Hackaday Prize Entry: Health-Monitoring Flexible Smartwatch

July 15, 2017 by John Baichtal 17 Comments

[Nick Ames]’s Flexible Smartwatch project aims to create an Open Source smartwatch made out of a flexible, capacitive e-ink touchscreen that uses the whole surface of the band. This wraparound smartwatch displays information from the on-board pulse and blood oximetry sensor as well as the accelerometer and magnetometer, giving you a clear idea of how stressed you are about your upcoming meeting.

The display [Nick] went with is called an electrophoretic display (EPD). It’s 400×200-pixels at 115ppi with a 4″ diagonal, and can bend around a wrist. It can draw shapes in 16 shades of gray with a refresh time of under a second or B&W with a faster refresh.

The smartwatch described in [Nick]’s project would be 2.5mm thick — certainly thin enough to fit under a sleeve. We suspect that success of the form factor may hinge on [Nick]’s success in making it not look like a hospital wristband. Although this gives us the thought that a biofeedback-sensing smart wristband is probably the future of hospital stays.

Hydrodipping 101

July 15, 2017 by Dan Maloney 34 Comments

Style counts, and sometimes all it takes to jazz up the product of a 3D-printer is a 2D printer and a how-to guide on hydrographic printing.

Hydrographic printing, sometimes called hydrodipping, is a process for transferring graphics onto complex-shaped objects in one simple step. A design is printed on a special film which is then floated on the surface of a tank of water. The object to be decorated is carefully dipped into the water right through the film and the design wraps around all the nooks and crannies in one step.

The video tutorial below details the steps to hydrographic printing and outlines how easy the method has become with the availability of water transfer films for inkjet printers. The film is polyvinyl acetate, which is essentially white glue and hence quite soluble in water. The film dissolves and leaves the ink floating on the surface, ready for dipping.

The video lists quite a few tips for optimizing the process for 3D-printed parts and should let you decorate your parts quickly and easily. And once you master the basics, you might want to look at mathematically warping your design to hydrodip complex surfaces.

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Let’s Play Spot The Fake MOSFET

July 15, 2017 by Brian Benchoff 82 Comments

Recently, the voice push to talk circuit in [Ryan]’s BITX40 radio was keyed down for a very long time. Blue smoke was released, a MOSFET was burnt out, and [Ryan] needed a new IRF510 N-channel MOSFET. Not a problem; this is a $1 in quantity one, but shipping from Mouser or Digikey will always kill you if you only buy one part at a time. Instead, [Ryan] found a supplier for five of these MOSFETs for $6 shipped. This was a good deal and a bad move because those new parts were fakes. Now we have an opportunity to play spot the fake MOSFET and learn that it’s all about the supply chain.

To be fair to the counterfeit MOSFET [Ryan] acquired, it probably would have worked just fine if he were using his radio for SSB voice. [Ryan] is using this radio for digital, and that means the duty cycle for this MOSFET was 100% for two minutes straight. The fake got hot, and the magic blue smoke was released.

Through an industry contact, [Ryan] got a new, genuine IRF510 direct from Vishay Semiconductors. This is a fantastic opportunity to do a side-by-side comparison of real and counterfeit semiconductors, shown at right. Take a look: the MOSFET on the left has clear lettering, the one on the right has tinned leads and a notched heatsink. [Ryan] posed the question to a few Facebook groups, and there was a clear consensus: out of 37 votes, 21 people chose the MOSFET on the left to be genuine.

The majority of people were wrong. The real chip looked ugly, had tinned leads, and a thinner heatsink. The real chip looked like a poor imitation of the counterfeit chip.

What’s the takeaway here? Even ‘experts’ — i.e. people who think they know what they’re talking about on the Internet — sometimes don’t have a clue when it comes to counterfeit components. How can you keep yourself from being burned by counterfeit components? Stick to reputable resellers (Mouser, Digikey, etc) and assume that too good to be true is too good to be true.

STM32CubeMX Makes Makefiles

July 15, 2017 by Elliot Williams 31 Comments

When hardware manufacturers make GUI code-generation tools, the resulting files often look like a canned-spaghetti truck overturned on the highway — there’s metaphorical overcooked noodles and red sauce all over the place. Sometimes we think they’re doing this willfully to tie you into their IDE. Not so the newest version of ST’s graphical STM32CubeMX, which guides you through a pleasant pin-allocation procedure and then dumps out, as of the latest version, a clean Makefile.

Yes, that’s right. This is a manufacturer software suite that outputs something you can actually use with whatever editor, GUI, compiler, or environment that you wish — even the command line. Before this release, you had to go through a hacky but functional script to get a Makefile out of the CubeMX. Now there’s official support for real hackers. Thanks, ST!

