Your BOM Is Not Your COGS

December 6, 2018 by 83 Comments

“The prototype was $12 in parts, so I’ll sell it for $15.” That is your recipe for disaster, and why so many Kickstarter projects fail. The Bill of Materials (BOM) is just a subset of the Cost of Goods Sold (COGS), and if you aren’t selling your product for more than your COGS, you will lose money and go out of business.

We’ve all been there; we throw together a project using parts we have laying around, and in our writeup we list the major components and their price. We ignore all the little bits of wire and screws and hot glue and time, and we aren’t shipping it, so there’s no packaging to consider. Someone asks how much it cost, and you throw out a ballpark number. They say “hey, that’s pretty reasonable” and now you’re imagining making it in volume and selling it for slightly higher than your BOM. Stop right there. Here’s how pricing really works, and how to avoid sinking time into an untenable business.

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Your USB Serial Adapter Just Became A SDR

December 6, 2018 by 39 Comments

To say that the RTL-SDR project was revolutionary might be something of an understatement. Taking a cheap little USB gadget and using it as a Software Defined Radio (SDR) to explore the radio spectrum from the tens of megahertz all the way into gigahertz frequencies with the addition of nothing more than some open source tools may go down as one of the greatest hacks of the decade. But even in the era of RTL-SDR, what [Ted Yapo] has manged to pull off is still pretty incredible.

With a Python script, a length of wire attached to the TX pin, and a mastery of the electron that we mere mortals can only hope to achieve, [Ted] has demonstrated using a common USB to serial adapter as an SDR transmitter. That’s right, using the cheap little UART adapter you’ve almost certainly got sitting in your parts bin right now and his software, you can transmit in the low megahertz frequencies and even up into VHF with some trickery. The project is still very much experimental, and though this may be the first time, we’re willing to bet this isn’t the last time you’ll be hearing about it.

The basic idea is that when sending certain characters over the UART serial line, they can combine with the start and stop bits to produce a square wave burst at half the baud rate. [Ted] found that sending a string of 0x55 at 19200 baud would generate a continuous square wave at 9600 Hz, and if he turned the baud rate all the way up to 2,000,000 where these USB adapters top out, that signal was transmitted at 1 MHz, right in the middle of the AM dial.

A neat trick to be sure, but alone not terribly useful. The next step was to modulate that signal by sending different characters over UART. [Ted] explains at great length his experiments with multi-level quantization and delta-sigma schemes, and each step of the way shows the improvement of the transmitted audio signal. Ultimately he comes up with a modulation scheme that produces a impressively clean signal, all things considered.

This alone is impressive, but [Ted] isn’t done yet. He realized that this method of transmission was generating some strong frequency harmonics which extended far beyond the theoretical maximum 1 MHz frequency of his UART SDR. In his experimentation he found he was able to pick up a signal from all the way out to 151 MHz, though it was too poor to be of any practical use. Dialing back the expectations a bit, he was able to successfully control a cheap 27 MHz RC toy using the 43rd harmonic of a 631 kHz signal at a range of about 10 feet with a FT232RL adapter, which he notes produces the cleanest signals in his testing.

[Ted] is still working on making transmissions cleaner and stronger by adding filters and amplifiers, but these early accomplishments are already very promising. His work reminds us of a low frequency version of the USB to VGA adapter turned GHz SDR transmitter, and we’re very eager to see where it goes from here.

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A Christmas Tree For Your Lab

December 6, 2018 by 12 Comments

It seems like holiday decorations come up earlier and earlier every year. You might not have room for a full-blown tree in your lab, but if you have an arbitrary waveform generator and a scope, Tektronix has a way for you to show your spirit electronically.

You can see the video below. Naturally, it features Tektronix gear, but we are pretty sure you could make it work with any arbitrary waveform generator that has at least two channels and a scope with an XY mode.

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1970s Lab Equipment Turned Retro Pi Terminal

December 5, 2018 by 20 Comments

When it was released, the Beckman Model 421 CRT controller represented the latest and greatest in liquid chromatography technology. Its 12 inch screen would allow the operator to view critical information such as flow rate and concentration, and its integrated keyboard simplified system control. It made liquid chromatography faster and easier, allowing lab technicians to focus on analysis rather than the complexities of operating the equipment.

But none of that matters right now. What matters is that [Igor Afanasyev] found one of these gloriously vintage devices at a local swap meet and decided it deserved a second chance at life. With a Raspberry Pi and a surprising amount of support hardware, he was able to turn this roughly 40 year old piece of scientific equipment into a multipurpose device that does everything from classic gaming to multimedia playback. It’s got a few quirks, but overall this is a gadget that any hacker would love to have kicking around their modern-day lab.

[Igor] explains that the Model 412 is essentially just a dumb terminal with no internal logic, so in theory it should have been possible to just hang the thing on a serial port and be done with it. But unfortunately the display drive board was dead, so a full rebuild was in order. This meant that there’s little left of the original device other than the keyboard and the case itself, but since it isn’t exactly a “vintage computer” in the traditional sense, we think the purists will allow it.

