If you hang out on certain kinds of sites, you can find huge-capacity USB drives and high-power yet tiny solar panels, all at shockingly low prices. Of course, the USB drives just think they are huge, and the solar panels don’t deliver the kind of power they claim. That seems to be the case with [Big Clive’s] latest folding solar panel purchase. The nice thing about the Internet is you can satisfy your urge to tear things open to see what’s inside of them vicariously instead of having to buy a lot of junk yourself. Thanks [Clive]!
The picture on the website didn’t match the actual product, which was the first sign, of course. The panel’s output in full sun was around 2.5 watts instead of the claimed 10 watts. He’s also seen sellers claim they are between 20 and 80-watt panels. But the interesting bits are when [Clive] decides to rip the panel into pieces and analyze the controller board.
At this point, most readers will be familiar with fused deposition modeling (FDM) 3D printers, and how a plastic filament is pushed through a heater and deposited as liquid through a nozzle. Most of us also know that there are a huge variety of materials that can be FDM printed, but there’s one which perhaps evades us: you can’t load a spool of metal wire into your printer and print in metal, or at least you can’t yet. It’s something [Rotoforge] is working on, with a project to make a hot end that can melt metal. Their starting point is a ceramic diesel engine glow plug, from which they expect 1300 C (2372 F).
The video below the break deals with the process of converting the glow plug, which mostly means stripping off the metal parts which make it a glow plug, and then delicately EDM drilling a hole through its ceramic tip. The video is well worth a watch for the in-depth examination of how they evolved the means to do this.
Sadly they aren’t at the point of printing metal with this thing, but we think the current progress is impressive enough to have a good chance of working. Definitely one to watch.
Join Hackaday Editors Elliot Williams and Tom Nardi as they go over their favorite hacks and stories from the past week. This episode starts off with an update on Hackaday Europe 2024, which is now less than a month away, and from there dives into wheelchairs with subscription plans, using classic woodworking techniques to improve your 3D printer’s slicer, and a compendium of building systems. You’ll hear about tools for finding patterns in hex dumps, a lusciously documented gadget for sniffing utility meters, a rare connector that works with both HDMI and DisplayPort, and a low-stress shortwave radio kit with an eye-watering price tag. Finally, they’ll take a close look at a pair of articles that promise to up your KiCAD game.
Check out the links below if you want to follow along, and as always, tell us what you think about this episode in the comments!
The radio frequency world is full of mysteries, some of which seem to take a lifetime to master. And even then, it seems like there’s always something more to learn, and some new subtlety that can turn a good design on paper into a nightmare of unwanted interference and unexpected consequences in the real world.
As [Ken Wyatt] aptly demonstrates in the video below, where you put gaps in return paths on a PCB is one way to really screw things up. His demo system is simple: a pair of insulated wires running from the center pins on BNC jacks and running along the surface of a piece of copper-clad board to simulate a PCB trace. The end of each wire is connected to the board’s ground plane through a 50 ohm resistor, with one wire running over a narrow slot cut into the board. A harmonics-rich signal is fed into each trace while an H-field EMC probe connected to a spectrum analyzer is run along the length of the trace.
With the trace running over the solid ground plane, the harmonics are plentiful, as expected, but they fall off very quickly away from the trace. But over on the trace with the gapped return trace it’s a far different story. The harmonics are still there, but they’re about 5 dBmV higher in the vicinity of the gap. [Ken] also uses the probe to show just how far from the signal trace the return path extends to get around the gap. And even worse, the gap makes it so that harmonics are detectable on the unpowered trace. He also uses a current probe to show how common-mode current will radiate from a long conductor attached to the backplane, and that it’s about 20 dB higher with the gapped trace.
OK, that headline is a bit of a cheap shot. But if you run the curl binary that Apple ships, you’re in for a surprise if you happen to use the --cacert flag. That flag specifies that TLS verification is only to be done using the certificate file specified. That’s useful to solve certificate mysteries, or to make absolutely sure that you’re connecting to the server you expect.
What’s weird here is that on a MacOS, using the Apple provided curl binary, --cacert doesn’t limit the program to the single certificate file. On an Apple system, the verification falls back to the system’s certificate store. This is an intentional choice by Apple, but not one that’s aimed particularly at curl. The real magic is in Apple’s SSL library, which forces the use of the system keychain.
