MCAS And The 737: When Small Changes Have Huge Consequences

March 14, 2019 by Tom Nardi 164 Comments

When the first 737 MAX entered service in May of 2017, it was considered a major milestone for Boeing. For nearly a decade, the aerospace giant had been working on a more fuel efficient iteration of the classic 737 that first took to the skies in 1967. Powered by cutting-edge CFM International LEAP engines, and sporting modern aerodynamic improvements such as unique split wingtips, Boeing built the new 737 to have an operating cost that was competitive with the latest designs from Airbus. With over 5,000 orders placed between the different 737 MAX variants, the aircraft was an instant success.

But now, in response to a pair of accidents which claimed 346 lives, the entire Boeing 737 MAX global fleet is grounded. While the investigations into these tragedies are still ongoing, the preliminary findings are too similar to ignore. In both cases, it appears the aircraft put itself into a dive despite the efforts of the crew to maintain altitude. While the Federal Aviation Administration initially hesitated to suspend operations of the Boeing 737 MAX, they eventually agreed with government regulatory bodies all over the world to call for a temporary ban on operating the planes until the cause of these accidents can be identified and resolved.

For their part, Boeing maintains their aircraft is safe. They say that grounding the fleet was done out of an “abundance of caution”, rather than in direct response to a particular deficiency of the aircraft:

Boeing continues to have full confidence in the safety of the 737 MAX. However, after consultation with the U.S. Federal Aviation Administration (FAA), the U.S. National Transportation Safety Board (NTSB), and aviation authorities and its customers around the world, Boeing has determined — out of an abundance of caution and in order to reassure the flying public of the aircraft’s safety — to recommend to the FAA the temporary suspension of operations of the entire global fleet of 371 737 MAX aircraft.

Until both accident investigations are completed, nobody can say with complete certainty what caused the loss of the aircraft and their passengers. But with the available information about what changes were made during the 737 redesign, along with Boeing’s own recommendations to operators, industry insiders have started to point towards a fault in the plane’s new Maneuvering Characteristics Augmentation System (MCAS) as a likely culprit in both accidents.

Despite the billions of dollars spent developing these incredibly complex aircraft, and the exceptionally stringent standards their operation is held to, there’s now a strong indication that the Boeing 737 MAX could be plagued with two common issues that we’ve likely all experienced in the past: a software glitch and poor documentation.

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Old Meets New In 3D Printed Telegraph

March 12, 2019 by Tom Nardi 12 Comments

We often think of 3D printing as a way to create specific components in our builds, everything from some hard-to-find little sprocket to a custom enclosure. More and more of the projects that grace the pages of Hackaday utilize at least a few 3D printed parts, even if the overall build itself is not something we’d necessarily consider a “printed” project. It’s the natural progression of a technology which at one time was expensive and complex becoming increasingly available to the maker and hacker.

But occasionally we see 3D printing used not to create new devices, but recreate old ones. A perfect example is the almost entirely 3D printed telegraph system created by [Matt]. Projects like this help bring antiquated technology back to a modern audience, and can be an excellent educational tool. Showing someone a diagram of how the telegraph worked is one thing, but being able to run off a copy on your 3D printer and putting a working model in their hands is quite another.

[Matt] acknowledges that he’s hardly the first person to 3D print a telegraph key, but says that he’d never seen the complete system done before. The key is perhaps the component most people are familiar with from film and old images, but alone it’s really nothing more than a momentary switch. To actually put it to use, you need a telegraph sounder on the receiving end to “play” the messages.

The sounder is a somewhat more complex device than the key, and uses an electromagnet to pull down a lever and produce an audible clicking noise. In the most basic case, the coil is directly connected to the key, but in a modern twist [Matt] has added a MOSFET into the circuit so the electromagnet is triggered locally within the sounder. This prevents sparks from eroding the contacts in the key, and alleviates problems associated with current loss over long wire runs.

