Don’t Be Salty: How To Make Desalination Work In Tomorrow’s World

September 8, 2022 by Maya Posch 60 Comments

Although water is often scarce for human consumption and agriculture, this planet is three-quarters covered by the stuff. The problem is getting the salt out, and this is normally done by the Earth’s water cycle, which produces rain and similar phenomena that replenish the amount of fresh water. Roughly 3% of the water on Earth is fresh water, of which a fraction is potable water.

Over the past decades, the use of desalination has increased year over year, particularly in nations like Saudi Arabia, Israel and the United Arab Emirates, but parched United States states such as California are increasingly looking into desalination technologies. The obvious obstacles that desalination faces – regardless of the exact technology used – involve the energy required to run these systems, and the final cost of the produced potable water relative to importing it from elsewhere.

Other issues that crop up with desalination include the environmental impact, especially from the brine waste and conceivably marine life sucked into the intake pipes. As the need for desalination increases, what are the available options to reduce the power needs and environmental impact?

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Ask Hackaday: Stripping Wires With Lasers

September 8, 2022 by Al Williams 22 Comments

Most of us strip the insulation off wires using some form of metal blade or blades. You can get many tools that do that, but you can also get by with skillfully using a pair of cutters, a razor blade or — in a pinch — a steak knife. However, modern assembly lines have another option: laser stripping. Now that many people have reasonable laser cutters, we wonder if anyone is using laser strippers either from the surplus market or of the do-it-yourself variety?

We are always surprised that thermal strippers are so uncommon since they are decidedly low-tech. Two hot blades and a spring make up the heart of them. Sure, they are usually expensive new, but you can usually pick them up used for a song. The technology for lasers doesn’t seem very difficult, although using the blue lasers most people use in cutters may not be optimal for the purpose. This commercial product, for example, uses infrared, but if you have a CO₂ laser, that might be a possibility.

The technique has found use in large-scale production for a while. Of course, if you don’t care about potential mechanical damage, you can get automated stripping equipment with a big motor for a few hundred bucks.

We did find an old video about using a CO₂ laser to strip ribbon cable, but nothing lately. Of course, zapping insulation creates fumes, but so does lasering everything, so we don’t think that’s what’s stopping people from this approach.

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Custom Lathe Tool Cuts Complex Oil Grooves

September 8, 2022 by Anne Ogborn 41 Comments

Oil grooves are used to lubricate the inside of a bearing, and can come in many forms — from a single hole that takes a few drops of oil, to helical patterns that distribute it over the entire internal surface. The ideal arrangement is a looping figure eight pattern similar to an oscilloscope Lissajous figure, but cutting these is a nightmare. That is, unless you’ve got the proper tool.

We figure [Machine Mechanic] must need to cut a lot of them, as they spent quite a bit of time perfecting this custom lathe attachment to automate the process. Through an assortment of clever linkages and a rod-turned-crank that was welded together in-situ, the device converts the rotational motion of the lathe into a reciprocating action that moves the cutting tool in and out of the bearing. Incidentally the business end of this gadget started life out as a bolt, before it was turned down and had a piece of tool steel brazed onto the end.

With a little adjustment, it seems like this device could also be used to carve decorative patterns on the outside of the workpiece. But even if this is the only trick it can pull off, we’re still impressed. This is a clever hack for a very specialized machine shop operation that most would assume you’d need a four-axis CNC to pull off.

Lathes seem at first like rather single purpose machines, we’re always pleased to discover strange and wonderful things being done with them, like this seemingly impossible-to-turn piece, and this combo wire EDM and lathe.

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Interfacing Broken PS4 Controllers With A Replacement PCB

September 7, 2022 by Lewin Day 5 Comments

[Becky] had some PS4 controllers that were sadly no longer functional. However, most of the buttons and joysticks still appeared to be okay. Thus, she set about designing a replacement PCB to breathe new life into these formerly bricked gamepads.

In the case of the PS4 controller, most of the buttons are of a membrane type, that talk to the main board inside via a series of contacts on a flex cable. Thus, [Becky] designed her PCB to interface with that to read most of the buttons. A breadboard and an LED came in handy to figure out which pads corresponded to which buttons on the controller. Replacement joysticks were sourced off Amazon to solder directly on to the replacement PCB.

