Fighting Back Against Dodgy Dyson Batteries

May 23, 2022 by Tom Nardi 65 Comments

If you’ve ever worked with multi-cell rechargeable battery packs, you know that the individual cells will eventually become imbalanced. To keep the pack working optimally, each cell needs to be analyzed and charged individually — which is why RC style battery packs have a dedicated balance connector. So if you know it, and we know it, why doesn’t Dyson know it?

It’s that question which inspired [tinfever] to start work on the FU-Dyson-BMS project. As you might have surmised from the name, [tinfever] believes that Dyson has intentionally engineered their V6 and V7 batteries to fail by not using the cell balancing function of the onboard ISL94208 battery management IC. What’s worse, once the cells get as little as 300 mV out of balance, the controller considers the entire pack to be shot and will no longer allow it to be charged.

These missing resistors deserve justice.

Or at least, that’s what used to happen. With the replacement firmware [tinfever] has developed, the pack’s battery management system (BMS) will ignore imbalanced cells so you can continue to use the pack (albeit at a reduced capacity). Of course the ideal solution would have been to enable cell balancing on the ISL94208, but unfortunately Dyson didn’t include the necessary resistors on the PCB. Though it’s worth noting that earlier versions of the board did have unpopulated spots for them, lending some credence to the idea that their omission was intentional on Dyson’s part.

But not everyone is onboard with the conspiracy theory. Over on the EEVBlog forums, some users pointed out that a poorly implemented cell balancing routine can be more problematic than not having one at all. It’s possible that Dyson had some bad experiences with the technology in earlier packs, and decided to move away from it and try to compensate by using higher-quality cells. That said, at least one person in the thread was able to revive their own “dead” battery pack by installing this unofficial firmware, so whether intentional or not, it seems there’s little debate that usable batteries are indeed being prematurely marked as defective.

Proper cell balancing is key even in DIY projects, so we do have to agree that it seems more than a little unusual that Dyson would intentionally turn off this important feature in their packs. But the jury is still out on whether or not Sir James is trying to pull a fast one on his customers — as Hanlon’s Razor states, “never attribute to malice that which is adequately explained by stupidity”.

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Resulting tweezer assembly, with a 3D printed replacement case for both of the probes

Hackaday Prize 2022: Glue-Hindered Smart Tweezer Repair Involves A Rebuild

May 23, 2022 by Arya Voronova 1 Comment

[Dan Julio] owns a pair of Miniware multimeter tweezers, a nifty helper tool for all things SMD exploration. One day, he found them broken – unable to recognize any component between the two probes. He thought it could be a broken connection problem, and decided to take them apart. Presence of some screws on their case fooled him – in the end, it turned out that the case was glued together, and could only be opened destructively. For an entry in the “Reuse, Recycle, Revamp” round of 2022 Hackaday Prize, he tells us how he brought these tweezers back from the dead.

During the disassembly, he broke a custom flexible PCB, which wasn’t reassuring either. However, that was no reason to give up – he reverse-engineered the connections and the charging circuitry, then assembled parts of the broken tweezers together using a small generic protoboard as a base. Indeed, it was likely a broken connection between probes, because the reassembled tweezers worked!

Of course, having exposed PCBs wouldn’t do, and from the very start, assembling these tweezers back together was not an option. Instead, he developed a replacement case in OpenSCAD, bringing the tweezers back to life as his trusty tool – and still leaving repairability on the table. If you’re interested in the details, he goes more into how these tweezers are designed when it comes to charging and connectivity, and we recommend that you give his write-up a read!

We’ve been seeing smart tweezers around for over a decade now, from reviews and hacks of commercially made ones, to DIY chopstick-based and PCB-based ones. If you already own a pair of tweezers you’ve grown attached to, you can neatly retrofit them with a capacitance sensing function!

