Author: Dan Maloney

3283 Articles

Just How Dodgy Are Cheap USB Chargers Anyway?

November 3, 2023 by 49 Comments

Aside from apparently having both the ability to reproduce on their own and simultaneously never being around when you need one, USB chargers seem innocuous enough. The specs are simple: convert mains voltage to 5 volts, and don’t kill anyone while doing it. Both specs are typically met by most designs, but judging by [DiodeGoneWild]’s latest USB charger teardown, the latter only just barely, and with a whole lot of luck.

The sad state of plug-in USB power supplies is one of [DiodeGoneWild]’s pet gripes, and deservedly so. Most USB chargers cram a lot of electronics into a mighty small volume, and are built to a price point, meaning that something has to give in the design. In the case of the two units he tears apart in the video below, it’s pretty clear where the compromises are. Neither unit met the specs on the label in terms of current supplied and voltage regulation, even the apparently more capable quick charger, which is the first to go under the knife. The PCB within holds some alarming surprises, like the minimal physical isolation between the mains part of the circuit and the low-voltage section, but the real treat is the Schottky diode that gets up to 170°C under full load. Safety tip: when you smell plastic burning, throw the thing out.

The second charger didn’t fare any better; although it didn’t overheat, that’s mainly because it shut itself off before it could deliver a fraction of its rated 1 amp output. The PCB construction was shoddy in the extreme, with a squiggly trace standing in for a proper fuse and a fraction of a millimeter separation between primary and secondary traces. The flyback transformer was a treat, too; who doesn’t want to rely on a whisper-thin layer of cheap lacquer to keep mains voltage out of your phone?

All in all, these designs are horrible, and we have to thank [DiodeGoneWild] for the nightmares we’ll have whenever we plug into one of these things from now on. On the other hand, this was a great introduction to switch-mode power supply designs, and what not to do with our own builds. Continue reading “Just How Dodgy Are Cheap USB Chargers Anyway?” →

Big Red Button Puts Toddler In Command Of Chromecast

November 3, 2023 by 12 Comments

Controversial position: the world needs more buttons. We’ve gotten so far away from physical interfaces like buttons, knobs, and switches in favor of sleek but sterile touch-screen “controls” that when we see something like this big red button so toddlers can start a TV show, we just have to latch onto the story and see what it’s all about.

As it turns out, the big red button itself is probably the least interesting part of [Mads Chr. Olesen] build. The real meat of the project is the reverse engineering effort needed to get Chromecast to start the show. As [Mads] explains, once upon a time a simple GET request to a URL was all it took to do so, but no more; Google has repeatedly nerfed the Chromecast API over the years, enough that [Mads] had some digging to do.

Luckily, pyChromecast is a thing, but using it for DRTV, a streaming service of the Danish Broadcasting Corporation, required figuring out the AppID of the DRTV app. It looks like [Mads] used Wireshark to sniff traffic to and from the Chromecast, and netlog-viewer to analyze the capture. That and a little Developer Tools action in Chrome led to all the information needed to modify pyChromecast to support DRTV. The rest of the project consisted of building a box for the huge red arcade button and wiring it up to a Wemos D1. A Raspberry Pi actually talks to the Chromecast, and now the toddler is able to call up his favorite show and pause and restart it at will, no parent required.

We appreciate the reverse engineering heroics [Mads] displays here, which provide good general lessons for other purposes. It’s been a while since we’ve seen a Chromecast physical interface build, too, so we appreciate the refresher.

Partial Relay-Based Calculator Puts The Click Where It Counts

November 3, 2023 by 15 Comments

It looks like [Michal Zalewski] is raising the next generation the right way. First, his eldest son asks for help building a one-bit computer from discrete transistors. Not to be left behind, his little brother then asked for help with an even more retro project, which resulted in this partially relay-based calculator. Maybe there is some hope for the future.

Now, purists will no doubt notice the ATmega64 microcontroller sitting in the middle of the main PCB on this project and cry “Foul!” But perfect is the enemy of done, and as [Michal] explains, at $6 a pop for the Omron relays he and his son chose, there’s only so far you can go with relay logic before you’re taking out a second mortgage. So the relays are limited to the ALU of the calculator, along with the drivers for the six seven-segment LED displays. The microcontroller is just there for housekeeping functions like scanning the keyboard and decoding digits. All the actual calculations are in the relay logic, not silicon. And we’d be remiss not to praise his son’s stylistic choices for this design — that it uses relays with clear covers, and that it has single-sided PCBs with curvy, hand-drawn traces traces that look hand-drawn on old-school yellow substrate. [Michal]’s heart must swell with pride to have fathered someone with such exquisite taste.

For his part, [Mikal] did some really good documentation for this build, including excellent descriptions of Boolean math with half- and full-adders and how relays are used to create the basic logic gates that comprise them. The calculator itself is still a work in progress, with microcontroller code still in development, but it’s working enough that you can enjoy the display driver’s clickiness in the video below. If that doesn’t do it for you, we’ve got other relay calculators to scratch that click itch. Continue reading “Partial Relay-Based Calculator Puts The Click Where It Counts” →

Pocketable Yagi Antenna Really Shoots For Distance

November 2, 2023 by 45 Comments

For amateur radio operators, the quest for the perfect antenna never seems to end. Perhaps that’s because our requirements are always changing. We never quite seem to get to one design that can do everything. This copper-foil Yagi antenna might not do everything, but it really seems to tick off the boxes for gain and directionality along with ultra-portability.

