Riding Mower Repair Uncovers Miniature Culprit

June 4, 2021 by 62 Comments

Most people would be pretty upset it the lawn mower they spent $4,000 USD on had a major failure within the first year of owning it. But for [xxbiohazrdxx], it was an excuse to take a peek under the hood and figure out what brought down this state-of-the-art piece of landscaping gear.

It should be said that, at least technically, the Husqvarna TS 348XD in question was still working. It’s just that [xxbiohazrdxx] noticed the locking differential, which is key to maintaining traction on hilly terrain, didn’t seem to be doing anything when the switch was pressed. Since manually moving the engagement lever on the transmission locked up the differential as expected, the culprit was likely in the electronics.

Testing the dead actuator.

As [xxbiohazrdxx] explains, the switch on the dash is connected to a linear actuator that moves the lever on the transmission. The wiring and switch tested fine with a multimeter, but when the actuator was hooked up to a bench power supply, it didn’t move. Even more telling, it wasn’t drawing any power. Definitely not a good sign. Installing a new actuator would have solved the problem, but it was an expensive part that would take time to arrive.

Repairing the dead actuator seemed worth a shot at least, so [xxbiohazrdxx] cracked it open. The PCB looked good, and there were no obviously toasted components. But when one of the internal microswitches used to limit the travel of the actuator was found to be jammed in, everything started to make sense. With the switch locked in the closed position, the actuator believed it was already fully extended and wouldn’t move. After opening the switch itself and bending the contacts back into their appropriate position, everything worked as expected.

A tiny piece of bent metal kept this $4,000 machine from operating correctly.

As interesting as this step-by-step repair process was, what struck us the most is [xxbiohazrdxx]’s determination to fix rather than replace. At several points it would have been much easier to just swap out a broken part for a new one, but instead, the suspect part was carefully examined and coaxed back to life with the tools and materials on-hand.

While there’s plenty of folks who wouldn’t mind taking a few days off from lawn work while they wait for their replacement parts to arrive, not everyone can afford the luxury. Expedient repairs are critical when your livelihood depends on your equipment, which is why manufacturers making it harder and more expensive for farmers to fix their tractors has become such a major issue in right to repair battles all over the globe.

Home Automation Controller Uses Chalk

June 4, 2021 by 10 Comments

Responding to the Rethink Displays challenge of the 2021 Hackaday Prize contest, freelance design engineer [Rick Pannen] brings a retro look to his DIY home automation controller. You could be forgiven for not even realizing it is a controller at first glance. [Rick] built this using a magnetic chalk board and installed all the control electronics on the back. The main processor is a Raspberry Pi 400 running Raspian with IOBroker and Node-Red. Panel lettering and graphics are done free-hand with, you guessed it, chalk.

The controls on this panel are an eclectic hodgepodge of meters, switches, and sensors that [Rick] scored on eBay or scavenged from friends. We are curious about the simple-looking rotary dial that sends a pulse train based on the number set on the dial — this seems to have all the functionality of an old phone’s rotary dial without any of the fun.

But [Rick]’s design allows for easy changes — dare we say, it encourages them — so maybe we’ll see a salvaged rotary dial added in future revisions. Also note the indoor lighting ON/OFF switch that must be a real joy to operate. We wonder, is there any way the controls could be magnetized and moved freely around the board without permanently attaching them? Maybe an idea for version 4 or 5.

This design has a lot of possibilities, and we look forward to any upgrades or derivative versions of this unique home automation controller. Let us know in the comments below if you have any suggestions for expanding upon this idea.

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ShakeAlert Promises Earthquake Early Warning Of About 10 Seconds

June 4, 2021 by 15 Comments

Earthquakes are highly destructive when they strike, and unlike many other natural disasters, they often hit with minimal warning. Unlike hurricanes and floods, and even volcanoes to an extent, earthquakes can be very difficult to predict. However, in recent decades, warning networks have proliferated around the world, aiming to protect affected communities from the worst outcomes in the event of a large tremor.