2022 Hackaday Prize: Congratulations To The Planet-Friendly Power Finalists!

May 23, 2022 by Elliot Williams 1 Comment

The 2022 Hackaday Prize is focused on lightening our load on the planet, and one obvious way to do so is to get and store renewable power locally — the theme of our first challenge round: Planet-Friendly Power. Our judges have studied all the entries and their votes are in. All of these ten projects will receive $500 right now and are eligible for the Grand Prize of $50,000, to be announced in November.

Most of the alternative energy sources you’d expect to see were represented: solar, wind, and water. But everyone brought their own twists to the topic. For instance, the Low Cost Solar Panel Solution demonstrates that there’s a lot more to a DIY solar project than just the panel. You need to support it, protect it, turn it to face the sun, and convert and store the power harvested. And [JP Gleyzes] even goes so far as to use recycled water bottles to make the 3D-printed parts. Sun Chaser 2 puts the panel on wheels, driving it out of the shade to collect maximum energy in a real-world backyard situation. Cute!

Finally, we had two great kite projects to harvest wind with minimal setups on the go: Kite Propulsion and Energy Independence While Travelling. Both are still in the experimental stages, but both have great documentation of where the research projects stand.

Finally, Moss Microbial Fuel Cell is really out there on the edge of current research. Combining the reasonably well established microbial fuel cell with the photosynthetic power of moss, [Guru-san] is able to light an LED for a few seconds at a time. It’s not much, but it’s also a desktop-scale project. And who can say no to leaf-shaped capacitor circuit sculptures to store the energy?

Hacker Power!

Those are just a few of the ten finalists, listed here in no particular order. Congratulations to all of you! We’re excited to follow your projects along their journey, and wish you all the best.

Ten Finalists from Planet-Friendly Power

Vintage Pro Audio Hack Chat

May 23, 2022 by Dan Maloney 5 Comments

Join us on Wednesday, May 25 at noon Pacific for the Vintage Audio Hack Chat with Frank Olson!

There was a time, and not all that long ago on the cosmic scale, that if you wanted to hear music, you either needed to make it yourself or hire someone to do it for you. For most of history, music was very much a here and now thing, and when the song was over, that was it.

Thankfully, those days are long gone, and for better or worse, we have instant access to whatever music we’re in the mood for. The Spotify client in your pocket is a far cry from the iPod of a few years back, or the Walkman of the 80s, or even a mid-century transistor radio. But no matter how you listen to your music, it all starts with getting the live music recorded, and that’s where we’ll be going with this Hack Chat.

Hooking up the preamps, mixers, mics, and recorders that make modern music possible is what Frank Olson is all about. You’ll probably recognize Frank’s name from his unique niche as a maker of wooden microphones, but dig a little deeper and he’s got a lot of experience with vintage pro audio gear. As both a musician and an audio engineer, Frank brings an enthusiast’s passion for recording gear to the Hack Chat, and we’re looking forward to picking his brain on the unique ways he’s found to turn sounds into music and to get to all down on tape.

Our Hack Chats are live community events in the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Wednesday, May 25 at 12:00 PM Pacific time. If time zones have you tied up, we have a handy time zone converter.

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An Illuminating Look At A Wolf 5151 Light Source

May 23, 2022 by Tom Nardi 8 Comments

While originally designed to put light where the sun don’t shine for medical purposes, [Nava Whiteford] says the Wolf 5151 Xenon endoscopic light source also works well for microscopy and general optical experiments, especially since you can get them fairly cheap on the second hand market. His cost just $50 USD, which is a steal when you consider a replacement for its 300 watt Olympus-made bulb will run you about 200 bucks alone.

That said, [Nava] recently moved on to a more compact light source, and figured that was a good enough excuse to crack open the Wolf 5151 and see what makes it tick. In this particular post he’s just looking at the optical side of things, which is arguably the most interesting aspect of the device. Helpfully, the whole assembly is mounted to its own sled of sorts that can be pulled from the light source for a closer examination.

Beyond that expensive bulb we mentioned earlier, there’s a thick piece of what appears to be standard plate glass being used as an IR and UV filter. [Nava] suspects this component is responsible for keeping the rest of the optics from overheating, which is backed up by the fact that the metal plate its mounted to appears to feature a K-type thermocouple to keep an eye on its operating temperature. Forward of that is a unique aspheric lens that features a rough spot to presumably scatter the light at the center of the beam.