We’ve previously seen 3D printing used to revive vintage games which are no longer available such as “The Amazing Dr. Nim”, and how modern techniques such as additive manufacturing can help put World War II aircraft back in the air. While there was never much question that 3D printing would be a big part of our future, it would seem to be taking a fairly active role in preserving our past as well.

No, Your 3D Printer Doesn’t Have A Fingerprint

March 12, 2019 by Tom Nardi 103 Comments

Hackers and makers see the desktop 3D printer as something close to a dream come true, a device that enables automated small-scale manufacturing for a few hundred dollars. But it’s not unreasonable to say that most of us are idealists; we see the rise of 3D printing as a positive development because we have positive intentions for the technology. But what of those who would use 3D printers to produce objects of more questionable intent?

We’ve already seen 3D printed credit card skimmers in the wild, and if you have a clear enough picture of a key its been demonstrated that you can print a functional copy. Following this logic, it’s reasonable to conclude that the forensic identification of 3D printed objects could one day become a valuable tool for law enforcement. If a printed credit card skimmer is recovered by authorities, being able to tell how and when it was printed could provide valuable clues as to who put it there.

This precise line of thinking is how the paper “PrinTracker: Fingerprinting 3D Printers using Commodity Scanners” (PDF link) came to be. This research, led by the University at Buffalo, aims to develop a system which would allow investigators to scan a 3D printed object recovered from a crime scene and identify which printer was used to produce it. The document claims that microscopic inconsistencies in the object are distinctive enough that they’re analogous to the human fingerprint.

But like many of you, I had considerable doubts about this proposal when it was recently featured here on Hackaday. Those of us who use 3D printers on a regular basis know how many variables are involved in getting consistent prints, and how introducing even the smallest change can have a huge impact on the final product. The idea that a visual inspection could make any useful identification with all of these parameters in play was exceptionally difficult to believe.

In light of my own doubts, and some of the excellent points brought up by reader comments, I thought a closer examination of the PrinTracker concept was in order. How exactly is this identification system supposed to work? How well does it adapt to the highly dynamic nature of 3D printing? But perhaps most importantly, could these techniques really be trusted in a criminal investigation?

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ESP8266 Gets Its Game On With Open Source Engine

March 11, 2019 by Tom Nardi 12 Comments

This is likely not to come as much of a shock to you, but the ESP8266 is pretty popular. At this point, we’re more surprised when a project that hits the tip line doesn’t utilize this incredibly cheap WiFi-enabled microcontroller. If you’re making a gadget that needs to connect to the Internet, there’s a good chance some member of the ESP family is going to be a good choice. But is it a one-trick MCU?

Well, judging by software frameworks like the “Little Game Engine” created by [Igor], it looks like the ESP is expanding its reach into offline projects as well. While it might not turn the ESP8266 into a next-gen gaming powerhouse, we’ve got to admit that the demos shown off so far are pretty impressive. When paired with a couple of buttons and a TFT display such as the ILI9341, the ESP could make for a particularly pocket-friendly game system.

The game engine that [Igor] has developed provides the programmer with a virtual screen resolution of 128×128, a background layer, and 32 sprites which offer built-in tricks like collision detection and rotation. All while running at a respectable 20 frames per second. This environment is ideal for the sort of 2D scrolling games that dominated the 8 and 16-bit era of gaming, and as seen in the video after the break, it can even pull off a fairly decent clone of “Flappy Bird”.

In addition, [Igor] created an online emulator and compiler which allows you to develop games using his engine right in your web browser. You can load up a selection of example programs and execute them to see what the engine is capable of, then try your hand at developing your own game before ever having to put the hardware together. Incidentally, the performance of this online development environment is fantastic; with even the fairly complex “Flappy Bird” example code compiling and starting in the emulator nearly instantaneously.

This isn’t the first handheld game we’ve seen powered by the ESP8266, but it would be fair to say this one is a generational leap over its predecessors. Of course, if you really want to start throwing around some pixels, you might want to make the leap to the ESP32; which is the heart of the incredibly awesome (and tiny) PocketSprite.

