Otis Boykin’s Precision Passives Propelled The Pacemaker

September 16, 2020 by Kristina Panos 11 Comments

The simplest ideas can be the ones that change the world. For Otis Boykin, it was a new way to make wirewound precision resistors. Just like that, he altered the course of electronics with his ideas about what a resistor could be. Now his inventions are in everything from household appliances and electronics to missile guidance computers.

While we like to geek out about developments in resistor tech, Otis’ most widely notable contribution to electronics is the control unit he designed for pacemakers, which regulate a person’s heartbeat. Pacemakers are a real-time clock for humans, and he made them more precise than ever.

Street Smarts and Book Smarts

Otis Frank Boykin was born August 29th, 1920 in Dallas, Texas to Sarah and Walter Boykin. Otis’ father was a carpenter who later became a preacher. His mother Sarah was a maid, and she died of heart failure when Otis was only a year old.

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Floating Spaceports For Future Rockets

September 14, 2020 by Tom Nardi 36 Comments

While early prototypes for SpaceX’s Starship have been exploding fairly regularly at the company’s Texas test facility, the overall program has been moving forward at a terrific pace. The towering spacecraft, which CEO Elon Musk believes will be the key to building a sustainable human colony on Mars, has gone from CGI rendering to flight hardware in just a few short years. That’s fast even by conventional rocket terms, but then, there’s little about Starship that anyone would dare call conventional.

An early Starship prototype being assembled.

Nearly every component of the deep space vehicle is either a technological leap forward or a deviation from the norm. Its revolutionary full-flow staged combustion engines, the first of their kind to ever fly, are so complex that the rest of the aerospace industry gave up trying to build them decades ago. To support rapid reusability, Starship’s sleek fuselage abandons finicky carbon fiber for much hardier (and heavier) stainless steel; a material that hasn’t been used to build a rocket since the dawn of the Space Age.

Then there’s the sheer size of it: when Starship is mounted atop its matching Super Heavy booster, it will be taller and heavier than both the iconic Saturn V and NASA’s upcoming Space Launch System. At liftoff the booster’s 31 Raptor engines will produce an incredible 16,000,000 pounds of thrust, unleashing a fearsome pressure wave on the ground that would literally be fatal for anyone who got too close.

Which leads to an interesting question: where could you safely launch (and land) such a massive rocket? Even under ideal circumstances you would need to keep people several kilometers away from the pad, but what if the worst should happen? It’s one thing if a single-engine prototype goes up in flames, but should a fully fueled Starship stack explode on the pad, the resulting fireball would have the equivalent energy of several kilotons of TNT.

Thanks to the stream of consciousness that Elon often unloads on Twitter, we might have our answer. While responding to a comment about past efforts to launch orbital rockets from the ocean, he casually mentioned that Starship would likely operate from floating spaceports once it started flying regularly:

While history cautions us against looking too deeply into Elon’s social media comments, the potential advantages to launching Starship from the ocean are a bit too much to dismiss out of hand. Especially since it’s a proven technology: the Zenit rocket he references made more than 30 successful orbital launches from its unique floating pad.

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Retrotechtacular: Forging In Closed Dies

September 4, 2020 by Jenny List 16 Comments

It is the norm for our Retrotechtacular series to concentrate on a technology that has passed out of use but is still of interest to Hackaday readers, so it is perhaps unusual now to feature one that is very much still with us. Drop forging is a technique for forming hot metal in dies under huge force, and while it is still a current technique the 1950s educational film we are featuring is definitely retro.

An automotive connecting rod, sectioned and acid treated to show the grain structure. (CC BY-SA 2.5)

If you have followed our occasional series on blacksmithing, you’ll be familiar with the process of forming metal by heating it to a temperature at which it becomes malleable enough to deform under pressure, and using a hammer to shape it against an anvil. This process not only shapes the metal, but also forms its inner grain crystal structure such that with careful management the forging process can impart significant resistance to fatigue in the finished item. Think of drop forging as automation of the manual blacksmithing process, with the same metallurgical benefits but in which the finished product is shaped in a series of dies rather than by the blacksmith’s hammer. It loses the craft of the smith over the process, but delivers an extremely consistent result along with a high production turnover.

