Starlink: A Review And Some Hacks

May 24, 2021 by 129 Comments

I could probably be described as a SpaceX enthusiast. I catch their launches when I can, and I’ve watched the development of Starship with great interest. But the side-effect of SpaceX’s reusable launch system is that getting to space has become a lot cheaper. Having excess launch capacity means that space projects that were previously infeasible become suddenly at least plausible. One of those is Starlink.

Starlink is SpaceX’s satellite Internet service. Wireless and cellular internet have helped in some places, but if you really live out in the sticks, satellite internet is your only option. And while satellite Internet isn’t exactly new, Starlink is a bit different. Hughesnet, another provider, has a handful of satellites in geostationary orbit, which is about 22,000 miles above the earth. To quote Grace Hopper, holding a nearly foot-long length of wire representing a nanosecond, “Between here and the satellite, there are a very large number nanoseconds.”

SpaceX opted to do something a bit different. In what seemed like an insane pipe dream at the time, they planned to launch a satellite constellation of 12,000 birds, some of them flying as low as 214 mile altitude. The downside of flying so low is that they won’t stay in orbit as long, but SpaceX is launching them significantly faster than they’re coming down. So far, nearly 1,600 Starlink satellites are in orbit, in a criss-crossing pattern at 342 miles (550 km) up.

This hundred-fold difference in altitude matters. A Hughesnet connection has a minimum theoretical latency of 480 ms, and in reality runs closer to 600 ms. Starlink predicts a theoretical minimum of under 10 ms, though real-world performance isn’t quite that low yet. In the few weeks I’ve had the service, ping times have fallen from mid-60s down to 20s and 30s. The way Starlink works right now, data goes up to the closest satellite and directly back to the connected ground station. The long-term plan is to allow the satellites to talk directly to each other over laser links, skipping over the ground stations. Since the speed of light is higher in a vacuum than in a fiber-optic cable, the fully deployed system could potentially have lower latency than even fiber Internet, depending on the location of the endpoint and how many hops need to be made.

I got a Starlink setup, and have been trying out the beta service. Here’s my experience, and a bonus hack to boot.

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A High Torque 3D Printed Harmonic Drive

May 24, 2021 by 5 Comments

Actuators that are powerful, accurate, compact, and cheap are like unicorns. They don’t exist. Yet this is what [3DprintedLife] needed for a robotic camera arm, so he developed a custom 3D printed high torque strain wave gearbox to be powered by a cheap NEMA23 stepper motor.

Strain wave gears, otherwise known as harmonic drives, are not an uncommon topic here on Hackaday. The work by deforming a flexible toothed spline with a rotating elliptical part, which engages with the internal teeth of an outer spline. The outer spline has a few more teeth, causing the inner spline to rotate slowly compared to the input, achieving very high gear ratios. Usually, the flexible spline is quite long to allow it to flex at one end while still having a rigid mounting surface at the other end. [3DprintedLife] got around this by creating a separate rigid output spline, which also meshes with the flexible spline. Continue reading “A High Torque 3D Printed Harmonic Drive” →

Ask Hackaday: How Is The Chip Shortage Affecting You?

May 24, 2021 by 133 Comments

Some friends of mine are designing a new board around the STM32F103 microcontroller, the commodity ARM chip that you’ll find in numerous projects and on plenty of development boards. When the time came to order the parts for the prototype, they were surprised to find that the usual stockholders don’t have any of these chips in stock, and more surprisingly, even the Chinese pin-compatible clones couldn’t be found. The astute among you may by now have guessed that the culprit behind such a commodity part’s curious lack of availability lies in the global semiconductor shortage.

A perfect storm of political unintended consequences, climate-related crises throttling Taiwanese chip foundries and shutting down those in the USA, and faulty pandemic recovery planning, has left the chipmakers unable to keep up with the demand from industries on the rebound from their COVID-induced slump. Particularly mentioned in this context is the automotive industry, which has seen plants closing for lack of chips and even models ditching digital dashboards for their analogue predecessors.

Chips on order everywhere on the Mouser website.
Chips on order everywhere on the Mouser website.

The fall-out from all this drama in the world’s car factories has filtered down through all levels that depend upon semiconductors; as the carmakers bag every scrap of chip fab capacity that they can, so in turn have other chip customers scrambled to keep their own supply lines in place. A quick scan for microcontrollers through distributors like Mouser or Digi-Key finds pages and pages of lines on back-order or out of stock, with those lines still available being largely either for niche applications, unusual package options, or from extremely outdated product lines. The chances of scoring your chosen chip seem remote and most designers would probably baulk at trying to redesign around an ancient 8-bit part from the 1990s, so what’s to be done?

Such things typically involve commercially sensitive information so we understand not all readers will be able to respond, but we’d like to ask the question: how has the semiconductor shortage affected you? We’ve heard tales of unusual choices being made to ship a product with any microcontroller that works, of hugely overpowered chips replacing commodity devices, and even of specialist systems-on-chip being drafted in to fill the gap. In a few years maybe we’ll feature a teardown whose author wonders why a Bluetooth SoC is present without using the radio functions and with a 50R resistor replacing the antenna, and we’ll recognise it as a desperate measure from an engineer caught up in 2021’s chip shortage.

So tell us your tales from the coalface in the comments below. Are you that desperate engineer scouring the distributors’ stock lists for any microcontroller you can find, or has your chosen device remained in production? Whatever your experience we’d like to know what the real state of the semiconductor market is, so over to you!