If you’re compiling on your own, you’ll need to update the BINPATH variable to point to your compiler. (We use the excellent GNU ARM Embedded Toolchain ourselves, which is super-easy to install on almost any Linux.) If you want to use STM32CubeMX with the Eclipse IDE, [kali prasad yadav] sent us PDF instructions — it’s not hard.

If you doubt that the availability of a free, open, and non-constraining toolchain can matter for a silicon vendor, we’d point to AVR and the Arduino platform that spun off of their support of GCC. Sure, Atmel still pushes their all-in-one wonder, Atmel Studio, which is better than the Arduino IDE by most any metric. But Studio is closed, and Arduino is open. We’d love to see the number of Studio users compared with Arduino users.

Congratulations to ST for taking a big step in the right, open-toolchain, direction.

Reflective Sensor Becomes Kart Racing Lap Counter

July 15, 2017 by Donald Papp 8 Comments

Once you have a track and a kart to race on it, what’s missing? A lap counter that can give your lap times in hardcopy, obviously! That’s what led [the_anykey] to create the Arduino-based Lap Timer to help him and his kids trim those precious seconds off their runs, complete with thermal printer for the results.

The hardware uses an infrared break-beam sensor module (a Velleman PEM10D) to detect when a kart passes by. This module is similar to a scaled-up IR reflective object sensor; it combines an IR emitter and receiver on one end, and is pointed at a reflector placed across the track, up to 10 meters away. When a kart breaks the beam, the module reports the event to the rest of the hardware. Only needing electronics on one side allows the unit to be self-contained.

An obvious shortcoming of this system is the inability to differentiate between multiple karts, but for timing a single driver’s performance it does the trick. What’s great about this project is it showcases how accessible hardware is today; a device like this is possible to put together with what are essentially off-the-shelf components available to any hobbyist, using an Arduino as the glue to hold it together. We’d only comment that a red-tinted piece of plastic as an overlay for the red display (and a grey-tinted one for the green) would make the LED displays much easier to read. Still, this is a very clean and well-documented build. See it in action in the video embedded below.

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Laser Exposing PCBs With A Blu-Ray Laser

July 14, 2017 by Jenny List 24 Comments

For those of us whose introduction to PCB making came decades ago and who share fond memories of permanent markers and crêpe paper sticky tape, the array of techniques available to PCB artists of today seem nothing short of magical. Toner transfer and peroxide etchant mixtures might seem run-of-the-mill to many readers, but even they are streets ahead of their predecessors from times past.

Photographic exposure of etch-resist coating has traditionally been performed with a UV lamp through a sheet of acetate film, but there is no reason why that should be the only way it can be performed. There have been plenty of projects using lasers or LEDs to draw a PCB design onto the coating as a raster, and a rather nice example from [Terje Io] using a Blu-Ray laser diode is the subject of the video below the break.

The diode is mounted on a gantry with a THK KR33 linear actuator that he tells us was unsuitable for his CNC mill due to backlash. This gives a claimed 1200 dpi resolution, over a 100 mm x 160 mm exposure area. Software is provided in a GitHub repository, taking a PNG image exported through a PDF printer. And since it’s got a UV laser, it can be used in a second pass to process UV-responsive soldermask film. ([Terje] cheats and uses a separate CNC mill to drill out the holes.) The result looks great.

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Behind The Scenes At A Professional Fireworks Show

July 14, 2017 by John Baichtal 18 Comments

Have you ever wondered what goes on behind the scenes at a big fireworks show? Last year [Kenneth] was asked to help manually ignite a fireworks show, and this consisted of him running down a row of shells with a road flare, lighting each one in turn. He apparently did so well that this year worked another show, this one with a more complicated setup.

The show [Kenneth] helped run consisted of 950 three-inch shells, wired in series into small groups, plus another 150 in 25-shell clusters used for the finale. The fireworks were organized in racks consisting of five three-inch diameter tubes of HDPE secured together by 2x4s. Each tube held a shell, and each shell came pre-wired with both a match fuse and electrically-triggered squib. Each squib or series of squibs connects to 45-channel breakouts, which connect to a control board.

Even after the show was completed, [Kenneth] had work to do, walking around and looking in each tube to see if there are any unfired shells. The dual wiring is so the shell can be fired with a flare if the squib is a dud. In this show they found six shells, and [Kenneth] was tasked with setting off those last shells with a road flare—otherwise they’d have to use a licensed and placarded vehicle just to transport a few shells.

For more fireworks goodness checkout this beautiful Arduino fireworks controller and this network-controlled fireworks launcher.

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