The film that we’ve placed below the break is an in-depth introduction to the industry in a very period style and with components for the automotive, aerospace, and defense industries of the day. It takes the viewer through the different types of press and examines the design of dies to produce in stages the required grain structure and shapes.

Of particular interest is the section on upset forging, a technique in which a piece of steel stock is forged end-on rather from above. The components themselves make the video worth watching, as we see everything from jet turbine blades to medical forceps in production, along with many parts from internal combustion engines. The smallest piece shown is a tiny carburetor part, while the largest is a huge aircraft carrier catapult part that requires a special vehicle to load it into the press.

Drop forging is generally the preserve of a large metalworking factory due to the size of the presses involved. But it’s not entirely beyond the capabilities of our community given the resources of a well-equipped hackerspace or blacksmith’s shop. My father made simple forging dies by assembling a basic shape in weld and pieces of steel stock before grinding it to his requirements and heat treating. Mounted in a large rotary fly press for repetitive small scale shaping and forming tasks in ornamental ironwork, I remember bumping them out from red hot steel bar in my early teens.

This is one of those techniques that’s useful to know about in our community, because while the need to manufacture significant quantities of ornamental ironwork may not come your way too often, it’s still worth having the capability should you need it. Meanwhile the video below the break should serve to provide you with enough heavy machinery enjoyment to brighten your day.

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Lithium Sulfur Batteries Slated For Takeoff

August 23, 2020 by Al Williams 60 Comments

Spectrum recently published a post on a new lithium sulfur battery technology specifically targeting electric aviation applications. Although lots of electric vehicles could benefit from the new technology, airplanes are especially sensitive to heavy batteries and lithium-sulfur batteries can weigh much less than modern batteries of equivalent capacity. The Spectrum post is from Oxis Energy who is about to fly tests with the new batteries which they claim have twice the energy density of conventional lithium-ion batteries. The company also claims the batteries are safer, which is another important consideration when flying through the sky.

The batteries have a cathode comprised of aluminum foil coated with carbon and sulfur — which avoids the use of cobalt, a cost driver in traditional lithium cell chemistries. The anode is pure lithium foil. Between the two electrodes is a separator soaked in an electrolyte. The company says the batteries go through multiple stages as they discharge, forming different chemical compounds that continue to produce electricity through chemical action.

The safety factor is due to the fact that, unlike lithium-ion cells, the new batteries don’t form dendrites that short out the cell. The cells do degrade over time, but not in a way that is likely to cause a short circuit. However, ceramic coatings may provide protection against this degradation in the future which would be another benefit compared to traditional lithium batteries.

We see a lot of exciting battery announcements, but we rarely see real products with them. Time will tell if the Oxis and similar batteries based on this technology will take root.

Airlines Seek Storage For Grounded Fleets Due To COVID-19

August 19, 2020 by Lewin Day 58 Comments

Ask any airline executive what their plans were back in January 2020, and you’d probably get the expected spiel about growing market share and improving returns for shareholders. Of course, the coronovirus pandemic quickly changed all that in the space of just a few months. Borders closed, and worldwide air travel ground to a halt.

Suddenly, the world’s airlines had thousands of planes and quite literally nowhere to go. Obviously, leaving the planes just sitting around in the open wouldn’t do them any good. So what exactly is involved in mothballing a modern airliner?

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Hackaday Links: August 2, 2020

August 2, 2020 by Dan Maloney 14 Comments

If you somehow manage to mentally separate yourself from the human tragedy of the COVID-19 pandemic, it really has provided a fascinating glimpse into how our planet operates, and how much impact seven billion people have on it. Latest among these revelations is that the shutdowns had a salubrious effect in at least one unexpected area: solar power. Researchers found that after the Indian government instituted mandatory lockdowns in March, output from solar power installations in Delhi increased by more than eight percent. The cause: the much-diminished smog, which let more sunlight reach solar panels. We’ve seen similar shutdown-related Earth-impact stories, from decreased anthropogenic seismicity to actually being able to see Los Angeles, and find them all delightfully revealing.

