New Part Day: Sonoff USB Smart Adaptor Taps A New WiFi Chip

December 26, 2019 by 49 Comments

For decades, we dreamt of a future where all of our electronics used a standardized power connector. Most of us probably didn’t expect that USB would ultimately fill that role, but we’ll take what we can get if it means a future without getting a new wall wart for every piece of tech we buy. From soldering irons to laptops, the number of things you can power with a lowly USB cable these days is pretty incredible.

Which makes it all the more surprising it took so long for somebody to come up with a way to toggle USB devices off and on over the network. The Sonoff “USB Smart Adaptor”, which the company says will start shipping before the end of the year, is the logical evolution of their exceptionally popular mains voltage smart switches. The Smart Adapter is designed to go between the device and its existing power supply, allowing the user to drag any USB powered device kicking and screaming into their existing smart home setup. All for the princely sum of $6.50 USD.

In the video after the break, Sonoff gives a few potential uses of the Smart Adapter: from controlling a string of LEDs to limiting how long a smartphone is allowed to charge for. But really, there’s a nearly limitless number of devices which could be easily and cheaply integrated into your home automation routines thanks to this gadget.

On the other end of the spectrum, those who are looking to keep a tighter control on the ears and eyes that are active in their home could use the Smart Adapter to make sure their Google and Amazon listening devices assistants are only powered up during certain hours of the day.

Unfortunately, there’s a catch. Sonoff smart switches are best known, at least among the type of folks who read Hackaday, for the fact that they’re based on the eminently hackable ESP8266 microcontroller. Given the size of this product and its intended use, it would seem logical enough to assume this device also utilizes the insanely popular chip. But according to a Sonoff representative, the USB Smart Adapter won’t be using an ESP at all; leaving its hackability an open question until people can actually get their hands on them and start poking around.

Continue reading “New Part Day: Sonoff USB Smart Adaptor Taps A New WiFi Chip” →

Custom Control Panels With Photogrammetry

December 26, 2019 by 22 Comments

One of the best applications for desktop 3D printing is the creation of one-off bespoke components. Most of the time a halfway decent pair of calipers and some patience is all it takes to model up whatever part you’re after, but occasionally things get complex enough that you might need a little help. If you ever find yourself in such a situation, salvation might be just a few marker scribbles away.

As [Mangy_Dog] explains in a recent video, he wanted to model a control panel for a laser cutter he’s been working on, but thought the shapes involved were a bit more than he wanted to figure out manually. So he decided to give photogrammetry a try. For the uninitiated, this process involves taking as many high-resolution images as possible of a given object from multiple angles, and letting the computer stitch that into a three dimensional model. He reasoned that if he had a 3D model of the laser’s existing front panel, it would be easy enough to 3D print some replacement parts for it.

That would be a neat enough trick on its own, but what we especially liked about this video was the tip that [Mangy_Dog] passed along about increasing visual complexity to improve the final results. Basically, the software is looking for identifiable surface details to piece together, so you can make things a bit easier for it by taking a few different colored markers and drawing all over the surface like a toddler. It might look crazy, but all those lines give the software some anchor points that help it sort out the nuances of the shape.

Unfortunately the markers ended up being a little more permanent than [Mangy_Dog] had hoped, and he eventually had to use acetone to get the stains off. Certainly something to keep in mind. But in the end, the 3D model generated was accurate enough that (after a bit of scaling) he was able to design a new panel that pops right on as if it was a factory component.

Hackaday readers may recall that when we last heard from [Mangy_Dog] he was putting the finishing touches on his incredible “Playdog Blackbone” handheld gaming system, which itself is a triumph of mating 3D printed components with existing hardware.

Continue reading “Custom Control Panels With Photogrammetry” →

Adding USB-C To The TS100, But Not How You Think

December 26, 2019 by 11 Comments

USB-C has its special Power Delivery standard, and is capable of delivering plenty of juice to attached hardware. This has led many to modify their TS-100 soldering irons to accept the connector. [Jana Marie] is the latest, though she’s taken rather a different tack than you might expect.

[Jana] didn’t want to modify the original hardware or hack in an adapter. Instead, she struck out on her own, developing an entire replacement PCB for the TS-100 iron. The firmware is rough and ready, and minimal work has been done on the GUI and temperature regulation. However, reports are that functionality is good, and [Jana]’s demonstration shows it handling a proper desoldering task with ease.

Files are on Github for those that wish to spin their own. The PCB is designed to snap neatly inside the original case for a nice fit and finish. Power is plentiful too, as the hardware supports USB Power Delivery 2.0, which is capable of running at up to 100 W. On the other hand, the stock TS-80 iron, which natively supports USB-C, only works with Quick Charge 3.0, and thus is limited to a comparatively meager 36 W.

We’ve seen plenty of TS-100 hacks over 2019. Some have removed the standard barrel jack and replaced it with a USB-PD board. Meanwhile, others have created adapters that plug in to the back of the iron. However, [Jana] is dictating her own terms by recreating the entire PCB. Sometimes it pays to go your own way!

[Thanks to elad for the tip!]