If you’ve been following [Ben Eadie (VE6SFX)]’s trip down the rabbit hole of lightweight antenna building, you’ll recall that he’s already knocked off a J-pole antenna and a stealthy mobile slot antenna using little more than copper foil tape. Both of those designs performed great, but [Ben] had bigger fish to fry: he wanted to build a directional antenna for the 2-meter band and go for distance. The traditional Yagi-Uda is generally the preferred design for beam antennas, but they tend to be bulky and cumbersome. But with a roll of copper foil tape [Ben] was able to lay out a three-element Yagi on a sheet of Tyvek wrap. Reinforced with some packing tape and stiffened with a couple of fiberglass rods attached to a 3D printed handle, and it was ready to go.

[Ben]’s field test results were most impressive. Not only was he able to open up repeaters up to 90 km away, but he was getting good signal reports to boot. He was even able to reach a repeater 150 km distant, just barely though. Still, that’s mighty impressive performance from something that looks like a Union Jack and rolls up to fit in a pocket.

Continue reading “Pocketable Yagi Antenna Really Shoots For Distance” →

Homebrew TEM Cell Lets You EMC Test Your Own Devices

November 2, 2023 by 14 Comments

Submitting a new device for electromagnetic compatibility (EMC) testing seems a little like showing up for the final exam after skipping all the lectures. You might get lucky and pass, but it really would have been smarter to take a few of the quizzes to see how things were going during the semester. Similarly, it would be nice to know you’re not making any boneheaded mistakes early in the design process, which is what this DIY TEM cell is all about.

We really like [Petteri Aimonen]’s explanation of what a TEM cell, or transverse electromagnetic cell, is: he describes it as “an expanded coaxial cable that is wide enough to put your device inside of.” It basically a cage made of conductive material that encloses a space for the device under test, along with a stripline going down its center. The outer cage is attached to the outer braid of a coaxial cable, while the stripline is connected to the center conductor. Any electric or magnetic field generated by the device inside the cage goes down the coax into your test instrument, typically a spectrum analyzer.

[Petteri]’s homebrew TEM is made from a common enough material: copper-clad FR4. You could use double-sided material, or even sheet copper if you’re rich, but PCB stock is easy to work with and gets the job done. His design is detailed in a second post, which goes through the process of designing the size and shapes of all the parts as well as CNC milling the sheets of material. [Petteri] tried to make the joints by milling part-way through the substrate and bending the sheet into shape, but sadly, the copper didn’t want to cooperate with his PCB origami. Luckily, copper foil tape and a little solder heal all wounds. He also incorporated a line impedance stabilization network (LISN) into the build to provide a consistent 50-ohm characteristic impedance.

How does it work? Pretty well, it seems; when connected to a TinySA spectrum analyzer, [Petteri] was able to find high-frequency conductive noise coming from the flyback section of a switch-mode power supply. All it took was a ferrite bead and cap to fix it early in the prototyping phase of the project. Sounds like a win to us.

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Hackaday Links: October 29, 2023

October 29, 2023 by 22 Comments

“As California goes, so goes the nation.” That adage has been true on and off for the last 100 years or so, and it’s true again now that GM’s Cruise self-driving car unit has halted operations across the United States, just a couple of days after California’s DMV suspended its license to conduct driverless tests on state roadways. The nationwide shutdown of testing was undertaken voluntarily by the company and takes their sore beset self-driving taxi fleet off the road in Phoenix, Houston, Austin, Dallas, and Miami, in addition to the California ban, which seemed to be mainly happening in San Francisco. Cruise’s fleet has suffered all manner of indignities over the last few months, from vandalism to “coning” pranks to even being used as rolling hookup spots, and that’s not to mention all the trouble they caused by brigading to the same address or losing games of chicken with a semi and a firetruck. We’re not sure what to make of all this; despite our somewhat snarky commentary on the company’s woes, we take little pleasure in this development other than to the degree it probably increases roadway safety in the former test cities. We really do want to see self-driving cars succeed, at least for certain use cases, but it seems like this is a case of too much, too soon for the technology we currently have at our disposal.

Continue reading “Hackaday Links: October 29, 2023” →

EcoEDA Integrates Your Junk Bin Into Your Designs

October 28, 2023 by 26 Comments

If you’re like us, there’s a creeping feeling that comes over you when you’re placing an order for parts for your latest project: Don’t I already have most of this stuff? With the well-stocked junk bins most of us sport and the stacks of defunct electronics that are almost always within arm’s length, chances are pretty good you do. And yet, we always seem to just click the button and place a new order anyway; it’s just easier.

But what if mining the treasure in your junk bin was easier? If you knew right at design time that you had something in your stash you could slot into your build, that would be something, right? That’s the idea behind ecoEDA, a Python-based KiCAD plugin by [Jasmine Lu], [Beza Desta], and [Joyce Passananti]. The tool integrates right into the schematic editor of KiCAD and makes suggestions for substitutions as you work. The substitutions are based on a custom library of components you have on hand, either from salvaged gear or from previous projects. The plug-in can make pin-for-pin substitutions, suggest replacements with similar specs but different pinouts, or even build up the equivalent of an integrated circuit from available discrete components. The video below gives an overview of the tool and how it integrates into the design workflow; there’s also a paper (PDF) with much more detail.

This seems like an absolutely fantastic idea. Granted, developing the library of parts inside all the stuff in a typical junk bin is likely the biggest barrier to entry for something like this, and may be too daunting for some of us. But there’s gold in all that junk, both literally and figuratively, and putting it to use instead of dumping it in a landfill just makes good financial and environmental sense. We’re already awash in e-waste, and anything we can do to make that even just a little bit better is probably worth a little extra effort. Continue reading “EcoEDA Integrates Your Junk Bin Into Your Designs” →