PCB Microsurgery Puts The Bodges Inside The Board

December 14, 2021 by Dan Maloney 23 Comments

We all make mistakes, and there’s no shame in having to bodge a printed circuit board to fix a mistake. Most of us are content with cutting a trace or two with an Xacto or adding a bit of jumper wire to make the circuit work. Very few of us, however, will decide to literally do our bodges inside the PCB itself.

The story is that [Andrew Zonenberg] was asked to pitch in debugging some incredibly small PCBs for a prototype dev board that plugs directly into a USB jack. The six-layer boards are very dense, with a forest of blind vias. The Twitter thread details the debugging process, which ended up finding a blind via on layer two shorted to a power rail, and another via shorted to ground. It also has some beautiful shots of [Andrew]’s “mechanical tomography” method of visualizing layers by slowly grinding down the surface of the board.

[Andrew] has only tackled one of the bodges at the time of writing, but it has to be seen to be believed. It started with milling away the PCB to get access to the blind via using a ridiculously small end mill. The cavity [Andrew] milled ended up being only about 480 μm by 600 μm and only went partially through a 0.8-mm thick board, but it was enough to resolve the internal short and add an internal bodge to fix a trace that was damaged during milling. The cavity was then filled up with epoxy resin to stabilize the repair.

This kind of debugging and repair skill just boggles the mind. It reminds us a bit of these internal chip-soldering repairs, but taken to another level entirely. We can’t wait to see what the second repair looks like, and whether the prototype for this dev board can be salvaged.

Thanks to [esclear] for the heads up on this one.

Fabulous Flexure Mechanism Makes For Resetting Cat Calendar

December 14, 2021 by Kristina Panos 18 Comments

When we met [Amy Makes Stuff] at the 2019 Hackaday Superconference, we were immediately impressed with the array of flexure mechanisms displayed on a board hanging around her neck. That must be where we saw [Amy]’s original version of the cat calendar — a simple way to know for sure whether the shared house’s cat has been fed once, twice, or not at all on a given day.

Left: a simple flexure that gets heavily stressed when actuated. Right: a slightly more complicated flexure that uses less force.

Awesome as it is, the flexure mechanism doesn’t reset the yes/no indicators when the day clicks over — that has to be done manually. So when [Amy] was offered to try a small desktop CNC, she decided it was time to make a new version that resets automatically. Check it out in the video after the break, which also includes an exploration of [Amy]’s choice of flexure design as well as a bonus review of the CNC.

This is just an all-around great video, especially after [Amy] neglected to mill out the check marks and circles, sending her down a rabbit hole of attempting to make branding bits for these that could be chucked into a soldering iron. Unfortunately, the mill stops short of having the necessary mettle for milling metal.

Although [Amy] is likely known for her flexures, she has a ton of skills. Remember when she resurrected that burned and bubbled laser cutter? Or the time she machined a honing jig for hand-sharpening chisels and planes?

Continue reading “Fabulous Flexure Mechanism Makes For Resetting Cat Calendar” →

What Really Goes Wrong With Your Tablet

December 14, 2021 by Jenny List 33 Comments

We’ve all seen our share of consumer electronic devices that need repair. It’s inevitable that, however well-cared-for it will be, there’s always the unforseen that brings its life to an end. Many of us will be using devices we’ve repaired ourselves, because often other people’s useless broken electronics can be our free stuff when we know how to fix them and they don’t. This is the arena the Restart Project operate in, as through their Restart Parties they provide repair services to save unnecessary landfill. Over nearly a decade in operation they’ve fixed a huge number of faulty items, and now they’re releasing some data and have analysed common fault modes and barriers to repair for some categories.

We’re restricted to tablets, printers, and batteries, and while many of the problems are the wear-and-tear such as tablet screens, power supplies, charging connectors, and paper feeds that most of us would expect, it’s the barriers to repair which the Restart Project are keen to draw attention to. Products that are near-impossible to open without damage, parts such as batteries which are difficult to remove, and unavailability of spares. It’s to become part of their campaigning for legal repairability standards across Europe.

Aside from their own analysis, the full data is all available for download should you have any extra insights. We’ve made our position on this matter very clear indeed.

Orbital Safety: The Challenges Of Surviving Space Junk

December 14, 2021 by Maya Posch 22 Comments

Hanging around in earth orbit is like walking into the middle of a Wild West gunfight — bullets are flying around everywhere, and even though none are purposefully aimed at you, one might have your name on it. Many of these bullets are artificial satellites that are actively controlled and monitored, but we also find dead satellites, remnants of satellites, discarded rocket stages, tools lost during spacewalks, and even flecks of paint and rust, much of it zipping around at multiple kilometers per second without any guidance.

While removing this space debris directly would be ideal, the reality is that any spacecraft and any spacesuit that has to spend time in orbit needs to be capable of sustaining at least some hits by space debris impacting it.