Circuit Sculpture Teaches Binary, Plays PONG

December 25, 2019 by 2 Comments

We sure wish we’d had a teacher like [Danko Bertović]. He built this beautiful circuit sculpture to teach his students how to count in binary and convert it to decimal and hexadecimal. If you don’t already know binary, you get to learn it on DIP switches and a dead-bugged ATMega328 in his latest Volos Projects video after the break. Lucky you!

Once the students have the hang of entering binary input on the switches, they can practice it on the four-banger calculator. This educational sculpture can also take text input and scroll it, but it takes a bit of work. You have to look up the ASCII value of each character, convert the decimal to binary, and program it in with the switches. There’s one more function on the menu — a one-player PONG game to help the students relax after a long day of flipping switches.

Funny enough, this project came to be after [Danko] came upon the DIP switch in his parts box and wasn’t quite sure what it was called. How great is it that he learned something about this part, and then used that knowledge to build this machine that uses the part to teach others? It’s surely the best fate that parts bin curiosities can hope for.

Don’t have the patience for circuit sculpture? You can make a pretty nice binary calculator with a bit of paper and a lot of compressed air.

Continue reading “Circuit Sculpture Teaches Binary, Plays PONG” →

DIY Scalar Network Analyzer

December 25, 2019 by 1 Comment

[Steven Merrifield] built his own Scalar Network Analyzer and it’s a beauty! [Steve]’s SNA has a digital pinout matching a Raspberry Pi, but any GPIO could be used to operate the device and retrieve the data from the ADC. The design is based around a few tried and true chips from Analog Devices. He’s taken some care to design it to be nice and accurate which is why he’s limited it to 1kHz to 30Mhz. We think it’s quite a fetching board once the shielding is in place.

We’ve covered network analyzers and their usefulness before. If you want to know how, for example, a mystery capacitor from your junk bin will respond to certain frequencies, a network analyzer could tell you. We’ve even taken a stab at hacking together our own.

There is more documentation on his website as well as some additional example curves. The board is easily ordered from OSHpark and the source code is available for review.

The HackadayPrize2019 is Sponsored by:

A Car That Runs On Homemade Chemical Reactions

December 25, 2019 by 11 Comments

The race for chemical engineering is quite literally on. Every year, the American Institute of Chemical Engineers (AlChE) brings together hundreds of university students to face-off to design the fastest car using techniques they’ve learned from chemical engineering courses.

The Chem-E-Car competition races cars which are only powered by chemical reactions. The goal is to come up with an elegant solution – you can’t simply jettison matter out the back as the method of locomotion. In particular, the rules don’t allow the use of liquid or obnoxious odor discharge, commercial batteries, brakes, or electrical/mechanical timing devices. However, this doesn’t mean that electronics are absent from these designs. Many teams must gather data in order to design a control system to improve the performance of their car.

Students have to build a power system, stopping mechanism, circuitry, and mechanical assembly for the body of the car, all to fit in a size constraint not much bigger than a shoebox. The competition primarily judges the accuracy of the chemical reaction for stopping the car more so than speed or power. Given that the load the car must carry is typically unknown until the day of the competition, this is a significant challenge, allowing teams to find a way to design a flexible reaction that can accommodate a range of loads and distances.

For example, this 2015 entry from the Rice University team (PDF) uses a fuel cell for locomotion and an iodine clock reaction as a timer for braking. The fuel cell powers an Arduino which monitors a light-dependent resistor. In between the LED and that LDR, the clock reaction turns opaque at a predictable time and triggers the motors to stop turning.

While many schools choose not to disclose their designs in order to gain a competitive edge, we applaud the teams who have shared the story of their builds. Kudos to the Rice team mentioned above, to the 2014 Rutger’s team whose white paper outlines the construction of aluminum air batteries worthy of Walter White, to the car from the Universitas Negeri Semarang, Indonesia powered by a thermoelectric generator (PDF), the UC Berkeley team for outlining numerous approaches to developing their power system, and the two Ohio State team’s entries seen winning the regional competition in the video below.

If you were on a team that compete the the Chem-E-Car, we want to hear about it!

Continue reading “A Car That Runs On Homemade Chemical Reactions” →

Finishing FDM Prints With SLS Resin

December 25, 2019 by 17 Comments

[Thomas Sanladerer] has a filament-based 3D printer and a resin one. Can the two types of raw material combine to make something better? [Thomas] did some experiments using some magnets to suspend the parts and a hot air soldering gun to heat things up.

The trick turns out to be cutting the resin with alcohol. Of course, you also need to use a UV light for curing.

The parts looked pretty good, although he did get different results depending on a few factors. To see how it would work on a practical part, he took a very large printed alien egg. The problem is, the egg won’t fit in the curing station. A few minutes with a heat sink, a drill press, and an LED module was all it took to build a handheld UV curing light.

The good news is you don’t need a resin printer to take advantage of the process — just the resin. He also points out that if you had parts which needed to maintain their dimensions because they mate with something else, you could easily mask the part to keep the resin away from those areas.

If this video (and the results it shows) has you interested, then you’ll love the in-depth account that [Donald Papp] wrote up last year about his own attempts to smooth 3D printed parts with UV resin.

Continue reading “Finishing FDM Prints With SLS Resin” →