Teardown: D50761 Aircraft Quick Access Recorder

October 15, 2018 by Tom Nardi 37 Comments

Everyone’s heard of the “black box”. Officially known as the Flight Data Recorder (FDR), it’s a mandatory piece of equipment on commercial aircraft. The FDR is instrumental in investigating incidents or crashes, and is specifically designed to survive should the aircraft be destroyed. The search for the so-called “black box” often dominates the news cycle after the loss of a commercial aircraft; as finding it will almost certainly be necessary to determine the true cause of the accident. What you probably haven’t heard of is a Quick Access Recorder (QAR).

While it’s the best known, the FDR is not the only type of recording device used in aviation. The QAR could be thought of as the non-emergency alternative to the FDR. While retrieving data from the FDR usually means the worst has happened, the QAR is specifically designed to facilitate easy and regular access to flight data for research and maintenance purposes. Its data is stored on removable media and since the QAR is not expected to survive the loss of the aircraft it isn’t physically hardened. In fact, modern aircraft often use consumer-grade technology such as Compact Flash cards and USB flash drives as storage media in their QAR.

Through the wonders of eBay, I recently acquired a vintage Penny & Giles D50761 Quick Access Recorder. This was pulled out of an aircraft which had been in service with the now defunct airline, Air Toulouse International. Let’s crack open this relatively obscure piece of equipment and see just what goes into the hardware that airlines trust to help ensure their multi-million dollar aircraft are operating in peak condition.

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The 3D Printed Plotter You Didn’t Know You Needed

October 15, 2018 by Tom Nardi 19 Comments

We’ve been seeing an influx of repurposed 3D printers recently. Thrifty hackers have been leveraging cheap 3D printers as a way to bootstrap their builds, on everything from laser engravers to pick and place machines. There’s nothing wrong with that, and honestly when you can get a cheap 3D printer for less than the cost of the components separately thanks to the economies of scale, you’d be foolish not to.

But there’s still something to be said for the classic RepRap mentality of building things using printed parts and smooth rods. Case in point, the largely 3D printed plotter that [darth vader] sent in for our viewing pleasure. This isn’t somebody sicking a pen on the extruder of their open box Monoprice special, this is a purpose built plotter and it shows. In the video after the break you can see not only how well it draws, but also how large of a work area it has compared to a modified 3D printer.

If you know your way around a 3D printer, most of it should look pretty familiar to you. Using the same GT2 belts, steppers, end stop switches, and linear bearings which are ubiquitous in 3D printers, it shouldn’t be difficult to source the parts to build your own. It even uses a Mega 2560 with RAMPS 1.4 running Marlin 1.1.9 for control.

The biggest difference is the physical layout. Since there’s no heavy hotend or extruder assembly to move around, the plotter has a cantilever design which gives it far greater reach. As it only needs to sightly lift the pen off the paper, there’s no need for a complex Z axis with leadscrews either; a simple servo mounted to the end of the arm is used to raise and lift the pen. We especially like the use of a tape measure as strain relief for his wiring, a fantastic tip that we (and many of you) fell in love with last year.

While it’s hard to beat just tossing a pen onto the business end of your desktop 3D printer in terms of convenience, we think it’s pretty clear from this build that the results don’t quite compare. If you want a real plotter, build a real plotter.

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Trashed TV Gets RGB LED Backlight

October 11, 2018 by Tom Nardi 34 Comments

It might not be obvious unless you’ve taken one apart, but most of the TVs and monitors listed as “LED” are simply LCD panels that use a bank of LEDs to illuminate them from behind. Similarly, what are generally referred to as “LCDs” are LCD panels that use fluorescent tubes for illumination. To get a true LED display with no separate backlight, you need OLED. Confused? Welcome to the world of consumer technology.

With those distinctions in mind, the hack that [Zenodilodon] recently performed on a broken “LED TV” is really rather brilliant. By removing the dead white LED backlights and replacing them with RGB LED strips, he not only got the TV working again, but also imbued it with color changing abilities. Perfect for displaying music visualizations, or kicking your next film night into high gear with a really trippy showing of Seven Samurai.

In the video after the break, [Zenodilodon] starts his RGB transplant by stripping the TV down to its principal parts. The original LEDs were toasted, so they might as well go straight in the bin alongside their driver electronics. But the LCD panel itself was working fine (tested by shining a laser pointer through it to see if there was an image), and the plastic sheets which diffuse the LED backlight were easily salvaged.

