The Coffee Must Flow: Replacing A Spent Lithium Cell In A Coffee Machine

May 11, 2021 by 37 Comments

When [hacky] bought a used Douwe Egberts Gallery 200 all-in-one coffee maker, the machine was known to have a ’empty battery’. Being one of those fancy coffee makers that handle everything from the grinding of coffee beans to the application of hot water and steam, it relies on instructions for each coffee recipe. Unfortunately, it turns out that this machine stores these on battery-backed SRAM, as [hacky] found out with help from friendly folk over at the Dutch Tweakers forum.

The Douwe Egberts Gallery 200 is a rebranded machine that’s also sold in Scandinavia as the Wittenborg FB 5100. These machines have an ST M48T58 TimeKeeper module that combines 8 kB of persistent SRAM with a real-time clock. Being powered from a single coin cell (lithium carbon monofluoride chemistry), their lifespan is limited.

Replacing the coin cell in an M48T58 TimeKeeper module with AA cells.

Fortunatley, a DE-9 connector is provided on the back to provide service/maintenance access to to the hardware. Using a conveniently available programming guide for the hardware, it was easy to figure out the pinout and baud rate (9600, 8 bit, ignore parity, no flow control). This allows for reprogramming the SRAM, but without replacing the battery this data would be gone again on the next start.

Based on the ST M48T58 datasheet, it’s not clear that the clip-on module containing the coin cell and crystal can be replaced, though one could simply plug in a new M48T58 module. Or, as [hacky] did, it’s also possible to cut open the ‘SNAPHAT’ top section and wire in a replacement battery module. With two 1.5V AA cells providing the 3V to the module, it was operational again.

Next up: working out what to write to the SRAM to make the coffee flow again.

Guitar With Hot-Swappable Pickups Lights Our Fire

May 11, 2021 by 17 Comments

There’s a story that goes something like this: Chet Atkins was playing his guitar when someone remarked, ‘that guitar sounds great!’ Mr. Atkins immediately stopped playing and asked, ‘how does it sound now?’ While it’s true that the sound ultimately comes from you and your attention to expression, we feel that different pickups on the same guitar can sound, well, different from each other.

However, this is merely speculation on our part, because changing pickups is pretty serious surgery, and there’s only one company out there making guitars with hot-swappable pickups. Since their low-end model is out of most people’s price range, [Mike Lyons] took one for the team and decided to build a guitar from scratch to test out various pickups of any size, from lipstick to humbucker. [Mike] can swap them out in under a minute, and doesn’t need any tools to do it.

[Mike] modeled the swapping system on that one company’s way of doing things, because why reinvent the wheel? The pickups are inserted through the back and held in place with magnets and a pair of cleverly-designed printed pieces — one to mount the pickup to, and the other inside the pickup cavity.

As far as actually connecting the things up, [Mike] went with a commercially-available quick-connect pickup solution that uses a mini four-conductor audio plug and jack. The body is based on the Telecaster, while the headstock is more Stratocaster — the perfect visual combination, if you ask us.

We are particularly fond of [Mike]’s list of caveats for this project, especially the requirement that it had to be built using only hand tools and a 3D printer. Although a drill press would have been nice to use, [Mike] did a fantastic job on this guitar. Whether you’re into guitars or not, this is a great story of an awesome build.

What, you don’t even have hand tools? You could just print the whole guitar instead.

DIN Rails For… Everything

May 11, 2021 by 58 Comments
Cross-section of a 35mm top hat DIN rail.

One of the great things about the Internet is it lets people find out what other people are doing even if they normally wouldn’t have much exposure to each other. For example, in some businesses DIN rails are a part of everyday life. But for a long time, they were not very common in hobby electronics. Although rails are cheap, boxes for rails aren’t always easy or cheap to obtain, but 3D printing offers a solution for that.

So while the industrial world has been using these handy rails for decades, we are starting to see hobby projects incorporate them more often and people like [Makers Mashup] are discovering them and finding ways to use them in projects and demonstrating them in this video, also embedded below.

If you haven’t encountered them yet, DIN rails are a strip of metal, bent into a particular shape with the purpose of mounting equipment like circuit breakers. A typical rail is 35 mm wide and has a hat-like cross-section which leads to the name “top hat” rail. A 25 mm channel lets you hide wiring and the surface has holes to allow you to mount the rail to a wall or a cabinet. These are sometimes called type O or type Ω rails or sections.

There are other profiles, too. A C-rail is shaped like a letter C and you can guess what a G section looks like, too. Rails do come in different heights, as well, but the 35 mm is overwhelmingly common. However, there are 15 mm rails and 75 mm rails, too.

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The Mysterious Wobble Of Muons

May 11, 2021 by 8 Comments

You might think that particle physicists would be sad when an experiment comes up with different results than their theory would predict, but nothing brightens up a field like unexplained phenomena.  Indeed, particle physicists have been feverishly looking for deviations from the Standard Model. This year, there have been tantalizing signs that a long unresolved discrepancy between theory and experiment will be confirmed by new experimental results.

In particular, the quest to measure the magnetic moment of muons started more than 60 years ago, and this has been measured ever more precisely since. From an experiment in 1959 at CERN in Switzerland, to the turn of the century at Brookhaven, to this year’s result at Fermilab, the magnetic moment of the muon seems to be at odds with theoretical predictions.

Although a statistical fluke is basically excluded, this value also relies on complex theoretical calculations that are not all in agreement. Instead of heralding a new era of physics, it might just be another headline too good to be true. But some physicists are mumbling “new particle” in hushed tones. Let’s see what all the fuss is about.