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The Fine Art Of Restoring Matchbox Cars

March 10, 2019 by Tom Nardi 25 Comments

Did you have anything planned for the next hour or so? No? That’s good because if you’re anything like us, watching even one of the restorations performed on [Marty’s Matchbox Makeovers] is likely to send you down a deep dark rabbit hole that you never knew existed. Even if you can’t tell the difference between Hot Wheels and Matchbox (seriously, that’s a big deal in the community), there’s something absolutely fascinating about seeing all the little tips and tricks used to bring these decades-old toy cars back into like new condition.

Sketching a replacement part to be 3D printed.

You might think that all it takes to restore a Matchbox car is striping the paint off, buffing up the windows, and respraying the thing; and indeed you wouldn’t be too far off the mark in some cases. But you’ve got to remember that these little cars have often been through decades of some of the worst operating conditions imaginable. That is, being the plaything of a human child. While some of the cars that [Marty] rebuilds are in fairly good condition to begin with, many of them look like they’ve just come back from a miniature demolition derby.

The ones which have had the hardest lives are invariably the most interesting. Some of the fixes, like heating up the interior and manually bending the steering wheel back into shape, are fairly simple. But what do you do when a big chunk of the vehicle is simply gone? In those cases, [Marty] will combine cyanoacrylate “super glue” with baking powder to fill in voids; and after filing, sanding, and painting, you’d never know it was ever damaged.

When a car needs more than just paint to finish it off, [Marty] will research the original toy and make new water slide decals to match what it would have looked like originally. If it’s missing accessories, such as the case with trucks which were meant to carry scale cargo, he’ll take careful measurements so he can design and print new parts. With some sanding and a touch of paint, you’d never know they weren’t original.

There’s plenty of arcane knowledge to be gained from folks like [Marty] who have experience with scale models. We don’t often see much of that come our way, but when we do, we’re always impressed at the lengths individuals will go to get that perfect end result. Whether or not you think you’ll find yourself rebuilding a pocket-sized school bus anytime soon, we think there are lessons to be learned from those who might. Continue reading “The Fine Art Of Restoring Matchbox Cars” →

RGB Word Clock Doesn’t Skimp On The Features

March 9, 2019 by Tom Nardi 5 Comments

Like most pieces of technology, word clocks seem to be getting better and better every year. As hackers get their hands on better microcontrollers and more capable LED controllers, these builds not only look more polished, but get improved features and functions. Luckily for us, the rise of these advanced modular components means they’re getting easier to build too. For an example of these parallel traits, look no further than VERBIS by [Andrei Erdei].

This colorful word clock is powered by an ESP8266, a 8×8 RGB LED matrix, and a WS2812 RGB LED controller module. [Andrei] used the diminutive ESP-01 which can plug right into the LED controller, and just needs a 3.3 VDC regulator board to complete the very compact electronics package.

To keep the LEDs from interfering with each other, [Andrei] has designed a 3D printed grid which fits over the matrix board. On top of that goes a piece of paper that has the letters printed on it. He mentions that he was able to get good results printing this “stencil” out on an inkjet printer by simply running the same piece of paper through a few times; picking up more black ink each time it went through. Judging by the sharp characters seen in the video after the break, the trick worked well.

With his hardware put together, [Andrei] turned his attention to the software. We really think the project shines here, as his clock not only supports NTP for automatically setting the time over the Internet, but offers a full web interface to control various functions such as the LED colors. You can even change the NTP server and network configuration right from the UI, which is a nice touch compared to just hard coding the values into the code. Even if you don’t use the same hardware, the open source control software is definitely something you should look into if you’re building your own word clock.

We recently covered another easy to build word clock that used an LED matrix and not a whole lot else, but it was quite tiny. This build is a much more reasonable size for a desk, but you’ll probably need to break out the laser cutter if you want to get much bigger.

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