3D Printed Battery Pack Keeps Old Drill Spinning

January 29, 2018 by Tom Nardi 12 Comments

The greatest enemy of proprietary hardware and components is time. Eventually, that little adapter cable or oddball battery pack isn’t going to be available anymore, and you’re stuck with a device that you can’t use. That’s precisely what happened to [Larry G] when the now antiquated 7.2V NiCd batteries used by his cordless drill became too hard to track down. The drill was still in great shape and worked fine, but he couldn’t power the thing. Rather than toss a working tool, he decided to 3D print his own battery pack.

The 3D modeling on the battery pack is impeccable

He could have just swapped new cells into his old pack, but if you’re going to go through all that trouble, why not improve on things a little? Rather than the NiCd batteries used by the original pack, this new pack is designed around readily available AA NiMH batteries. For the light repairs and craft work he usually gets himself into, he figures these batteries should be fine. Plus he already had them on hand, and as we all know, that’s half the battle when putting a project together.

Interestingly, the original battery pack was wired in such a way that it provided two voltages. In older tools such as this one, this would be used for rudimentary speed control. Depending on which speed setting the drill is on, it would either connect to 4 or 6 cells in the original pack. [Larry] didn’t want to get involved with the extra wiring and never used the dual speeds anyway, so his pack only offers the maximum speed setting. Though he does mention that it may be possible to do PWM speed control in the battery itself via a 555 timer if he feels like revisiting the project.

[Larry] tells us the pack itself was rendered completely from scratch, using only the original battery pack and trial-and-error to get the fit perfect. He reused the side-mounted release buttons to save time, but otherwise everything is 3D printed in PETG for its strength and chemical resistance.

This is an entry in Hackaday’s

Repairs You Can Print contest

The twenty best projects will receive $100 in Tindie credit, and for the best projects by a Student or Organization, we’ve got two brand-new Prusa i3 MK3 printers. With a printer like that, you’ll be breaking stuff around the house just to have an excuse to make replacement parts.

Smaller And Smarter: The Electron Rocket Takes Flight

January 29, 2018 by Tom Nardi 67 Comments

On January 21st, 2018 at 1:43 GMT, Rocket Lab’s Electron rocket lifted off from New Zealand’s Mahia Peninsula. Roughly eight minutes later ground control received confirmation that the vehicle entered into a good orbit, followed shortly by the successful deployment of the payload. On only their second attempt, Rocket Lab had become the latest private company to put a payload into orbit. An impressive accomplishment, but even more so when you realize that the Electron is like no other rocket that’s ever flown before.

Not that you could tell from the outside. If anything, the external appearance of the Electron might be called boring. Perhaps even derivative, if you’re feeling less generous. It has the same fin-less blunted cylinder shape of most modern rockets, a wholly sensible (if visually unexciting) design. The vehicle’s nine first stage engines would have been noteworthy 15 years ago, but today only serve to draw comparisons with SpaceX’s wildly successful Falcon 9.

But while the Electron’s outward appearance is about as unassuming as they come, under that jet-black outer skin is some of the most revolutionary rocket technology seen since the V-2 first proved practical liquid fueled rockets were possible. As impressive as its been watching SpaceX teach a rocket to fly backwards and land on its tail, their core technology is still largely the same as what took humanity to the Moon in the 1960’s.

Vehicles that fundimentally change the established rules of spaceflight are, as you might expect, fairly rare. They often have a tendency to go up in a ball of flames; figuratively if not always literally. Now that the Electron has reached space and delivered its first payload, there’s no longer a question if the technology is viable or not. But whether anyone but Rocket Lab will embrace all the changes introduced with Electron may end up getting decided by the free market.

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Spiral Laser Cut Buttons Make A Super-Slim USB MIDI Board

January 29, 2018 by Jenny List 15 Comments

We see a huge variety of human-computer interface devices here at Hackaday, and among them are some exceptionally elegant designs. Of those that use key switches though, the vast majority employ off the shelf components made for commercial keyboards or similar. It makes sense to do this, there are some extremely high quality ones to be had.

Sometimes though we are shown designs that go all the way in creating their key switches from the ground up. Such an example comes from [Brandon Rice], and it a particularly clever button design because of its use of laser cutting to achieve a super-slim result. He’s made a sandwich of plywood with the key mechanisms formed in a spiral cut on the top layer. He’s a little sketchy on the exact details of the next layer, but underneath appears to be a plywood spacer surrounding a silicone membrane with conductive rubber taken from a commercial keyboard. Beneath that is copper tape on the bottom layer cut to an interweaving finger design for the contacts. An Adafruit Trinket Pro provides the brains and a USB interface, and the whole device makes for an attractive and professional looking peripheral.

You can see the results in action as he’s posted a video, which we’ve included below the break.

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Inventing The Microprocessor: The Intel 4004

January 29, 2018 by Steven Dufresne 66 Comments

We recently looked at the origins of the integrated circuit (IC) and the calculator, which was the IC’s first killer app, but a surprise twist is that the calculator played a big part in the invention of the next world-changing marvel, the microprocessor.

There is some dispute as to which company invented the microprocessor, and we’ll talk about that further down. But who invented the first commercially available microprocessor? That honor goes to Intel for the 4004.