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3D-Printed Desiccant Container Exploits Infill

May 11, 2021 by 15 Comments

Desiccant is common in 3D printing because the drier plastic filament is, the better it prints. Beads of silica gel are great for controlling humidity, but finding a porous container for them that is a convenient size is a little harder. 3D printing is a generally useful solution for custom containers, but suffers from a slight drawback in this case: printing dense grills or hole patterns is not very efficient for filament-based printers. Dense hole patterns means lots of stopping and starting for the extruder, which means a lot of filament retractions and longer print times in general.

The green model is used as a modifier to the orange container (of which only the corners are left visible here)

[The_Redcoat]’s solution to this is to avoid hole patterns or grills altogether, and instead print large wall sections of the container as infill-only, with no perimeter layers at all. The exposed infill pattern is dense enough to prevent small beads of desiccant from falling through, while allowing ample airflow at the same time. The big advantage here is that infill patterns are also quite efficient for the printer to lay down. Instead of the loads of stops and starts and retractions needed to print a network of holes, infill patterns are mostly extruded in layers of unbroken lines. This translates to faster print speeds and an overall more reliable outcome, even on printers that might not be as well tuned or calibrated as they could be.

To get this result, [The_Redcoat] modeled a normal, flat-walled container then used OpenSCAD to create a stack of segments to use as a modifier in PrusaSlicer. The container is printed as normal, except where it intersects with the modifier, in which case those areas get printed with infill only and no walls. The result is what you see here: enough airflow for the desiccant to do its job, while not allowing any of the beads to escape. It’s a clever use of both a high infill as well as the ability to use a 3D model as a slicing modifier.

There’s also another approach to avoiding having to print a dense pattern of holes, though it is for light-duty applications only: embedding a material like tulle into a 3D print, for example, can make a pretty great fan filter.

The Russian Woodpecker: Official Bird Of The Cold War Nests In Giant Antenna

May 11, 2021 by 44 Comments

On July 4th, 1976, as Americans celebrated the country’s bicentennial with beer and bottle rockets, a strong signal began disrupting shortwave, maritime, aeronautical, and telecommunications signals all over the world. The signal was a rapid 10 Hz tapping that sounded like a woodpecker or a helicopter thup-thupping on the roof. It had a wide bandwidth of 40 kHz and sometimes exceeded 10 MW.

This was during the Cold War, and plenty of people rushed to the conclusion that it was some sort of Soviet mind control scheme or weather control experiment. But amateur radio operators traced the mysterious signal to an over-the-horizon radar antenna near Chernobyl, Ukraine (then part of the USSR) and they named it the Russian Woodpecker. Here’s a clip of the sound.

The frequency-hopping Woodpecker signal was so strong that it made communication impossible on certain channels and could even be heard across telephone lines when conditions were right. Several countries filed official complaints with the USSR through the UN, but there was no stopping the Russian Woodpecker. Russia wouldn’t even own up to the signal’s existence, which has since been traced to an immense antenna structure that is nearly half a mile long and at 490 feet, stands slightly taller than the Great Pyramid at Giza.

This imposing steel structure stands within the irradiated forest near Pripyat, an idyllic town founded in 1970 to house the Chernobyl nuclear plant workers. Pictured above is the transmitter, also known as Duga-1, Chernobyl-2, or Duga-3 depending on who you ask. Located 30 miles northeast of Chernobyl, on old Soviet maps the area is simply labeled Boy Scout Camp. Today, it’s all within the Chernobyl Exclusion Zone.

It was such a secret that the government denied it’s existence, yet was being heard all over the world. What was this mammoth installation used for?

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Original Game Boy Powered Up With GBA Motherboard

May 11, 2021 by 10 Comments

The Game Boy DMG-01 is about as iconic as a piece of consumer electronics can get, but let’s be honest, it hasn’t exactly aged well. While there’s certainly a number of games for the system that are still as entertaining in 2021 as they were in the 80s and 90s, the hardware itself is another story entirely. Having to squint at the unlit display, with its somewhat nauseating green tint, certainly takes away from the experience of hunting down Pokémon.

Which is precisely why [The Poor Student Hobbyist] decided to take an original Game Boy and replace its internals with more modern hardware in the form of a Game Boy Advance (GBA) SP motherboard and aftermarket IPS LCD panel. The backwards compatibility mode of the GBA allows him to play those classic Game Boy and Game Boy Color games from their original cartridges, while the IPS display brings them to life in a way never before possible.

Relocating the cartridge connector took several attempts.

Now on the surface, this might seem like a relatively simple project. After all, the GBA SP was much smaller than its predecessors, so there should be plenty of room inside the relatively cavernous DMG-01 case for the transplanted hardware. But [The Poor Student Hobbyist] made things quite a bit harder on himself by deciding early on that there would be no external signs that the Game Boy had been modified; beyond the wildly improved screen, anyway.

That meant deleting the GBA’s shoulder buttons, though since the goal was always to play older games that predated their addition to the system, that wasn’t really a problem. The GBA’s larger and wider screen is still intact, albeit hidden behind the Game Boy’s original bezel. It turns out the image isn’t exactly centered on the physical display, so [The Poor Student Hobbyist] came up with a 3D printed adapter to mount it with a slight offset. The adapter also allows the small tactile switch that controls the screen brightness to be mounted where the “Contrast” wheel used to go.

An incredible amount of thought and effort went into making the final result look as close to stock as possible, and luckily for us, [The Poor Student Hobbyist] did a phenomenal job of documenting it for others who might want to make similar modifications. Even if you’re not in the market for a rejuvenated Game Boy, it’s worth browsing through the build log to marvel at the passion that went into this project.

Some would argue [The Poor Student Hobbyist] should have just put a Raspberry Pi into a Game Boy case and be done with it, but where’s the fun in that? Sure it might have been a somewhat better Bitcoin miner, but there’s something to be said for playing classic games on real hardware.