[Becky] also took advantage of Fusion 360’s design tools to 3D print a simulcra of the final design. This helped get the fit just right inside the gamepad’s shell. Continue reading “Interfacing Broken PS4 Controllers With A Replacement PCB” →

Improve CD Sound By Shaving?

September 7, 2022 by Al Williams 89 Comments

We always enjoy the odd things that people do to try to get better audio reproduction. Exotic cables, special amplifiers, and higher resolution digitization come to mind. Most of this is dubious, at best, but [Techmoan] brings up something we must have missed back in the day: shaving CDs with a gadget that was marketed as the “CD Sound Improver.” The theory is that bad CD reproduction comes from light scatter of the laser. The solution, according to the maker of this vintage equipment, is to cut a 36-degree bevel to act as a light trap. You can see the gadget in the video below.

The device claims it reduced vibration, improved audio, and even helped DVDs playback better video. As you might imagine, this has little hope of actually working. The box is essentially a motor-driven turntable, a razor blade, and a port for a vacuum cleaner to suck up the mess. You were told to color the edge with a marker, too.

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The MOS 7600 Video Game Chip Gives Up Its Secrets

September 7, 2022 by Jenny List 5 Comments

A good chip decapping and reverse engineering is always going to capture our interest, and when it comes from [Ken Shirriff] we know it’s going to be a particularly good one. This time he’s directed his attention to the MOS 7600 all-in-one video game chip (Nitter), a mostly forgotten device from the 6502 chipmaker which we featured a few weeks ago when it was the subject of a blogger’s curiosity. The question then was whether it contained a microprocessor or not and even whether it was another 6502 variant, and the answer revealed in the decapping answers that but will disappoint the 6502 camp.

On the chip is a mixture of analog and digital circuitry, with some elements of a more traditional game chip alongside a ROM, a PLA, and a serial CPU core. The PLA stores pixel data while the ROM stores the CPU code, and the CPU serves to perform calculations necessary to the games themselves. He hasn’t fully reverse-engineered either, but the two areas of the chip are mask-programmed to produce the different games with which the chip could be found.

So the answer to the original question is that there is a CPU on board, but it’s not a 6502 and the operation is a hybrid between dedicated game chip and CPU-controlled chip. What we find interesting is that this serial CPU core might have as we mused in the previous piece made the heart of a usable 1970s microcontroller, was this a missed opportunity on the part of MOS? We’ll never know, but at least another piece of early video game history has been uncovered.

Ethersweep: An Easy-To-Deploy Ethernet Connected Stepper Controller

September 7, 2022 by Dave Rowntree 35 Comments

[Neumi] over on Hackaday.IO wanted a simple-to-use way to drive stepper motors, which could be quickly deployed in a wide variety of applications yet to be determined. The solution is named Ethersweep, and is a small PCB stack that sits on the rear of the common NEMA17-format stepper motor. The only physical connectivity, beside the motor, are ethernet and a power supply via the user friendly XT30 connector. The system can be closed loop, with both an end-stop input as well as an on-board AMS AS5600 magnetic rotary encoder (which senses the rotating magnetic field on the rear side of the motor assembly – clever!) giving the necessary feedback. Leveraging the Trinamic TMC2208 stepper motor driver gives Ethersweep silky smooth and quiet motor control, which could be very important for some applications. A rear-facing OLED display shows some useful debug information as well as the all important IP address that was assigned to the unit.

Control is performed with the ubiquitous ATMega328 microcontroller, with the Arduino software stack deployed, making uploading firmware a breeze. To that end, a USB port is also provided, hooked up to the uC with the cheap CP2102 USB bridge chip as per most Arduino-like designs. The thing that makes this build a little unusual is the ethernet port. The hardware side of things is taken care of with the Wiznet W5500 ethernet chip, which implements the MAC and PHY in a single device, needing only a few passives and a magjack to operate. The chip also handles the whole TCP/IP stack internally, so only needs an external SPI interface to talk to the host device.