With the old LEDs removed, [Zenodilodon] laid out his new strips and soldered them up to the external controller. He was careful to use all white wires, as he was worried colored wires might reflect the white light and be noticeable on the display. After buttoning the TV back up, he went through a few demonstrations to show how the image looked with the white LEDs on, as well as some interesting effects that could be seen when the LEDs are cycling through colors.

The RGB strips don’t light up the display as well as the original backlight did, as there are some obvious dark spots and you can see some horizontal lines where the strips are. But [Zenodilodon] says the effect isn’t too bad in real-life, and considering it was a cheap TV the image quality was probably never that great to begin with.

On the flip side, if you find an LED TV or monitor in the trash with a cracked screen, it might be worth taking it home to salvage its super-bright white LEDs for your lighting projects.

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International Space Station Is Racing The Clock After Soyuz Failure

October 11, 2018 by Tom Nardi 120 Comments

Today’s failed Soyuz launch thankfully resulted in no casualties, but the fate of the International Space Station (ISS) is now in question.

Just two minutes after liftoff, the crew of the Soyuz MS-10 found themselves in a situation that every astronaut since the beginning of the manned space program has trained for, but very few have ever had to face: a failure during launch. Today the crew of two, Russian Aleksey Ovchinin and American Nick Hague, were forced to make a ballistic re-entry into the Earth’s atmosphere; a wild ride that put them through higher G forces than expected and dropped the vehicle approximately 430 km from the launch site in Baikonur. Both men walked away from the event unharmed, but while the ordeal is over for them, it’s just beginning for the crew of the ISS.

Until a full investigation can be completed by Roscosmos, Russia’s space agency, the Soyuz rocket is grounded. This is standard procedure, as they obviously don’t want to launch another rocket and risk encountering the same issue. But as the Soyuz is currently the only way we have to get humans into space, this means new crew can’t be sent to the ISS until Roscosmos is confident the issue has been identified and resolved.

Soyuz MS-11, which would have brought up three new crew members to relieve those already on the Station, was scheduled for liftoff on December 20th. While not yet officially confirmed, that mission is almost certainly not going to be launching as scheduled. Two months is simply not long enough to conduct an investigation into such a major event when human lives are on the line.

The failure of Soyuz MS-10 has started a domino effect which will deprive the ISS of the five crew members which were scheduled to be aboard by the end of 2018. To make matters worse, the three current crew members must return to Earth before the end of the year as well. NASA and Roscosmos will now need to make an unprecedented decision which could lead to abandoning the International Space Station; the first time it would be left unmanned since the Expedition 1 mission arrived in November 2000.

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The Crustacean Battle Bot Of Your Nightmares

October 11, 2018 by Tom Nardi 10 Comments

We’ve all seen a movie or TV show that got our imagination going, and the more studious of us might get fired up over a good book (one without pictures, even). You never know were inspiration might come from, which is why it’s so hard to track down in the first place. But one place we don’t often hear about providing many hackers with project ideas is the grocery store. But of course the more we learn about [Michael Kohn], the more we realize he’s got a very unique vision.

On a recent trip to the grocery store, [Michael] saw a two pack of frozen lobsters and thought they would make fine battling robots. You know, as one does. Unfortunately the process of taking a frozen lobster and turning it into a combat droid (which incidentally does include eating the thing at some point in the timeline) ended up being so disgusting that he only finished one of them. Whether that makes this poor fellow the winner or loser though…that’s a question that will require some contemplation.

The first step was cooking and eating the beast, and after that came cleaning the shell of as much remaining meat and innards as possible. He then baked it in a toaster oven for 40 minutes and let it sit for a couple of days to make sure it didn’t have any residual smell. Once he confirmed the shell was clean, he glued it back together and got started on mounting it to his hardware.

A wooden frame under the lobster holds the dual HD-1711MG mini servos that power the karate chop action of the claws, as well as the electronics. [Michael] used a ATtiny85 and NTD4963N MOSFETs to make a basic RC platform which responds to IR from a Syma S107 toy helicopter controller. He tried to power everything with AAA and then AA batteries, but found they just didn’t give him the juice he needed once the bot got going. So the final version utilizes a 5 V regulator and a standard RC 7.2v LiPO battery pack.