For the display, [Igor] used an LCD he salvaged from an old digital picture frame. It was the right size to fit the opening, and thanks to an unpopulated VGA header on the board, wasn’t too difficult to get connected to the Pi with an HDMI adapter. He also added a hardware VGA scanline generator board so that no matter what the Pi shows it will have that classic old-school look; a fantastic detail we don’t usually see on builds like this.

The keyboard on the Model 412 was more of a control panel than a traditional input device, so not only does it have keycaps which say things like “FLOW RATE” and “WRITE TAPE”, but it has a fairly weird layout. After reverse engineering the somewhat unusual key matrix, he spun up a custom firmware for the Arduino Pro Micro using QMK which would let him use the board on the Pi as a standard USB input device. But rather than replace the keys, [Igor] created a little cheat-sheet overlay that he could put over the board to see what keys translate to which letters. It’s awkward for sure, but we really appreciate that he preserved the unique nature and look of the Model 412.

Like the Heathkit H19 that was brought back to life with an internal Raspberry Pi or the DEC VT100 with a BealeBone inside there’s something about the visual aesthetic and no-nonsense approach of these vintage terminals which continue to make them compelling into the 21st century.

A Portal Port Programmed For Platforms Of The Past

December 5, 2018 by 6 Comments

If you still have a Commodore 64 and it’s gathering dust, don’t sell it to a collector on eBay just yet. There’s still some homebrew game development happening from a small group of programmers dedicated to this classic system. The latest is a Portal-like game from [Jamie Fuller] which looks like a blast.

The Commodore doesn’t have quite the same specs of a Playstation, but that’s no reason to skip playing this version. It has the same style of puzzles where the player will need to shoot portals and manipulate objects in order to get to the goals. GLaDOS even makes appearances. The graphics by [Del Seymour] and music by [Roy Widding] push the hardware to its limits as well.

If you don’t have a C64 laying around, there are some emulators available such as VICE that can let you play this game without having to find a working computer from the 80s. You can also build your own emulator if you’re really dedicated, or restore one that had been gathering dust. And finally, we know it’s not, strictly speaking, a port of Portal, but some artistic license in headlines can be taken on occasion.

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The Complete Beginner’s Guide To Building A CNC Machine

December 5, 2018 by 18 Comments

Despite appearances, [This Old Tony]’s latest series has little to do with CNC-ifying an Etch A Sketch. Although he certainly achieves that, more or less, automating the classic toy is just the hook for a thorough lesson in CNC machine building starting with the basics.

Fair warning: we said basics, and we mean it. [Old Tony]’s intended audience is those who haven’t made the leap into a CNC build yet and need the big picture. Part one concentrates on the hardware involved – the steppers, drivers, and controller. He starts with one of those all-in-one eBay packages, although he did upgrade the motion controller to a Mach4 compatible board; still, the lessons should apply to most hardware.

By the end of part one, the Etch A Sketch is connected to two of the steppers and everything is wired up and ready to go for part two, the first part of which is all about inputs and outputs. Again, this is basic stuff, like how relays work and why you might need to use them. But that’s the kind of stuff that can baffle beginners and turn them off to the hobby, so kudos to [Old Tony] for the overview. The bulk of the second part is about configuring Mach4 Hobby, with a ton of detail and some great tips and tricks for getting a machine ready to break some end mills.

For someone looking to get into a CNC build, [Old Tony]’s hard-won CNC experience really fills in the gaps left by other tutorials. And it looks like a third part, dealing with making all this into something more than an automated Etch A Sketch, is in the works. We’re looking forward to that.

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Thrift Store Razor Scooter Gets More Kick

December 5, 2018 by 27 Comments

Beyond pride, the biggest issue keeping adults off small motorized scooters is the fact that their tiny motors usually don’t have the power to move anything heavier than your average eighth grader. That didn’t stop [The_Didlyest] from snapping up this $7 thrift store find, but it did mean the hot pink scooter would need to be beefed up if it had any hope of moving 170 lbs of hacker.

Logically, the first step was fitting a more capable motor. [The_Didlyest] used an electric wheelchair motor which had a similar enough diameter that mounting it was fairly straightforward. The original sprocket and chain are still used, as are the mounting holes in the frame (though they had to be tapped to a larger size). That said, the new motor is considerably longer than its predecessor so some frame metal had to be cut away. This left the scooter without a kickstand and with a few inches of motor hanging out of its left side, but it’s all in the name of progress.

Naturally the upgraded motor needed similarly upgraded batteries to power it, so [The_Didlyest] put together a custom pack using eighteen 18650 cells spot welded together for a total output of 25V. Coupled with a 60A battery management system (BMS), the final 6S 3P configured pack is a very professional little unit, though the liberal application of duct tape keeps it from getting too full of itself.

Unfortunately the original motor controller consisted of nothing but relays, and didn’t allow adjusting speed. So that needed to go as well. In its place is a homebrew speed controller made with three parallel MOSFETs and an Arduino to read the analog value from the throttle and convert that into a PWM signal.

[The_Didlyest] says the rear tire is now in need of an upgrade to transmit all this new power to the road, and some gearing might be in order, but otherwise the scooter rebuild was a complete success. Capable of mastering hills and with a top speed of about 10 MPH, the performance is certainly better than the stock hardware.

Of course this is far from the first time we’ve seen somebody put a little extra pepper on a scooter. Some of them even end up being street-legal rides.