Orbital Mechanics

That it’s easy to create new debris should come as no surprise to anyone. What may take a bit more imagination is just how long it can take for this debris to make its way towards earth’s atmosphere, where it will uneventfully burn up. Everything in orbit is falling toward the earth, but its tangential velocity keeps it from hitting — like a marble spinning around the hole in a funnel. Drag from the planet’s atmosphere is the friction that eventually slows the object down, and where it orbits in the planet’s atmosphere determines how long this descent will take. Continue reading “Orbital Safety: The Challenges Of Surviving Space Junk” →

A robotic turret shooting plastic balls at a man

Automated Turret Keeps Dorm Clean, RoboCop Style

December 14, 2021 by Robin Kearey 17 Comments

Students’ dorm rooms are not generally known to be the most orderly of places. Whether it’s mountains of dishes in the sink, piles of clothes waiting to be washed, or random bits and bobs strewn across the hallway, cleaning up is pretty low on the agenda for many dorm dwellers.

[Luis Marx] seems to have invented a useful solution to his (or his roommates’) sloppiness: a robotic turret that opens fire on anyone who leaves items unattended (video, in German, embedded below). This system uses a set of “clutter sensors” that can be placed in strategic locations around the house and will detect stray objects using ultrasonic sensors. If any are found, the main system is alerted through WiFi. The turret will then search for any persons in its vicinity and start shooting them with little plastic balls.

The turret in question is a beautifully-designed piece of kit made from 3D printed parts and controlled by an ESP32. It can swivel around its axis and tilt up and down using two servos, while its firing mechanism is driven by a DC motor. It tracks its target thanks to a camera-based object sensor that can recognize humans. The whole thing gives us a bit of a RoboCop vibe; we’d half expect it to shout Pick up those clothes. You have twenty seconds to comply.

While this might not be the definitive solution to messy dorm rooms, we like the creative thinking behind it. We’ve seen auto-targeting turrets before, but not in household applications like this. Of course there are plenty of other robots that can help you with domestic tasks.

Continue reading “Automated Turret Keeps Dorm Clean, RoboCop Style” →

Teardown: Verizon AC791L Jetpack 4G Mobile Hotspot

December 14, 2021 by Tom Nardi 24 Comments

The saying “time and tide wait for no man” is usually used as a verbal kick in the pants, a reminder that sometimes an opportunity must be seized quickly before it passes by. But it can also be interpreted as a warning about the perpetual march of time and how it impacts the world around us. In that case, we would do well to add cellular technology to the list of proverbial things that wait for no one. Do you need 5G? No. Do you want it? Probably not. But it’s here, so be a good consumer and dump all your 4G hardware in the name of technical progress.

This line of logic may explain how the Verizon-branded Netgear AC791L 4G “Jetpack” hotspot you see here, despite being in perfect working order, found itself in the trash. The onset of 5G must have been particularly quick for the previous owner, since they didn’t even bother to wipe their configuration information from the device. In the name of journalistic integrity I won’t divulge the previous owner’s identity; but I will say that their endearing choice of WPA2 key, iluvphysics, makes for a nice fit with our publication.

A quick check of eBay shows these devices, and ones like it, are in ample supply. At the time of this writing, there were more than 1,500 auctions matching the search term “Verizon jetpack”, with most of them going for between $20 and $50 USD. We like cheap and easily obtainable gadgets that can be hacked, but is there anything inside one of these hotspots that we can actually use? Let’s find out.

Continue reading “Teardown: Verizon AC791L Jetpack 4G Mobile Hotspot” →

Oh Deere, Is That Right To Repair Resolution Troubling You?

December 14, 2021 by Jenny List 103 Comments

Over the years a constant in stories covering the right to repair has come from an unexpected direction, the farming community. Their John Deer tractors, a stalwart of North American agriculture, have become difficult to repair due to their parts using DRM restricting their use to authorised Deere agents. We’ve covered farmers using dubious software tools to do the job themselves, we’ve seen more than one legal challenge, and it’s reported that the price of a used Deere has suffered as farmers abandon their allegiance to newer green and yellow machines. Now comes news of a new front in the battle, as a socially responsible investment company has the tractor giant scrambling to block their shareholder motion on the matter.

Deere have not been slow in their fight-back against the threat of right-to-repair legislation and their becoming its unwilling poster-child, with CTO Jahmy Hindman going on record stating that 98% of repairs to Deere machinery can be done by the farmer themself (PDF, page 5) without need for a Deere agent. The question posed by supporters of the shareholder action is that given the substantial risk to investors of attracting a right-to-repair backlash, why would they run such a risk for the only 2% of repairs that remain? We’d be interested to know how Deere arrived at that figure, because given the relatively trivial nature of some of the examples we’ve seen it sounds far-fetched.

It’s beyond a doubt that Deere makes high-quality agricultural machinery that many farmers, including at least one Hackaday scribe, have used to raise a whole heap of crops. The kind of generational brand loyalty they have among their customers simply can’t be bought by clever marketing, it’s been built up over a century and a half. As spectators to its willful unpicking through this misguided use of their repair operation we hope that something like this shareholder move has the desired effect of bringing it to a close. After all, it won’t simply be of benefit to those who wish to repair their tractor, it might just rescue their now-damaged brand before it’s too late.

Curious about previous coverage on this ongoing story? This article from last year will give context.

Header image: Nheyob / CC BY-SA 4.0