Put A Hardened Edge On Mild Steel With Just A Drill Bit. Sort Of.

December 27, 2020 by 31 Comments

People have been working metal for so long that the list of tips and tricks is now nearly infinite. So it’s always a joy to pick up a new trick, especially one as simple as putting a hardened edge on mild steel using a drill bit as a filler rod.

This tip comes to us by way of [Jody], aka “The Weldmonger” on YouTube. Subscribing to his channel is a sure way to keep your welding ego in check; you may be good, but [Jody] is better, and he’s willing to share as much of his experience in video format as possible. For this tip, he starts with a cheap chipping hammer, the universal welder’s tool that helps remove the glass-like slag that forms during shielded-metal arc welding, or what’s commonly known as stick welding. The mild steel of the hammer makes it hard to keep an edge, so [Jody] pulled out his TIG welder and laid down a bead on the cutting edge using an old drill bit as a fill rod. The video below shows the process in all its simplicity.

The tool steel of the drill bit is far harder than the mild steel of the hammer, but still soft enough to take an edge, and the resulting tool is much improved. We’ve seen something similar to this before, when hard-facing filler rod was built up on the edge of a mild steel slug to make a cutter for internal weld seams. We liked that hack, but knowing the same thing can be done with something we’ve all likely got in abundance in the shop is a neat trick. Thanks, [Jody]!

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76-bit Trombones Led By The Big MIDI File

December 27, 2020 by 30 Comments

Inspired by the creative genius of Martin Molin of Wintergatan fame, [iSax] set out to create a robotic MIDI-controlled trombone. It takes years for humans to develop the control and technique required to play the trombone well as the tone produced into the mouthpiece (embouchure) is a tricky combination of air pressure, lip tension, airflow, resonance in the mouth, and other sources of complex pressure.

[iSax] gives a thorough walkthrough of the machine, which is powered by two separate sources of air, one for the position of the slide and the other for producing sound. A potentiometer provides feedback on the position of the slide and a servo controls the flow rate into the silicone resonance chamber. The chamber can be tuned via a stepper motor that applies pressure, slightly altering the chamber’s frequency and pressure. An Arduino with Firmata allows the device to controlled easily from any host computer. A detailed writeup in PDF form is on the Hackday.io project page.

As you can imagine, simulating a human mouth is a daunting task and the number of variables meant that [iSax] ended up with something only vaguely trombone-like. While ultimately it didn’t turn out to be the astounding music machine that [iSax] hoped, it did end up being a fun feat of engineering we can appreciate and admire. Progress towards automatic brass instruments seems to be coming slowly as we saw similar results with this robotic trumpet. Maybe someday we’ll have robot brass sections, but not today.

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Custom Powerbank In Compact Form Factor

December 27, 2020 by 28 Comments

The wide availability and power density of 18650 lithium-ion cells have made them a good option for everything from electric cars to flashlights. [Theo] needed a new power source for his FPV drone goggles, so he designed his own power bank with a very compact charge controller.The narrow PCB slips in between the cells

While [Theo] could charge the batteries with an RC battery charger, he preferred the convenience of one with a standard 5V micro USB input, and wanted battery level indication to avoid having the FPV goggles die unexpectedly mid-flight. When four 18650 cells are held in a cube arrangement, a 8x8x65 mm gap is formed between the cells. In this space [Theo] was able to fit a custom PCB with a micro USB jack, 1.3 mm power jack, BQ25606 charge controller, TPS61085 boost converter, and ATtiny MCU with LED for battery level feedback. The charge controller also allows 5V devices to be charged via USB, while the boost converter outputs 9V via the 1.3mm jack for [Theo]’s FPV goggles. Everything fits inside a nice compact 3D printed enclosure.

The project was not without hiccups. After ordering and building the PCB he discovered some minor PCB layout mistakes, and realized the boost converted could only output 600mA at 9V, which was not enough for his more power-hungry googles. He plans to fix this in the next version.

We’ve seen custom power banks in quite a few shapes and sizes, including one that runs on power tool batteries (which probably also have 18650s inside) and one that has just about every output you could want, including AC and wireless QI charging.

A Tracker For Radio Sondes

December 27, 2020 by 12 Comments

Radiosondes – the telemetry packages carried aloft by sounding balloons for atmospheric weather data measurements – are regularly used by weather bureaus around the world to collect data, and there are quite a number of launches daily. Most of them are in Europe, but they also happen at many locations in North and South America, Japan, and Australia. The balloons burst when they reach a high enough altitude, the radiosonde falls back, and most often there is no effort made to recover them since they are deemed “expendable”. So it’s Finders Keepers, and rich pickings for any hacker who is fortunate enough to grab the fallen radiosondes. For successful recovery, you need to first be able to track those radiosondes, and that’s why leet guy [Robert Stefanowicz aka p1337] built his Weather ballon tracker (sic) project.

