Author: Navarre Bartz

247 Articles

A long, skeletal neck of a swan automaton sits on a table. Two men are on either side of it, lowering the swan's body back on.

Restoring The Silver Swan Automaton

November 18, 2023 by 15 Comments

It’s easier than ever to build your own robot, but humans have been building automatons since before anyone had even thought of electronics. One beautiful example is the Silver Swan, built in the 18th century.

The brainchild of [John Joseph Merlin] and silversmith [James Cox], the swan features three separate clockwork drives, appearing to swim in a moving river where it snatches fish in its motorized beak. Mark Twain said the swan had “a living grace about his movements and living intelligence in his eyes” when he saw it at the International Exhibition in Paris in 1867.

The swan has been delighting people for 250 years, and recently received some much-deserved maintenance. In the video below, you can see museum staff disassembling the swan including its 113 neck rings which protect the three different chain drives controlling its lifelike motions. Hopefully, with some maintenance, this automaton will still be going strong in 2273.

If you’d like to Bring Back the Age of Automatons, perhaps you should study this bird bath or the “Draughtsman-Writer.”

Continue reading “Restoring The Silver Swan Automaton” →

A large, teardrop-shaped van with a wide, friendly face sits in a grassy field. A grey canvas pop top is opened on its top and solar panels extend from either side of its roof, making it look somewhat like a large insect with wings extended.

An Off-Grid EV Camper Van

November 14, 2023 by 34 Comments

Despite our predilection for creature comforts like electricity, it can be nice to get away from it all from time-to-time. Students from Eindhoven University of Technology developed Stella Vita to let you glamp from the power of the sun alone.

Solar-powered vehicles have been plying the highways for decades, but we’re only now getting vehicles with multiple seats that could potentially be used for transport outside of protected race conditions. While production vehicles that can charge off the sun are yet to appear in any appreciable numbers, universities are continuing to push the envelope of what’s possible in a solar car.

Stella Vita is a whale shark-esque camper van designed to be as aerodynamic as possible while still housing all the accoutrements one would want when car camping including a large bed, inductive cooktop, fridge, shower, sink, toilet, and standing room via a pop top. The 2 kW solar array expands to 4 kW when parked via two wings extending from the pop top that also function as awnings for your base camp. By keeping the car lightweight (1,700 kg or 3,700 lb) and aerodynamic, it can go about 600 km (370 mi) on a single charge with its 60 kWh battery.

While it’s still experimental, the team took Stella Vita on a road trip of 3,000 km (1,900 mi) to the south of Spain and were able to get there with only a couple charging stops to account for technical difficulties. A full charge on solar alone takes 2-3 days, which we can see being a convenient amount of time to stop in one spot for your outdoor adventures before heading home or to your next destination.

If you want to build a slightly smaller off-grid camper that’s fueled by coffee instead, you might want to check out this bike camper or this other example.

Continue reading “An Off-Grid EV Camper Van” →

An ebike motor with the controller cover removed. A number of wires and connectors take up most of the space in the cavity.

Open Brain Surgery For EBikes And EScooters

November 6, 2023 by 7 Comments

Personal Electric Vehicles (PEVs) all contain the same basic set of parts: a motor, a battery, a motor controller, some sensors, and a display to parse the information. This simplicity allowed [casainho] to develop a custom controller setup for their own PEVs.

Built around the venerable VESC motor controller, [casainho]’s addition is the EBike/EScooter board that interfaces the existing motor of a device to the controller. Their ESP32-powered CircuitPython solution takes the sensor output of a given bike or scooter (throttle, cadence, or torque) and translates it into the inputs the controller uses to set the motor power.

They’ve also designed an ESP32-based display to interface the rest of the system to the user while riding. Since it also runs CircuitPython, it’s easy to reconfigure the functions of the three button device to display whatever you’d like as well as change various drive modes of your system. I know I’d love to see my own ebikes have a different mode for riding on road versus on shared paths since not getting run over by cars and not harassing pedestrians aren’t going to have the same power profile.

If you want to find more ways to join the PEV revolution, check out this wild omni-wheeled bike or this solar car built from two separate e-bikes. If that doesn’t suit your fancy, how about an off-label use for an e-bike battery to power your laptop off grid?

A woman with a black vest and pink shirt with curly hair stands behind a podium in front of a projected presentation. She is speaking and has her hands moving in a vague guesture.

Supercon 2022: Carrie Sundra Discusses Manufacturing On A Shoestring Budget

October 31, 2023 by 2 Comments

Making hardware is hard. This is doubly true when you’re developing a niche hardware device that might have a total production run in the hundreds of units instead of something mass market. [Carrie Sundra] has been through the process several times, and has bestowed her wisdom on how not to screw it up.

