere near as over-organized as the woodworking organizer that inspired it. If you’ve never heard of a French cleat, Google around a bit and you’ll see some amazing shops where the system of wall-mounted, mitered cleats with mating parts on everything from shelves to cabinets are put to great use. A properly built French cleat can support tremendous loads; [Eric]’s system is scaled down a bit in deference to the lighter loads typically found in the electronics shop. His cleats are 2″ x 3″ pieces of pine, attached to a sheet of plywood that was then screwed to the wall. His first pass at fixtures for the cleats used a Shaper Origin CNC router, but when that proved to be slow he turned to laser-cut plywood. The summary video below shows a few of the fixtures he’s come up with so far; we particularly like the oscilloscope caddy, and the cable hangers are a neat trick too.

What we like about this is the flexibility it offers, since you can change things around as workflows develop or new instruments get added. Chalk one up for [Eric] for organization without overcomplication.

Continue reading “A French Cleat Twist On Electronics Bench Organization” →

Animatronics Hack Chat

May 18, 2020 by 4 Comments

Join us on Wednesday, May 20 at noon Pacific for the Animatronics  Hack Chat with Will Cogley!

While robots have only a made a comparatively recent appearance on the technology timeline, people have been building mechanical simulations of living organisms for a long time indeed. For proof, one needs only to look back at the automatons built by clever craftsmen to amuse and delight their kings and queens. The clockwork mechanisms that powered fanciful birds and animals gave way to the sophisticated dolls and mannequins that could perform complex tasks like writing and performing music, all with the goal of creating something that looked and acted like it was alive.

Once the age of electronics came around, the springs that drove the early automatons and the cams that programmed their actions were replaced by motors and control circuits. New materials made once-clunky mechanisms finer and more precise, sensors and servos made movements more lifelike, and the age of animatronics was born.

Animatronics have since become a huge business, mostly in the entertainment industry. From robotic presidents to anachronistic dinosaurs to singing rodents designed to sell pizza, animatronics have been alternately entertaining and terrifying us for decades. The fact that they’re not “real” robots doesn’t make the melding of mechanical, electrical, and computer systems into a convincing representation of a real being any less challenging. Will Cogley has more than a few amazing animatronic designs under his belt, some of which we’ve featured on Hackaday. From hearts to hands to slightly terrifying mouths, Will puts a ton of work into his mechanisms, and he’ll stop by the Hack Chat to tell us all about designing and building animatronics.

join-hack-chatOur Hack Chats are live community events in the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Wednesday, May 20 at 12:00 PM Pacific time. If time zones have got you down, we have a handy time zone converter.

Click that speech bubble to the right, and you’ll be taken directly to the Hack Chat group on Hackaday.io. You don’t have to wait until Wednesday; join whenever you want and you can see what the community is talking about.

Continue reading “Animatronics Hack Chat” →

Hackaday Links Column Banner

Hackaday Links: May 17, 2020

May 17, 2020 by 9 Comments

Consider it the “Scarlet Letter” of our time. An MIT lab is developing a face mask that lights up to alert others when the wearer has COVID-19. The detection technology is based on sensors that were developed for the Ebola virus scare and uses fluorescently tagged DNA fragments freeze-dried onto absorbent strips built into the mask. The chemistry is activated by the moisture in the sputum expelled when the wearer coughs or sneezes while wearing the mask; any SARS-CoV-2 virus particles in the sputum bind to the strips, when then light up under UV. The list of problems a scheme like this entails is long and varied, not least of which is what would possess someone to willingly don one of these things. Still, it’s an interesting technology.

Speaking of intrusive expansions of the surveillance state, Singapore is apparently now using a Boston Dynamics Spot robot to enforce social-distancing rules in its public parks and gardens. The familiar four-legged, bright yellow dog-bot is carrying cameras that are relaying images of park attendees to some sort of image analysis program and are totally not capturing facial or personal data, pinky swear. If people are found to be violating the two-meter rule, Spot will bark out a prerecorded reminder to spread out a bit. How the system differentiates between people who live together who are out getting some fresh air and strangers who should be staying apart, and whether the operators of this have ever seen how this story turns out are open questions.