The hardware is all off-the-shelf, packaged in a pretty cool 3D printed package designed to make it look like the hand held radio that it is. At its heart is the ESP32 based TTGO T-BEAM V1.0 which has almost everything needed for this project. Add an OLED display, 18650 Li-Po cells, antenna and connectors and you can put it all together in an evening over your favourite beverage.

[DL9RDZ] wrote the software which runs on the T-Beam, available at the RDZ-Sonde repo on Github, that allows hunting these balloons. Setup is straightforward, and you need to fiddle with just a couple of well-explained config parameters. Once connected to your WiFi, config and settings can be accessed via convenient web URL’s and the single user action button on the TTGO offers quick access to different functional modes. At the moment, the software is written to decode signals from the widely used Vaisala RS41, Graw DFM06 and Graw DFM09 radiosondes. This LINK provides details for some of the popular radiosonde models.

Once you’re done building this piece of hunting gear, you’ll need some additional help finding out when and where the launches are taking place. If you’re in Europe, you luck out – there is a live radiosonde tracker map, thanks to the great work done by [Michał Lewiński – SQ6KXY]. If you live else where and know of similar resources, let us know in the comments. As a side note, Wikipedia tells us there are about 1300 launch sites worldwide and twice a day missions, so there’s quite a number of fallen pieces of hardware lying around just waiting to be picked up. At the very least, each will have a GPS module and temperature and humidity sensors that you can recover.

So, what do you do with the recovered radiosondes ? Here’s a tip on a “Fallen Radiosonde reborn as active L-band antenna“. And If you’d like to get the skinny on radiosondes, check out “Radiosondes: getting data from upstairs”

Thanks for the tip, [Alex aka MD23F3].

3D Printed Server Case Holds 14 Raspberry Pis

December 26, 2020 by 26 Comments

If you ever need to cluster up to 14 Raspberry Pis and an equal number of 2.5 inch hard drives, you might want to look at the Raspberry Pi Server Mark III case from [Ivan Kuleshov]. The original Mark I design came from Thingiverse, but the Mark III is a complete redesign.

The redesign allows for more boards along with a reduction in the number of parts. That takes less plastic and less time to print. The design is also modular, so there should be new components in the future.

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Analyzing The “Source Code” Of The COVID-19 Vaccine

December 26, 2020 by 54 Comments

Computer programs are written in code, which comes in many forms. At the lowest level, there’s machine code and assembly, while higher-level languages like C and Python aim to be more human-readable. However, the natural world has source code too, in the form of DNA and RNA strings that contain the code for the building blocks of life. [Bert] decided to take a look at the mRNA source code of Tozinameran, the COVID-19 vaccine developed by BioNTech and Pfizer.

The analysis is simple enough for the general reader, while nonetheless explaining some highly complex concepts at the cutting edge of biology. From codon substitutions for efficiency and the Ψ-base substitution to avoid the vaccine being destroyed by the immune system, to the complex initialisation string required at the start of the RNA sequence, [Bert] clearly explains the clever coding hacks that made the vaccine possible. Particularly interesting to note is the Prolase substitution, a technique developed in 2017. This allows the production of coronavirus spike proteins in isolation of the whole virus, in order to safely prime the immune system.

It’s a great primer and we can imagine it might inspire some to delve further into the rich world of genetics and biology. We’ve featured other cutting edge stories on COVID-19 too; [Dan Maloney] took a look at how CRISPR techniques are helping with the testing effort. If there’s one thing the 2020 pandemic has shown, it’s humanity’s ability to rapidly develop new technology in the face of a crisis.

Squeezing Every Bit From An ATMega

December 26, 2020 by 16 Comments

While the ATMega328 is “mega” for a microcontroller, it’s still a fairly limited platform. It has plenty of I/O and working memory for most tasks, but this Battleship game that [thorlancaster328] has put together really stretches the capabilities of this tiny chip. Normally a Battleship game wouldn’t be that complicated, but this one has audio, an LED display, and can also play a fine rendition of Nyan Cat to boot, which really puts the Atmel chip through its paces.

The audio is played through a 512-byte buffer and an interrupt triggers the microcontroller when to fill the buffer while it works on the other processes. The 12×12 LED display is also fed through a shift register triggered by the same interrupt as the audio, and since the build uses so many shift registers the microcontroller can actually output four separate displays (two players, each with a dispaly for shots and one for ships). It will also eventually support a player-vs-computer mode for the battleship game, and also has a mode where it plays Nyan cat just to demonstrate its own capabilities.

We’re pretty impressed with the amount of work this small microcontroller is doing, largely thanks to code optimization from its creator [thorlancaster328]. If there’s enough interest he also says he will provide the source code too. Until then, be sure to check out this other way of pushing a small microcontroller to its limits.

Thanks to [Thinkerer] for the tip!