Author: Dan Maloney

3209 Articles

A Quick And Stealthy Mobile Slot Antenna From Copper Tape

October 25, 2023 by 41 Comments

[Ben Eadie (VE6SFX)] is at it again with the foil tape, and this time he’s whipped up a stealthy mobile sunroof antenna for the amateur radio operator with the on-the-go lifestyle.

You may recall [Ben]’s recent duck tape antenna for the 70-cm ham band, an ultra-lightweight design that lends itself to easy packing for portable operation. The conductors in that antenna were made from copper foil tape, a material that’s perfect for all sorts of specialized applications, like the slot antenna that he builds in the video below. In the ham world, slot antennas are most frequently seen cut into the main reflector of a direct satellite dish, often in hopes of avoiding the homeowner association’s antenna police. Even in the weird world of RF, it’s a strange beast because it relies on the absence of material in a large planar (or planar-ish) conductive surface.

Rather than grabbing an angle grinder to make a slot in the roof of his car, [Ben] created a “virtual” slot with copper tape on the inside of his car’s sunroof. His design called for a 39″ (0.99-m) slot, so he laid out a U-shaped slot to fit the window and outlined it with copper foil tape. His method was a little complex; he applied the copper tape to a transparent transfer film first, then stuck the whole thing to the underside of the glass in one go. It didn’t quite go as planned, but as he learned in the duck tape antenna, the copper tape makes it easy to repair mistakes. A BNC connector with pigtails is attached across the slot about 4″ (10 cm) up from the end of one of the short legs of the slot; yes, this looks like a dead short, but such are the oddities of radio.

Is it a great antenna? By the numbers on [Ben]’s NanoVNA, not really. But any antenna that gets you heard is a good antenna, and this one was more than capable in that regard. We’ll have to keep this in mind for impromptu antennas and for those times when secrecy is a good idea.

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Using Industrial CT To Examine A $129 USB Cable

October 24, 2023 by 79 Comments

What in the world could possibly justify charging $129 for a USB cable? And is such a cable any better than a $10 Amazon Basics cable?

To answer that question, [Jon Bruner] fired up an industrial CT scanner to look inside various cables (Nitter), with interesting results. It perhaps comes as little surprise that the premium cable is an Apple Thunderbolt 4 Pro USB-C cable, which sports 40 Gb/s transfer rates and can deliver 100 Watts of power to a device. And it turns out there’s a lot going on with this cable from an engineering and industrial design perspective. The connector shell has a very compact and extremely complex PCB assembly inside it, with a ton of SMD components and at least one BGA chip. The PCB itself is a marvel, with nine layers, a maze of blind and buried vias, and wiggle traces to balance propagation delays. The cable itself contains 20 wires, ten of which are shielded coax, and everything is firmly anchored to a stainless steel shell inside the plastic connector body.

By way of comparison, [Jon] also looked under the hood at more affordable alternatives. None were close to the same level of engineering as the Apple cable, ranging as they did from a tenth to a mere 1/32nd of the price. While none of the cables contained such a complex PCB, the Amazon Basics cable seemed the best of the bunch, with twelve wires, decent shielding, and a sturdy crimped strain relief. The other cables — well, when you’re buying a $3 cable, you get what you pay for. But does that make the Apple cable worth the expense? That’s for the buyer to decide, but at least now we know there’s something in there aside from Apple’s marketing hype.

We’ve seen these industrial CT scanners used by none other than [Ken Shirriff] and [Curious Marc] to reverse engineer Apollo-era artifacts. If you want a closer look at the instrument itself, check out the video below

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Learning About Capacitors By Rolling Your Own Electrolytics

October 24, 2023 by 17 Comments

Ever wonder what’s inside an electrolytic capacitor? Many of us don’t, having had at least a partial glimpse inside after failure of the cap due to old age or crossed polarity. The rest of us will have to rely on this behind-the-scenes demo to find out what’s inside those little aluminum cans.

Perhaps unsurprisingly, it’s more aluminum, at least for the electrolytics [Denki Otaku] rolled himself at the Nippon Chemi-Con R&D labs. Interestingly, both the anode and cathode start as identical strips of aluminum foil preprocessed with proprietary solutions to remove any oils and existing oxide layers. The strips then undergo electrolytic acid etching to create pits to greatly increase their surface area. The anode strips then get anodized in a solution of ammonium adipate, an organic acid that creates a thin aluminum oxide layer on the strip. It’s this oxide layer that actually acts as the dielectric in electrolytic capacitors, not the paper separator between the anode and cathode strips.

Winding the foils together with the paper separator is pretty straightforward, but there are some neat tricks even at the non-production level demonstrated here. Attachment of lead wires to the foil is through a punch and crimp operation, and winding the paper-foil sandwich is actually quite fussy, at least when done manually. No details are given on the composition of the electrolyte other than it contains a solvent and an organic acid. [Denki] took this as an invitation to bring along his own electrolyte: a bottle of Coke. The little jelly rolls get impregnated with electrolyte under vacuum, put into aluminum cans, crimped closed, and covered with a heat-shrink sleeve. Under test, [Denki]’s hand-rolled caps performed very well. Even the Coke-filled caps more or less hit the spec on capacitance; sadly, their ESR was way out of whack compared to the conventional electrolyte.

There are plenty more details in the video below, although you’ll have to pardon the AI voiceover as it tries to decide how to say words like “anode” and “dielectric”; it’s a small price to pay for such an interesting video. It’s a much-appreciated look at an area of the industry that few of us get to see in detail.

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Hackaday Links: October 22, 2023

October 22, 2023 by 9 Comments

The second of three major solar eclipses in a mere six-year period swept across the United States last week. We managed to catch the first one back in 2017, and still have plans for the next one in April of 2024. But we gave this one a miss, mainly because it was “just” an annular eclipse, promising a less spectacular presentation than a total eclipse.