Those who lived through 9/11 in the United States no doubt remember the deafening silence that descended over the country for three days while every plane in the civil aviation fleet was grounded. One had no idea how much planes contributed to the noise floor of life until they were silenced. So too with the lockdown implemented worldwide to deal with the COVID-19 pandemic, except with the sometimes dramatic reduction in pollution levels. We’ve all seen pictures where people suddenly realize that Los Angeles isn’t necessarily covered by an orange cloud of smog, and that certain mountain ranges are actually visible if you care to look. But getting some hard data is always useful, and these charts show just how much the pollution situation improved in a number of countries throughout the world after their respective lockdowns. For some cities, the official lockdown was a clear demarcation between the old pollution regime and the new, but for some, there was an obvious period before the lockdown was announced where people were obviously curtailing their activity. It’s always interesting pore over data like this and speculated what it all means.

While the in-person aspects of almost every conference under the sun have been canceled, many of them have switched to a virtual meeting that can at least partially make up for the full experience. And coming up next weekend is Virtually Maker Faire, in the slot where Bay Area Maker Faire would normally be offered. The call for makers ends today, so get your proposals in and sign up to attend.

And finally, there aren’t too many times in life you’ll get a chance to get to visualize a number so large that an Evil Empire was named for it. The googol, or 10100, was a term coined by the nine-year-old nephew of mathematician Edward Kasner when he asked the child for a good name for a really big number. To put the immensity of that number into perspective, The Brick Experiment Channel on YouTube put together an improbably long gear train using Lego pieces we’ve never seen before with a reduction ratio of 10103.4:1. The gear train has a ton of different power transmission elements in it, from plain spur gears to worm drives and even planetary gears. We found the 2608.5:1 harmonic gear particularly fascinating. There’s enough going on to keep even a serious gearhead entertained, but perhaps not for the 5.2×1091 years it’ll take to revolve the final gear once. Something, something, heat-death of the universe. [Ed note: prior art, which we were oddly enough thinking of fondly just a few days ago. Synchronicity!]

CNC Plasma Cutter Filter Gets The Slag Out

May 16, 2020 by 10 Comments

No matter what kind of tools and materials you use in your shop, chances are pretty good that some process is going to release something that you don’t want to breathe. Table saw? Better deal with that wood dust. 3D-printer? We’ve discussed fume control ad nauseam. Soldering? It’s best not to inhale those flux fumes. But perhaps nowhere is fume extraction more important than in the metal shop, where vaporized bits of metal can wreak respiratory havoc.

Reducing such risks was [Shane Wighton]’s rationale behind this no-clean plasma cutter filter. Rather than a water table to collect cutting dross, his CNC plasma cutter is fitted with a downdraft table to suck it away. The vivid display of sparks shooting out of the downdraft fans belied its ineffectiveness, though. [Shane]’s idea is based on the cyclonic principle common to woodshop dust collectors and stupidly expensive vacuum cleaners alike. Plastic pipe sections, split in half lengthwise and covered in aluminum tape to make them less likely to catch on fire from the hot sparks, are set vertically in the air path. The pipes are arranged in a series of nested “S” shapes, offering a tortuous path to the spark-laden air as it exits the downdraft.

The video below shows that most of the entrained solids slow down and drop to the bottom of the filter; some still pass through, but testing with adhesive sheets shows the metal particles in the exhaust are much reduced. We like the design, especially the fact that there’s nothing to clog or greatly restrict the airflow.

Looking for more on CNC plasma cutter builds? We’ve got you covered, from just the basics to next-level.

Continue reading “CNC Plasma Cutter Filter Gets The Slag Out” →

Printable, Castable Feeders Simplify Pick-and-Place Component Management

May 14, 2020 by 10 Comments

It goes without saying that we love to see all the clever ways people have come up with to populate their printed circuit boards, especially the automated solutions. The idea of manually picking and placing nearly-microscopic components is reason enough to add a pick and place to the shop, but that usually leaves the problem of feeding components to the imagination of the user. And this mass-production-ready passive component feeder is a great example of that kind of imagination.