Custom Keyfob Fixes Mazda Design Mistake

May 24, 2021 by 60 Comments

While Mazda has made some incredible advances in fuel efficient gasoline engines over the past few years, their design group seems to have fallen asleep at the wheel in the meantime, specifically in regards to the modern keyfob design. The enormous size and buttons on the side rather than the face are contrary to what most people need in a keyfob: small size and buttons that don’t accidentally get pressed. Luckily, though, the PCB can be modified with some effort.

This particular keyfob has a relatively simple two-layer design which makes it easy to see where the connections are made. [Hack ‘n’ Tink] did not need the panic button or status LED which allowed him to simply cut away a section of the PCB, but changing the button layout was a little trickier. For that, buttons were soldered to existing leads on the face of the board using 30-gage magnet wire and silicone RTV. From there he simply needed to place the battery in its new location and 3D print the new enclosure.

The end result is a much smaller form factor keyfob with face buttons that are less likely to accidentally get pressed in a pocket. He also made sure that the battery and button relocation wouldn’t impact the antenna performance. It’s a much-needed improvement to a small but crucial part of the car; the only surprise is that a company that’s usually on point with technology and design would flop so badly on such a critical component.

Thanks to [Brian] for the tip!

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Cocktail Of Chemicals Makes This Blueprint Camera Unique

May 24, 2021 by 18 Comments

When you’re looking at blueprints today, chances are pretty good that what you’re seeing is anything but blue. Most building plans, diagrams of civil engineering projects, and even design documents for consumer products never even make it to paper, let alone get rendered in old-fashioned blue-and-white like large-format prints used to produced. And we think that’s a bit of a shame.

Luckily, [Brian Haidet] longs for those days as well, so much so that he built this large-format cyanotype camera to create photographs the old-fashioned way. Naturally, this is one of those projects where expectations must be properly scaled before starting; after all, there’s a reason we don’t go around taking pictures with paper soaked in a brew of toxic chemicals. Undaunted by the chemistry, [Brian] began his journey with simple contact prints, with Sharpie-marked transparency film masking the photosensitive paper, made from potassium ferricyanide, ammonium dichromate, and ammonium iron (III) oxalate, from the UV rays of the sun. The reaction creates the deep, rich pigment Prussian Blue, contrasting nicely with the white paper once the unexposed solution is washed away.

[Brian] wanted to go beyond simple contact prints, though, and the ridiculously large camera seen in the video below is the result. It’s just a more-or-less-lightproof box with a lens on one end and a sheet of sensitized paper at the other. The effective ISO of the “film” is incredibly slow, leading to problematically long exposure times. Coupled with the distortion caused by the lens, the images are — well, let’s just say unique. They’ve got a ghostly quality for sure, and there’s a lot to be said for that Prussian Blue color.

We’ve seen cyanotype chemistry used with UV lasers before, and large-format cameras using the collodion process. And we wonder if [Brian]’s long-exposure process might be better suited to solargraphy.

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Python Runs Through A Zombified 8-Bit AVR

May 23, 2021 by 16 Comments

As amazing as CircuitPython is, it hasn’t yet been ported to any 8-bit microcontrollers. [Chris Heo] was unsatisfied with his inability to use Python on his 8-bit ATmega4808 AVR, so he worked out a way to zombify it and bend it to his will using Python on his PC.

The trick to making this all work is the UPDI interface: a single-wire UART interface for programming and debugging Microchip’s newer 8-bit AVR microcontrollers. UPDI reaches deep into the microcontroller’s core, allowing you to stop and start execution of microcontroller code and access all of the onboard data and I/O. [Chris] realized this could be used to stop execution of any code running on the AVR and directly control the output pins using the pyupdi library. Since UPDI lets him modify the AVR’s I/O registers, he was also able to blink an LED and use the microcontrollers UART to send a message back to his PC without compiling a single line of code.

This may seem like an entirely unnecessary hack, but for devices too small or basic to have a JTAG interface for debugging this could be the best way to test and debug peripherals in an assembled circuit. We hope this catches on and would love to see how much of the chip can be controlled in this way. Maybe this will make it easy to experiment with the programmable logic that’s on some of the newer AVRs.

Iridescent Rainbow Chocolate, Just Add Diffraction Grating!

May 23, 2021 by 15 Comments

Chocolate plus diffraction grating equals rainbow chocolate

Here’s a great picture from [Jelly & Marshmallows] that shows off the wild effects of melted chocolate poured onto a diffraction grating. A diffraction grating is a kind of optical component whose micro-features act to disperse and scatter light. Diffraction gratings are available as thin plastic film with one side that is chock full of microscopic ridges, and the way light interacts with these ridges results in an iridescent, rainbow effect not unlike that seen on a CD or laserdisc.

It turns out that these micro-ridges can act as a mold, and pouring chocolate over a diffraction grating yields holo-chocolate. These photos from [Jelly & Marshmallows] show this effect off very nicely, but as cool as it is, we do notice that some of the letters seem a wee bit hit-or-miss in how well they picked up the diffraction grating pattern.

Fortunately, we know just what to suggest to take things to the next level. If you want to know more about how exactly this effect can be reliably accomplished, you’ll want to check out our earlier coverage of such delicious optics, which goes into all the nitty-gritty detail one could ever want about getting the best results with either melted sugar, or dark chocolate.