ShakeAlert is the name of the earthquake monitoring project run by the United States Geological Survey, which has just announced that it now offers early warning services to the entire west coast of the United States. Let’s take a look at how earthquake monitoring works, how that feeds into early warnings, and how this can make a difference in the case of a major quake.

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Hackaday Podcast 121: Crazy Bikes, DIY Flip Dots, EV Mountain Climbing, And Trippy Tripterons

June 4, 2021 by 3 Comments

Hackaday editors Mike Szczys and Elliot Williams discuss a great week of hardware hacks. Two delightful mechanical hacks focus on bicycles: one that puts a differential on the front fork, and the other a flywheel between the knees. Elliot was finally impressed by something involving AI — a machine-learning guitar pedal. You’ve heard of a delta bot? The tripteron is similar but with a single rail for the three arms. After a look at flip dots, tiny robots, and solar air planes we close the show geeking out about racing electric vehicles up a hill and stories of the hardware that has made closed captions possible.

Take a look at the links below if you want to follow along, and as always, tell us what you think about this episode in the comments!

Direct download (55 MB or so.)

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Give 3D Printed Plastic A Well-Worn Metal Look

June 4, 2021 by 13 Comments

Affordable 3D printers let us turn ideas into physical reality without a big expensive workshop, but with their power came some disadvantages. The nature of FDM printers impart layer lines and nozzle ridges in the parts they produce. They can be minimized with optimized print settings, but never eliminated. [Emily Velasco] loves the power of 3D printing but not how the parts look. So she put in the effort to make 3D-printed plastic look like distressed metal and showed us how she did it. (Video also embedded after the break.)

This video is a follow-up to her Pet Eye project in response to feedback on Twitter. She had mentioned that the  salvaged metal box for Pet Eye wasn’t quite big enough to hold everything, so she had to extend its internal volume with a 3D print box on the back. It fit in so well that the offhand comment surprised many people who wanted to know more about how it was done. So she designed a demonstration cube covered with mechanical characteristics, and gave us this walkthrough of its transformation.

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This Week In Security: Ransomware, WeLock, And Amazon Arbitration

June 4, 2021 by 9 Comments

Another week of ransomware, and this time it’s the beef market that’s been shut down, due to a crippling infrastructure attack out of Russia — but hold up, it’s not that simple. Let’s cover the facts. Some time on Sunday, May 30, JBS USA discovered a ransomware attack against their systems. It seems that their response team did exceptionally well, pulling the plug on affected machines, and starting recovery right away. By Wednesday, it was reported that most of their operations were back in action.
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Soldering Iron Plus Camera Gimbal Helps Cancel Out Hacker’s Hand Tremors

June 4, 2021 by 39 Comments

Soldering requires steady hands, so when [Jonathan Gleich] sadly developed a condition called an essential tremor affecting his hands, soldering became much more difficult. But one day, while [Jonathan] was chatting with a friend, they were visited by the Good Ideas Fairy and in true hacker fashion, he ended up repurposing a handheld camera stabilizing gimbal to hold a soldering iron instead of a camera or smartphone. Now instead of the gimbal cancelling out hand movements to keep a camera steady, it instead helps keep a soldering iron steady.

While the inner workings of the cheap gimbal unit didn’t need modification, there were a couple of things that needed work before the project came together. The first was to set up a way to quickly and easily connect and disconnect the soldering iron from the gimbal. Thanks to a dovetail-like connector, the iron can be safely stored in its regular holster and only attached when needed.

The other modification is more subtle. The stabilizer motors expect to be managing something like a smartphone, but a soldering iron is both lighter and differently balanced. That meant that the system worked, but not as well as it needed to. After using some small lead weights to tweak the mass and center of gravity of the soldering iron — making it feel and move a bit more like an iPhone, as far as the gimbal was concerned — results were improved.

The soldering iron stabilizer works well enough for now, but we don’t doubt that [Jonathan] already has further tweaks in mind. This is a wonderful repurposing of a consumer device into an assistive aid, so watch it in action in the short video embedded below.

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