The internet is strewn with the remains of unfulfilled crowdfunding campaigns for tantalizing devices that seemed so simple when they showed of the prototype. How does one get something from the workbench into the world without losing their life savings and reputation?

[Sundra] walks us through her process for product development that has seen several products successfully launch without an army of pitchfork-wielding fiber crafters line up at her door. One of the first concepts she stresses is that you should design your products around the mantra, “Once it leaves your shop IT SHOULD NEVER COME BACK.” If you design for user-serviceability from the beginning, you can eliminate most warranty returns and probably make it easier to manufacture your widget to boot. Continue reading “Supercon 2022: Carrie Sundra Discusses Manufacturing On A Shoestring Budget” →

Two hands hold an electric motor rotor and a 3D printed coil structure next to each other. A multimeter in the background displays 297.0 mV.

ModuCoil – A Modular Coil For Motor And Generator Projects

October 2, 2023 by 2 Comments

While renewable energy offers many opportunities for decentralizing energy production, it can sometimes feel that doing so on a truly local level remains unachievable with increasingly large utility-scale deployments re-centralizing the technology. [AdamEnt] hopes to help others seize the means of energy production with the development of the ModuCoil.

This modular coil is intended to be used in motor and generator applications, and features a 3D printed structure to wind your copper about as well as a series of ferromagnetic machine screws and nuts meant to boost the field strength. This project really emphasizes the rapid part of rapid prototyping with this version 2 of the coil following only a week after the first.

[AdamEnt] only reached a peak of ~600 mV in the short test of a single coil, but is optimistic the current design could hit 1V/coil given a fully wound coil actually affixed to something instead of just held in his hand. It’s definitely early stages, but we think this could be the start of an interesting ecosystem of motor and generator designs.

If you want to learn more about how those big wind turbines work, look here, or you could check out a 3D printed brushless motor, or where all that copper comes from anyway.

Continue reading “ModuCoil – A Modular Coil For Motor And Generator Projects” →

Two men in black shirts stand between a white and a blue exercise bike sitting on a table in front of them. The exercise bikes have black drums slightly larger than a coffee can affixed to the front of the bike which houses the shredding mechanism. In the background is a "Precious Plastics Torino" circular logo.

Getting Shredded Plastic…and Legs

September 23, 2023 by 10 Comments

While electric motors have taken the drudgery out of many tasks, human power has its advantages. [Precious Plastic Torino] has developed a human-powered plastic shredder for those times when an electric motor just won’t do.

Designed primarily for educational purposes at venues where electricity can be difficult to source, but also useful for off-grid environments, this exercise bike-based shredder can take small pieces of plastic and shred them into tiny pieces suitable for use with any of the other machines in the Precious Plastics ecosystem like their injection molding machine. As with all [Precious Plastics] projects, the files are will be open source; however, there is a six month exclusivity period for Patreon subscribers to help fund development efforts.

The build is relatively simple: take an old exercise bike, remove the unnecessary bits, and run the chain up to drive a shredding mechanism mounted on the front of the bike. We think they should’ve kept the flywheel to help keep the momentum going while shredding but can’t fault them for wanting to keep the prototype as simple as possible. Maybe the next step is getting these in spin classes around the country so people can get their exercise and help recycle in their community at the same time!

If this shredder doesn’t suit your fancy, maybe recycle your plastic with SHREDII or this other DIY effort. If you’d rather generate electricity on your exercise bike, then try building this bike generator.

Continue reading “Getting Shredded Plastic…and Legs” →

A silver front loader cargo bike sits in a parking lot in front of an electric vehicle charger. A cable runs from the charger to the bike.

Fast Charging A Cargo Bike From An Electric Car Charger

September 18, 2023 by 15 Comments

Fast charging is all the rage with new electric cars touting faster and faster times to full, but other EVs like ebikes and scooters are often left out of the fun with exceedingly slow charging times. [eprotiva] wanted to change this, so he rigged up a fast charging solution for his cargo bike.

Level 2 electric vehicle chargers typically output power at 7 kW with the idea you will fill up your electric car overnight, but when converted down to 60 V DC for a DJI Agras T10 battery, [eprotiva] is able to charge from 20% to 100% capacity in as little as 7 minutes. He originally picked this setup for maxing the regen capability of the bike, but with the high current capability, he found it had the added bonus of fast charging.

The setup uses a Tesla (NACS) plug since they are the most plentiful destination charger, but an adapter allows him to also connect to a J1772 Type 1 connector. The EV charging cable is converted to a standard 240 V computer cable which feeds power to a drone charger. This charger can be set to “fast charge” and then feeds into the battery unit. As an added bonus, many chargers that do cost money don’t start charging until after the first five minutes, so the bike is even cheaper to power than you’d expect.

For some reason, you can watch him do this on TikTok too.

If you too want to join the Personal EV Revolution, be sure to checkout how to choose the right battery for your vehicle and a short history of the Segway.