Almost every design we’ve seen for homebrew PnP component feeders have one of two things in common: they’re 3D-printed, or they’re somewhat complex. Not that those are bad things, but they do raise issues. Printing enough feeders for even a moderately large project would take forever, and the more motors and sensors a feeder has, the greater the chance of a breakdown. [dining-philosopher] solved both these problems with a simple design using only two parts, which can be resin cast. A lever arm is depressed by a plunger that’s attached to the LitePlacer tool, offset just enough so that the suction cup is lined up with the component location on the tape. A pawl in the lower arm moves forward when the tool leaves after picking up the part, engaging with the tape sprocket holes and advancing to the next component.

[dining-philosopher] didn’t attack the cover film peeling problem in his version, choosing to peel it off manually and use a weight to keep it taut and expose the next component. But in a nice example of collaboration, [Jed Smith] added an automatic film peeler to the original design. It complicates things a bit, but the peeler is powered by the advancing tape, so it’s probably worth it.

Continue reading “Printable, Castable Feeders Simplify Pick-and-Place Component Management” →

How Much Is That Plotter In The Window?

May 14, 2020 by 11 Comments

We live in a strange time indeed. People who once eschewed direct interactions with fellow humans now crave it, but to limited avail. Almost every cashier at the few stores deigned essential enough to maintain operations are sealed away behind plastic shields, with the implication that the less time one spends lingering, the better. It’s enough to turn an introvert into an extrovert, at least until the barriers are gone.

We get the idea that the need to reach out and touch someone is behind [Niklas Roy]’s “Please Leave a Message”, an interactive art installation he set up in the front window of his Berlin shop. Conveniently located on a downtown street, his shop is perfectly positioned to attract foot traffic, and his display is designed to catch the eye and perhaps crack a smile. The device consists of a large wooden easel holding the guts from an old X-Y pen plotter, an Arduino and an ESP-8266, and a couple of drivers for the plotter’s steppers. Passers-by are encouraged to scan a QR code that accesses a web page served up by the ESP-8266, where they can type in a brief message. The plotter dutifully spells it out on a scroll of paper for all to see, using a very nice font that [Niklas] designed to be both readable and easily plotted. The video below shows it in action with real people; it seems to be a crowd-pleaser.

[Niklas] has been incredibly prolific, and we’ve covered many of his interactive art installations. Just search for his name and you’ll find everything from a pressure-washer dancing waters display to a plus-sized pinball machine.

Continue reading “How Much Is That Plotter In The Window?” →

Side-Channel Attack Turns Power Supply Into Speakers

May 11, 2020 by 12 Comments

If you work in a secure facility, the chances are pretty good that any computer there is going to be stripped to the minimum complement of peripherals. After all, the fewer parts that a computer has, the fewer things that can be turned into air-gap breaching transducers, right? So no printers, no cameras, no microphones, and certainly no speakers.

Unfortunately, deleting such peripherals does you little good when [Mordechai Guri] is able to turn a computer power supply into a speaker that can exfiltrate data from air-gapped machines. In an arXiv paper (PDF link), [Guri] describes a side-channel attack of considerable deviousness and some complexity that he calls POWER-SUPPLaY. It’s a two-pronged attack with both a transmitter and receiver exploit needed to pull it off. The transmitter malware, delivered via standard methods, runs on the air-gapped machine, and controls the workload of the CPU. These changes in power usage result in vibrations in the switch-mode power supply common to most PCs, particularly in the transformers and capacitors. The resulting audio frequency signals are picked up by a malware-infected receiver on a smartphone, presumably carried by someone into the vicinity of the air-gapped machine. The data is picked up by the phone’s microphone, buffered, and exfiltrated to the attacker at a later time.

Yes, it’s complicated, requiring two exploits to install all the pieces, but under the right conditions it could be feasible. And who’s to say that the receiver malware couldn’t be replaced with the old potato chip bag exploit? Either way, we’re glad [Mordechai] and his fellow security researchers are out there finding the weak spots and challenging assumptions of what’s safe and what’s vulnerable.

Continue reading “Side-Channel Attack Turns Power Supply Into Speakers” →