If you’re not big on shellfish, never fear. He’s created similar roving contraptions based around sausages and carrots too. One could say he’s truly a man of refined…taste.

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Recovering Data From A Vintage MFM Drive

October 10, 2018 by Tom Nardi 53 Comments

Even if you aren’t a vintage computer aficionado, you’re probably aware that older computer hard drives were massive and didn’t hold much data. Imagine a drive that weighs several pounds, and only holds 1/1000th of what today’s cheapest USB flash drives can. But what you might not realize is that if you go back long enough, the drives didn’t just have lower capacity, they utilized fundamentally different technology and relied on protocols which are today little more than historical footnotes.

A case in point is the circa 1984 Modified Frequency Modulation (MFM) drive which [Michał Słomkowski] was tasked with recovering some files from. You can’t just pop this beast into a USB enclosure; copying files from it required an interesting trip down computing’s memory lane, with a sprinkling of modern techniques that are sure to delight hackers who still like to dip their toes into the MS-DOS waters from time to time.

The drive, a MiniScribe 2012, has its own WD1002A-WX1 8-bit ISA controller card. [Michał] is the kind of guy who just so happens to have an ISA-compatible AT motherboard laying around, but he didn’t have the correct cooler for its Pentium processor. He stuck a random heatsink down onto it with a rubber band and set the clock speed as low as possible, which worked well enough to get him through the copying process.

Not wanting to fiddle with floppies, [Michał] then put together a setup which would let him PXE boot MS-DOS 6.22 under Arch Linux. He used PXELINUX, part of the syslinux package, and created an entry for DOS in the configuration file under the pxelinux.cfg directory. He then installed netboot which combines a DHCP and TFTP server into one simple package, and configured it for the MAC address of the AT machine’s 3com 3C905C-TXM network card.

With the hardware and operating system up and running, it was just a matter of getting the files off of the MFM drive and onto something a bit more contemporary. He tried to copy them to a secondary IDE drive, but it seemed there was some kind of conflict as both drives wouldn’t operate at the same time. So he pulled another solution from his bag of tricks: using a USB mass storage device on MS-DOS. By emulating a SCSI drive, he was able to get a standard flash drive plugged into a PCI USB card working, which ultimately dragged these ~35 year old files kicking and screaming into the 21st century.

We love keeping old hardware alive here at Hackaday, and documented methods to not only PXE boot DOS but use USB storage devices when you get it up and running will hopefully inspire some more hackers to blow the dust off that old 386 in the attic.

3D Printed Catamaran Eats Benchy’s Lunch

October 10, 2018 by Tom Nardi 18 Comments

If we’ve learned anything, it’s that 3D printers are exceptionally well suited to printing little boats. According to the Internet, 3D printers are at their best when pumping out cute PLA boats in all the colors of the rainbow; perfect for collecting dust on a shelf somewhere. Ask not what your Benchy can do for you, ask what you can do your Benchy.

But this 3D printed boat isn’t so cute and cuddly. In fact, it’s an absolute beast. Built by [Wayne Andrews], this nearly meter long 3D printed racing catamaran looks more Batman than Popeye. In the video after the break you can see a recent run of the boat on the lake, and we think you’ll agree it definitely has the performance to back up its fierce looks.

Impressively, the hull isn’t printed out of some expensive high-tech filament. It’s the cheapest PLA [Wayne] could get his hands on, and glued together with nothing more exotic than Loctite Super Glue Gel. The secret is the internal “West System” fiberglass cloth and resin work, which is the same stuff used on real boat hulls. It took about 5 days of continuous printing to produce all the pieces needed to assemble the hull, which is a scaled up version of a design by [Thomas Simon].

The internal layout is about what you’d expect in a fast RC boat. It’s running on a 1900 Kv motor powered by dual 6S batteries and a water cooled 180 A Seaking ESC which provides 5 BHP to the Octura x452 propeller. On the business end of his boat, [Wayne] used a commercial aluminum strut and rudder unit. Running gear printed out of something strong like nylon would be an interesting experiment, but perhaps a tall order for this particular motor.

We recently covered a 3D printed jet boat that’s no slouch either, but if you’re looking for a more relaxed ride you could always 3D print a FPV lifeboat.

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