This is the continuation of a series of posts where I create a schematic and PCB in various EDA tools. Already, we’ve looked at Eagle CAD, KiCad, and took a walk down memory lane with one of the first PCB design tools for the IBM PC with Protel Autotrax. One of the more controversial of these tutorials was my post on Fritzing. Fritzing is a terrible tool that you should not use, but before I get to that, I need to back up and explain what this series of posts is all about.
The introduction to this series of posts laid it out pretty bare. For each post in this series, I will take a reference schematic for a small, USB-enabled ATtiny85 development board. I recreate the schematic, recreate the board, and build a new symbol and footprint in each piece of software. That last part — making a new symbol and footprint — is a point of contention for Fritzing users. You cannot create a completely new part in Fritzing. That’s a quote straight from the devs. For a PCB design tool, it’s a baffling decision, and I don’t know if I can call Fritzing a PCB design tool now.
Coming in at 125 cubic centimeters displacement, [Keith Harlow]’s fuel injected masterpiece isn’t too far from the size of some motor scooter engines. We doubt the local Vespa club would look upon it as legit mod, but we’d love to see it. [Keith]’s build log is a long series of forum posts, but from what we’ve seen it looks like every part was made by hand with the exception of the fuel injection system. Even the caps for the spark plugs were custom injection molded right in [Keith]’s shop. And it appears that no CNC was used – even those intake headers and the rotors for the supercharger were hogged out of aluminum using a manual mill. The exhaust headers alone are straight up works of art. There’s a staggering amount of work here, which begs the question: why? The answer in this case is obviously, “Because he can.”
Few builds compare to the level of craftsmanship on display here. The Clickspring skeleton clock comes to mind, but for model engine builds we’d have to point to [Keith]’s earlier 1/4-scale V8 engine. And we’ll hasten to add that as much time as [Keith] has spent building these works of mechanical art, he’s probably dedicated just as much time to documenting them and giving back to his community. We can all learn a lesson from that.
Normally, when something explodes it tends to be a bad day for all involved. But not every explosion is intended to maim or kill. Plenty of explosions are designed to save lives every day, from the highway to the cockpit to the power grid. Let’s look at some of these pyrotechnic wonders and how they keep us safe.
Explosive Bolts
The first I can recall hearing the term explosive bolts was in relation to the saturation TV coverage of the Apollo launches in the late 60s and early 70s. Explosive bolts seemed to be everywhere, releasing umbilicals and restraining the Saturn V launch stack on the pad. Young me pictured literal bolts machined from solid blocks of explosive and secretly hoped there was a section for them in the hardware store so I could have a little fun.
Pyrotechnic fasteners are mechanical fasteners (bolts, studs, nuts, etc.) that are designed to fail in a predictable fashion due to the detonation of an associated pyrotechnic device. Not only must they fail predictably, but they also have to be strong enough to resist the forces they will experience before failure is initiated. Failure is also typically rapid and clean, meaning that no debris is left to interfere with the parts that were previously held together by the fastener. And finally, the explosive failure can’t cause any collateral damage to the fastened parts or nearby structures.
Pyrotechnic fasteners fall into two broad categories. Explosive bolts look much like regular bolts, and are machined out of the same materials you’d expect to find any bolt made of. The explosive charge is usually internal to the shank of the bolt with an initiating device of some sort in the head. To ensure clean, predictable separation, there’s a groove machined into the bolt to create a shear plane.
Frangible nuts are another type of pyrotechnic fastener. These tend to be used for larger load applications, like holding down rockets. Frangible nuts usually have two smaller threaded holes adjacent to the main fastener thread; pyrotechnic booster charges split the nut across the plane formed by the threaded holes to release the fastener cleanly.
“Eject! Eject! Eject!”
Holding back missiles is one thing, but where pyrotechnic fasteners save the most lives might be in the cockpits of fighter jets around the world. When things go wrong in a fighter, pilots need to get out in a hurry. Strapping into a fighter cockpit is literally sitting on top of a rocket and being surrounded by explosives. Most current seats are zero-zero designs — usable at zero airspeed and zero altitude — that propel the seat and pilot out of the aircraft on a small rocket high enough that the parachute can deploy before the pilot hits the surface. Dozens of explosive charges take care of ripping the aircraft canopy apart, deploying the chute, and cutting the seat free from the parachuting pilot, typically unconscious and a couple of inches shorter from spinal disc compression after his one second rocket ride.
There’s little doubt that airbags have saved countless lives since they’ve become standard equipment in cars and trucks. When you get into a modern vehicle, you are literally surrounded by airbags — steering wheel, dashboard, knee bolsters, side curtains, seatbelt bags, and even the rear seat passenger bags. And each one of these devices is a small bomb waiting to explode to save your life.
When we think of explosives we tend to think of substances that can undergo rapid oxidation with subsequent expansion of hot gasses. By this definition, airbag inflators aren’t really explosives, since they are powered by the rapid chemical decomposition of nitrogenous compounds, commonly sodium azide in the presence of potassium nitrate and silicon dioxide. But the difference is purely academic; anyone who has ever had an airbag deploy in front of them or watched any of the “hold my beer and watch this” airbag prank video compilations will attest to the explosive power held in that disc of chemicals.
When a collision is detected by sensors connected to the airbag control unit (ACU), current is applied to an electric match, similar to the engine igniters used in model rocketry, buried within the inflator module. The match reaches 300°C within a few milliseconds, causing the sodium azide to rapidly decompose into nitrogen gas and sodium. Subsequent reactions mop up the reactive byproducts to produce inert silicate glasses and add a little more nitrogen to the mix. The entire reaction is complete in about 40 milliseconds, and the airbags inflate fully within 80 milliseconds, only to deflate again almost instantly through vent holes in the back of the bag. By the time you perceive that you were in an accident, the bag hangs limply from the steering wheel and with any luck, you get to walk away from the accident.