The current state of things is that this option is simply not going to do the right thing in the Apple provided binary. It’s documented with the note that “this option is supported for backward compatibility with other SSL engines, but it should not be set.” It’s an unfortunate situation, and we’re hopeful that a workaround can be found to restore the documented function of this option. Continue reading “This Week In Security: Apple Backdoors Curl, Tor’s New Bridge, And GhostRace”→
CATS is a new communication and telemetry standard intended to surpass the current Automatic Packet Reporting System (APRS) standard by leveraging modern, super-cheap Frequency Shift Keying (FSK) transceivers rather than standard FM units. The project is in the early stages, but as of this writing, there is a full open source software stack and reference hardware for both Raspberry Pi-based gateway devices and an STM32-based mobile device.
CATS packets are called ‘whiskers!’
From a radio perspective, CATS uses raw FSK rather than the inefficient AFSK used by APRS. A real killer for channel utilization is the PTT time; this is the dead time around a packet APRS requires for ‘keying up’ and ‘keying down.’ The CATS standard is aggressive with PTT timing, enabling the channel to get going on sending the data sooner.
Additionally, compared to APRS, the packet baud rate increases from 1200 baud to 9600 baud. Other key points are using LDPC encoding for forward error correction and data whitening (a useful PDF guide from Ti) to smooth over any burst errors.
One of the neat concepts of APRS is the APRS-IS (APRS Internet service). This enables amateur radio services to be connected over the Internet, vastly improving range. The CATS equivalent is called FELINET (if you’re not spotting all the ‘cat’ references by now, go and get another coffee). Together with the I-gate hardware, FELINET bridges the CATS radio side with the current APRS network. As FELINET expands to more than the current few dozen nodes, APRS services will no longer be required, and FELINET may well replace it. Interestingly, all software for FELINET, the APRS relay, and the I-Gate firmware are written in Rust. We told you learning Rust was going to be worth the effort!
On the reference hardware side of things, the CATS project has delivered a Raspberry Pi hat, which uses a 1 watt RF4463 transceiver and supporting passives. The design is about as simple as it can be. A mobile transceiver version uses an STM32 micro to drive the same RF4463 but with supporting power supplies intended to run from a typical automotive outlet. Both designs are complete KiCAD projects. Finally, once you’ve got some hardware in place and the software installed, you will want to be able to debug it. CATS has you covered with an RTL-SDR I-Gate module, giving you an independent packet log.
It might not count as “DC to daylight,” but an electromechanical attenuator that covers up to 70 GHz is pretty close, and getting a guided tour of its insides is quite a treat.
Perhaps unsurprisingly, this one comes to us from [Shahriar] at “The Signal Path,” where high-end gear most of us never get a chance to work with goes for one last hurrah after it releases the magic smoke. And indeed, that appears to be exactly what happened to the Rohde & Schwarz 75 dB step attenuator, a part that may have lived in the front end of one of their spectrum analyzers. As one would expect from such an expensive component, the insides have some pretty special engineering. The signal is carried through the five attenuation stages on a narrow strip of copper. Each stage uses a solenoid to move the strip between either a plain conductor or a small Pi pad with a specified attenuation. The attention to detail inside the cavity is amazing, with great care taken to maintain the physical orientation of the stripline to prevent impedance mismatches and unwanted reflections.
The Pi pads themselves are fascinating, too, especially under [Shahriar]’s super-duper microscope. All of them were destructively removed from the cavity before getting to him, but it’s still pretty clear what’s going on. That’s especially true with the 5-dB pad, which bears clear signs of the overload that brought on the demise of the whole attenuator. We suppose a repair would have been feasible if it had been just the one pad that needed replacement, but with all of them broken, it’s off to the scrap bin. Or to the recycler — there appears to be plenty of gold in there.
We thought this was a fantastic look under the covers of an exquisitely engineered part. Too bad it didn’t rate the [Shahriar] X-ray treatment, as this multimeter repair or this 60-GHz phased array did. Oh, well — maybe next time.