Remember Google Glass? It’s hard to forget, what with all the hype leading up to launch and the bitter disappointment of realizing that actually wearing the device wouldn’t go over well in, say, a locker room. That said, the idea of smart glasses had promise, and several startups tried to make a go of combining functionality with less out-there styling that wouldn’t instantly be seen as probable cause for being a creep. One such outfit was North, who made the more-or-less regular looking (if a bit hipsterish) Focals smart glasses. But alas, North was bought out by Google back in June, and as with so many things Google acquires, Focals smart glasses are being turned off. Anyone who bought the $600 specs will reportedly get their money back, but the features of the smart glasses will no longer function. Except, you know, you’ll still be able to look through them.

It looks like someone has finally come up with a pretty good use case for the adorably terrifying robot mini-dogs from Boston Dynamics. Ford Motors has put two of the yellow robots to work in their sprawling Van Dyke Transmission Plant in Michigan. Dubbed Fluffy and Spot (aww), the dogs wander around the plant with a suite of cameras and sensors, digitally mapping the space to prepare for possible future modifications and expansions. The robots can cover a lot of ground during the two hours that their batteries last, and are even said to be able to hitch a ride on the backs of other robots when they’re tuckered out. Scanning projects like these can keep highly trained — and expensive — engineers busy for weeks, so the investment in robots makes sense. And we’re sure there’s totally no way that Ford is using the disarmingly cute robo-pets to keep track of its employees.

We all know that the Linux kernel has some interesting cruft in it, but did you know that it can actually alert you to the fact that your printer is aflame? We didn’t either until Editor-in-Chief Mike Szczys shared this reddit post that details the kernel function lp_check_status and how it assumes the worst if it detects the printer is online but also in “check mode.” The Wikipedia entry on the “lp0 on fire” error message has some interesting history that details how it’s not as implausible as it might seem for a printer, especially one in the early 1970s, to burst into flames under the right conditions. A toner fuser bar running amok on a modern laser printer is one thing, but imagine a printer with a fusing oven running out of control.

And finally, because 2020 is apparently the gift that can’t stop giving, at least in the weirdness department, the US Department of Defense let it slip that the office charged with investigating unidentified aerial phenomena is not quite as disbanded as they once said it was. Reported to have been defunded in 2017, the Advanced Aerospace Threat Identification Program actually appears to live on, as the Unidentified Aerial Phenomena Task Force, operating out of the Office of Naval Intelligence. Their purpose is ostensibly to study things like the Navy videos of high-speed craft out-maneuvering fighter jets, but there are whispers from former members of the task force that “objects of undetermined origin have crashed on earth with materials retrieved for study.” All this could just be a strategic misdirection, of course, but given everything else that has happened this year, we’re prepared to believe just about anything.

Lonnie Johnson, Prolific Engineer And Hero To Millions Of Kids (Even If They Don’t Know It)

June 16, 2020 by Jenny List 29 Comments

The current generation Super Soaker XP30. (Hasbro)

To be a child in the 1970s and 1980s was to be of the first generations to benefit from electronic technologies in your toys. As those lucky kids battled blocky 8-bit digital foes, the adults used to fret that it would rot their brains. Kids didn’t play outside nearly as much as generations past, because modern toys were seducing them to the small screen. Truth be told, when you could battle aliens with a virtual weapon that was in your imagination HUGE, how do you compete with that.

How those ’80s kids must have envied their younger siblings then when in 1990 one of the best toys ever was launched, a stored-pressure water gun which we know as the Super Soaker. Made of plastic, and not requiring batteries, it far outperformed all squirt guns that had come before it, rapidly becoming the hit toy of every sweltering summer day. The Super Soaker line of water pistols and guns redefined how much fun kids could have while getting each other drenched. No longer were the best water pistols the electric models which cost a fortune in batteries that your parents would surely refuse to replace — these did it better.

You likely know all about the Super Soaker, but you might not know it was invented by an aerospace engineer named Lonnie Johnson whose career included working on stealth technology and numerous projects with NASA.

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