Grid Down
We’ve covered a little about utility poles and all the fascinating bits of gear that hang off them. One of the pieces of safety gear that lives in the “supply space” at the top of the poles is the fuse cutout, or explosive disconnector. This too is a place where a small explosion can save lives — not only by protecting line workers but also by preventing a short circuit from causing a fire.
Cutouts are more than just fuses, though. Given the nature of the AC transmission and distribution grid, the lines that cutouts protect are at pretty high voltages of 11 kV or more. That much voltage means the potential for sustained arcing if contacts aren’t rapidly separated; the resulting plasma can do just as much if not more damage than the short circuit. So a small explosive cartridge is used to rapidly kick the fuse body of a cutout out of the frame and break the circuit as quickly as possible. Arc suppression features are also built into the cutout to interrupt the arc before it gets a chance to form.
[Big Clive] recently did a teardown of another piece of line safety gear, an 11 kV lightning arrestor with an explosive disconnector. With a Dremel tool and a good dose of liquid courage, he liberated a carbon slug from within the disconnector, which when heated by a line fault ignites a .22 caliber charge similar to those used with powder actuated fastener tools. The rapid expansion of gasses ruptures the cases of the disconnector and rapidly breaks the circuit.
Conclusion
We’ve covered a few of the many ways that the power of expanding gas can be used in life safety applications. There are other ways, too — snuffing out oil field fires comes to mind, as does controlled demolition of buildings. But the number of explosives protecting us from more common accidents is quite amazing, all the more so when you realize how well engineered they are. After all, these everyday bombs aren’t generally blowing up without good reason.
To keep hackers fueled and hacking, why not hack a coffee maker into a coffee brewing robot? [Carter Hurd] and [David Frank] did just that at The Ohio State’s Hack OHI/O 24 hour Hackathon. They even won the “Best Hardware Hack”. The video below shows it in action but the guys sent us some extra details on how it’s made.
Alexa coffee maker robot
The electronics
To give it a voice they put Alexa on a Raspberry Pi. Using an audio splitter they have the voice go both to a speaker and to an Arduino. The Arduino then uses the amplitude of the audio signal’s positive values to determine how much to open the “mouth”, the coffee maker’s hinged cover. As is usually the case, there’s some lag, but the result is still quite good.
The brewing is also controlled by the Arduino. They plan to add voice control so that they can simply ask, “Alexa, make me coffee”, but for now they added a switch on the side to start the brewing. That switch tells the Arduino to work one servo to open the cover, another to insert a coffee filter, and two more to scoop up some coffee from a container and dump it into the filter.
They replaced the coffee maker’s on/off switch with a relay so that after the Arduino closes the cover again, it uses the relay to start the brewing. The result is surprisingly human-like. We especially like the graceful movement achieved by the two servos for scooping up and dumping the coffee. Full disclosure: they did admit that it would often either not scoop enough coffee or scoop enough but spill a bunch on the group.
Turning an Arduino of virtually any sort into a simple AVR 6-pin ISP programmer is old hat. But when Atmel came out with a series of really tiny AVR chips, the ATtiny10 and friends with only six pins total, they needed a new programming standard. Enter TPI (tiny programming interface), and exit all of your previously useful DIY AVR programmers.
[Kimio Kosaka] wrote a dual-purpose TPI and ISP firmware for the ATmegaxxUn chips that are used as a USB-serial bridge on the Unos, and constitute the only chip on board a Leonardo or Micro. The catch? You’re going to have to do a little bit of fine-pitch soldering. Specifically, [Kosaka-san] wants you to get access to an otherwise obscured signal by drilling out a via. We’d do it just for that alone.
One day there will be no more need for flames. [slider2732] has put yet another nail in the coffin of this most ancient of all technology by making a candle that uses a flicker LED that you blow out. A little more miniaturization and we’ll have them fully integrated into the size of birthday cake candles (Hint hint, hackers!).
You may have seen these candle flicker LEDs. They have a small chip inside them that modulates the LED’s light to flicker like a candle. We’ve even reported on what [Cpldcpu] found when he reverse engineered them first here and then here.
What [slider2732] did was to buy an electronic candle that used one of the LEDs actually shaped like a flame, and to drill a hole near the ‘flame’. He them embedded a microphone behind the hole. That goes to an LM386 amplifier circuit and from there to an Arduino Pro Mini all powered by a LiPo. As you’d expect, the Arduino code is very simple, just watch the pin from the amplifier and based on an internal variable, turn the LED on or off. We really like how none of the electronics is visible and how you actually have to lean over and blow into the top of the candle to blow it out. You can see this demonstrated in the video below.
At the end of the 1970s, the 8-bit home computer market had been under way for several years. Companies like Apple and Commodore had produced machines that retain a cult following to this day, and there was plenty for the computer enthusiast to get to grips with. As always though with a new technology, the trouble was that an Apple II or a Commodore Pet wasn’t cheap. If you didn’t have much cash, or you were a young person with uncomprehending or impoverished parents, they were out of reach. You could build a computer from a kit if you were brave or technically competent enough, but otherwise you were out of luck.
As you might imagine, the manufacturers understood that there was an untapped market for cheaper hardware, so as we entered the new decade a range of budget machines that appeared to satisfy that demand. Gone were internal expansion slots, dedicated monitors and mass storage, for cheap keyboards, domestic TV monitors, and home cassette recorders. 1980s teenagers would have computers of their own, their parents safe in the knowledge they were educational while the kids themselves were more interested in the games. Continue reading “A Thoroughly Modern Sinclair ZX80”→