Path To The 4004

Busicom calculator motherboard based on 4004 (center) and the calculator (right)

We pick up the tale with Robert Noyce, who had co-invented the IC while at Fairchild Semiconductor. In July 1968 he left Fairchild to co-found Intel for the purpose of manufacturing semiconductor memory chips.

While Intel was still a new startup living off of their initial $3 million in financing, and before they had a semiconductor memory product, as many start-ups do to survive they took on custom work. In April 1969, Japanese company Busicom hired them to do LSI (Large-Scale Integration) work for a family of calculators.

Busicom’s design, consisting of twelve interlinked chips, was considered a complicated one. For example, it included shift-register memory, a serial type of memory which complicates the control logic. It also used Binary Coded Decimal (BCD) arithmetic. Marcian Edward Hoff Jr — known as “Ted”, head of the Intel’s Application Research Department, felt that the design was even more complicated than a general purpose computer like the PDP-8, which had a fairly simple architecture. He felt they may not be able to meet the cost targets and so Noyce gave Hoff the go-ahead to look for ways to simplify it.

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Chasing The Electron Beam At 380,000 FPS

January 29, 2018 by Adam Fabio 20 Comments

Analog TV is dead, but that doesn’t make it any less awesome. [Gavin and Dan], aka The Slow Mo Guys recently posted a video about television screens. Since they have some incredible high-speed cameras at their disposal, we get to see the screens being drawn, both on CRT and more modern LCD televisions.

Now we all know that CRTs draw one pixel at a time, drawing from left to right, top to bottom. You can capture this with a regular still camera at a high shutter speed. The light from a TV screen comes from a phosphor coating painted on the inside of the glass screen. Phosphor glows for some time after it is excited, but how long exactly? [Gavin and Dan’s] high framerate camera let them observe the phosphor staying illuminated for only about 6 lines before it started to fade away. You can see this effect at a relatively mundane 2500 FPS.

Cranking things up to 380,117 FPS, the highest speed ever recorded by the duo, we see even more amazing results. Even at this speed, quite a few “pixels” are drawn each frame. [Gavin] illustrates that by showing how Super Mario’s mustache is drawn in less than one frame of slow-mo footage. You would have to go several times faster to actually freeze the electron beam. We think it’s amazing that such high-speed analog electronics were invented and perfected decades ago.

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The Noisiest Seven-Segment Display Ever

January 29, 2018 by Dan Maloney 30 Comments

Few mechanical clocks are silent, and many find the sounds they make pleasant. But the stately ticking of an old grandfather clock or the soothing sound of a wind-up alarm clock on the nightstand are nothing compared to the clattering cacophony that awaits [ProtoG] when he finishes the clock that this electromechanical decimal to binary to hex converter and display will be part of.

Undertaken as proof of concept before committing to a full six digit clock build, we’d say [ProtoG] is hitting the mark. Yes, it’s loud, but the sound is glorious. The video below shows the display being put through its paces, and when the clock rate ramps up, the rhythmic pulsations of the relays driving the seven-segment flip displays is hypnotizing. The relays, one per segment of the Alfa Zeta flip displays, have DPDT contacts wired to flip a segment by reversing polarity. As a work in progress, [ProtoG] hasn’t shared many more details yet, but he promises to keep us up to date on the converter aspect of the circuit. Right now it just seems like a simple but noisy driver. We’ll be following this one with interest.

If you prefer your clocks quieter but still like funky displays, check out this mixed media circus-themed clock.

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Opt-Out Fitness Data Sharing Leads To Massive Military Locations Leak

January 28, 2018 by Roger Cheng 79 Comments

People who exercise with fitness trackers have a digital record of their workouts. They do it for a wide range of reasons, from gathering serious medical data to simply satisfying curiosity. When fitness data includes GPS coordinates, it raises personal privacy concerns. But even with individual data removed, such data was still informative enough to spill the beans on secretive facilities around the world.

Strava is a fitness tracking service that gathers data from several different brands of fitness tracker — think Fitbit. It gives athletes a social media experience built around their fitness data: track progress against personal goals and challenge friends to keep each other fit. As expected of companies with personal data, their privacy policy promised to keep personal data secret. In the same privacy policy, they also reserved the right to use the data shared by users in an “aggregated and de-identified” form, a common practice for social media companies. One such use was to plot the GPS data of all their users in a global heatmap. These visualizations use over 6 trillion data points and can be compiled into a fascinating gallery, but there’s a downside.

This past weekend, [Nathan Ruser] announced on Twitter that Strava’s heatmap also managed to highlight exercise activity by military/intelligence personnel around the world, including some suspected but unannounced facilities. More worryingly, some of the mapped paths imply patrol and supply routes, knowledge security officers would prefer not to be shared with the entire world.

This is an extraordinary blunder which very succinctly illustrates a folly of Internet of Things. Strava’s anonymized data sharing obsfucated individuals, but didn’t manage to do the same for groups of individuals… like the fitness-minded active duty military personnel whose workout habits are clearly defined on these heat maps. The biggest contributor (besides wearing a tracking device in general) to this situation is that the data sharing is enabled by default and must be opted-out:

“You can opt-out of contributing your anonymized public activity data to Strava Metro and the Heatmap by unchecking the box in this section.” —Strava Blog, July 2017

We’ve seen individual fitness trackers hacked and we’ve seen people tracked through controlled domains before, but the global scope of [Nathan]’s discovery puts it in an entirely different class.

[via Washington Post]