Our vote for the most fascinating component has to go to the Neutral Density (ND) filter, which is used to control the intensity of the light. In a more pedestrian light source you could just dim the bulb, but in this case, the Wolf 5151 uses a metal disk with an array of holes drilled into it. By rotating the disc with a DC motor, the lens can be variably occluded to reduce the amount of light that reaches the aperture, which connects to the fiber cable.

While it’s perhaps no surprise the build quality of this medical gear is considerably beyond the commercial gadgets most of us get to play with, it still doesn’t hold a candle (no pun intended) to the laser module pulled from a Tornado jet fighter.

Knowing Your Place: The Implications Of GPS Spoofing And Jamming

May 23, 2022 by Maya Posch 30 Comments

Artificial satellites have transformed the world in many ways, not only in terms of relaying communication and for observing the planet in ways previously inconceivable, but also to enable incredibly accurate navigation. A so-called global navigation satellite system (GNSS), or satnav for short, uses the data provided by satellites to pin-point a position on the surface to within a few centimeters.

The US Global Positioning System (GPS) was the first GNSS, with satellites launched in 1978, albeit only available to civilians in a degraded accuracy mode. When full accuracy GPS was released to the public under the 1990s Clinton administration, it caused a surge in the uptake of satnav by the public, from fishing boats and merchant ships, to today’s navigation using nothing but a smartphone with its built-in GPS receiver.

Even so, there is a dark side to GNSS that expands beyond its military usage of guiding cruise missiles and kin to their target. This comes in the form of jamming and spoofing GNSS signals, which can hide illicit activities from monitoring systems and disrupt or disable an enemy’s systems during a war. Along with other forms of electronic warfare (EW), disrupting GNSS signals form a potent weapon that can render the most modern avionics and drone technology useless.

With this in mind, how significant is the threat from GNSS spoofing in particular, and what are the ways that this can be detected or counteracted?

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A fusion splicer being used to repair an optical fiber

Using A Fusion Splicer To Repair A Samsung TV’s Cable

May 23, 2022 by Robin Kearey 31 Comments

Some Samsung TVs come with a system called One Connect, where all external cabling is connected to a separate box so that only one small signal cable goes to the TV. In some versions, the cable linking the TV with its Connect Box is a pure fiber optic cable that’s nearly transparent and therefore easy to hide.

Thin fiber optic cables are fragile however; when [Elecami Wolf] got one of these TVs for a very low price it turned out that this was because its One Connect cable had snapped. Replacement cables are quite expensive, so [Elecami Wolf] went on to investigate the inner workings of the fiber optic cable and figured out how to repair a broken one.

The cable consists of four pairs of plastic-coated glass fibers, which are attached to receivers and transmitters inside the thick connectors on either end. Repairing the cable required two things: figuring out which fibers should connect to each other, and a reliable way of connecting them together.

The first was difficult enough: a simple 1:1 connection didn’t work, so it took a bit of work to figure out the correct connection setup. One clever trick was pointing a camera at a working cable and comparing the flashing lights at each end; this helped to identify the right order for two of the four pairs. For the other two, a combination of reverse-engineering the electronic circuits and some systematic trial-and-error yielded a complete wiring diagram.

For the second part, [Elecami Wolf] called on a fiber optic expert who lent him a fusion splicer. This is a rather neat piece of equipment that semi-automatically brings two pieces of fiber together and welds them with an electric arc. Once this was complete, it was a matter of covering the splices to protect them from sharp bends, and the fancy TV was working again.

Although not everyone will have access to a multi-mode fusion splicer machine, [Elecami Wolf]’s videos provide fascinating insights into the workings of modern fiber-optic based consumer electronics. This might be the first fiber-optic splicing attempt we’ve seen; but if you’re trying to hook up an optical fiber to your circuit, this ball lens setup is a neat trick.

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