Looks like we were wrong about that, at least judging by photographs of last week’s “Ring of Fire” eclipse. NASA managed to catch a shot of the Moon’s shadow over the middle of the US from the Deep Space Climate Observer at Lagrange Point 1. The image, which shows both the compact central umbra of the shadow and the much larger penumbra, which covers almost the entire continent, is equal parts fascinating and terrifying. Ground-based photographers were very much in the action too, turning in some lovely shots of the eclipse. We particularly like this “one-in-a-million” shot of a jet airliner photobombing the developing eclipse. Shots like these make us feel like it was a mistake to skip the 10-hour drive to the path of annularity.

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Stage Lighting Hack Keeps La Bohème From Becoming A Dumpster Fire

October 22, 2023 by 20 Comments

With all due respect to the Utah Opera’s production of La bohème, we just couldn’t resist poking a little fun at master electrician [David Smith]’s quick lighting hack for the opera. And who knew an opera from 1896 would need a garbage can fire? Live and learn.

In what appears to be a case of “The show must go on,” [David] was called on to improve an existing fire effect for one scene in the opera, which was reportedly a bit “artificial and distracting.” This is a pretty common problem in live productions of all types; it’s easy to throw light at a problem, but it’s often hard to make it both convincing and unobtrusive. Luckily, he had both the time to come up with something, and a kit full of goodies to make it happen. A balled-up strip of Neopixels provided the light, with an Arduino running some simple code to randomize the intensity and color of the RGBs. [David] stuck with the warm white, red, and green colors, to keep the color temperature about right for a fire, and drove the LEDs with a couple of MOSFETs that he keeps in his kit to fix busted dimmer packs.

The overall effect worked well, but the holes knocked in the side of the greatly abused garbage can let too much light out, making the effect distracting on stage. The remedy was simple: a cylinder of printer paper surrounding the LED tape. The paper not only acted as a diffuser but held the tape in place inside the can. The electrical crew ran two circuits to the can — one to keep the Arduino running throughout the show, and one to power the LED tape. The former made sure the audience didn’t see the microcontroller boot sequence, and the latter gave the electrician a way to control the effect from the dimmer console. The brief video below shows it in action during a rehearsal.

Hats off to [David] and the whole crew for the stagecraft heroics and for getting this thrown together so quickly.

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Junk Bin Cyberdish Turns You Into The Satellite Tracker

October 21, 2023 by 3 Comments

The good thing about listening in on satellites is that they tend to beam down all kinds of juicy information from their lofty perches. The bad thing about satellites is that to stay in those orbits, they’ve got to be moving really fast, and that means that you’ve got to track them if you want to keep a nice consistent signal during a pass. And that can lead to all sorts of complexity, with motorized two-axis mounts and fancy tracking software.

Or does it? Not if you’re willing to act as the antenna mount, which is the boat [Gabe] from the saveitforparts channel on YouTube recently found himself in when searching for L-band signals from the GOES satellite. His GOES setup uses a 30″ (0.8 m) dish repurposed from a long-range wireless networking rig. Unfortunately, the old security camera pan-tilt unit it was mounted on wasn’t quite up to satellite tracking duty, so [Gabe] pulled the dish off and converted it to manual tracking.

With a freshly wound helical antenna and a SAWbird LNA at the focal point, the dish proved to be pretty easy to keep on track manually, while providing quite the isometric workout. Aiming was aided by an app called Stellarium which uses augmented reality to point out objects in the night sky, and a cheap tablet computer was tasked with running SDR++ and capturing data. Sadly, neither of these additions brought much to the party, with the latter quickly breaking and the former geared more toward stargazing than satellite snooping. But with some patience — and some upper-body strength — [Gabe] was able to track GOES well enough with the all-in-one “cyberdish” to get some usable images. The whole saga is documented in the video after the break.

Kudos to [Gabe] for showing us what can be accomplished with a little bit of junk and a lot of sticktoitiveness. He promises that a legit two-axis mount is in the works, so we’ll be on the lookout for that. We’ve seen a few of those before, and [Chris Lott] did a great overview of satellite tracking gear a while back, too.

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Simple Circuit Keeps Process Control Loops In Tune

October 19, 2023 by 7 Comments

Spare a moment’s pity for the process engineer, whose job it is to keep industrial automation running no matter what. These poor souls seem to be forever on call, fielding panicked requests to come to the factory floor whenever the line goes down. Day or night, weekends, vacations, whatever — when it breaks, the process engineer jumps.

The pressures of such a gig can be enormous, and seem to have weighed on [Tom Goff] enough that he spent a weekend building a junk bin analog signal generator to replace a loop calibrator that he misplaced. Two process control signaling schemes were to be supported — the 0 to 10 VDC analog signal, and the venerable 4-20 mA current loop. All that’s needed for both outputs is an Arduino and an LM358 dual op-amp, plus a few support components. The 0-10 V signal starts as a PWM output from the Arduino, with its 0-5 V average amplified by one of the op-amps set up as a non-inverting amp with a gain of 2. With a little filtering, the voltage output is pretty stable, and swings nicely through the desired range — see the video below for that.

The current loop output is only slightly more complicated. An identical circuit on a separate Arduino output generates the same 10 V max output, but a code change limits the low end of the range to 1 V. This output of the op-amp is fed through a 500-Ω trimmer pot, and the magic of Ohm’s Law results in a 4-20 mA current. The circuit lives on a piece of perf board in a small enclosure and does the job it was built for — nothing fancy needed.

And spoiler alert: [Tom] found the missing loop calibrator — after he built this, of course. Isn’t that always the way?

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