Open-Source Firmware For Soldering Irons

August 2, 2023 by 23 Comments

For most of us, the first soldering iron we pick up to start working on electronics has essentially no features at all. Being little more than resistive heaters plugged straight into the wall with perhaps a changeable tip, there’s not really even a need for a power switch. But doing anything more specialized than through-hole PCB construction often requires a soldering iron with a little more finesse, though. Plenty of “smart” soldering irons are available for specialized soldering needs now, and some are supported by the open-source IronOS as well.

The project, formerly known as TS100, is a versatile soldering iron control firmware that started as an alternative firmware for only the TS100 soldering iron. It has since expanded to have compatibility with several other soldering irons and hosts a rich set of features, including temperature control, motion activation, and the ability to temporarily increase the temperature when using the iron. The firmware is also capable of working with irons that use batteries as well as irons that use USB power delivery.

For anyone with a modern smart soldering iron, like the Pinecil or various Miniware iron offerings, this firmware is a great way of being able to gain fine control over the behavior of one’s own soldering iron, potentially above and beyond what the OEM firmware can do. If you’re still using nothing more than a 30W soldering iron that just has a wall plug, take a look at a review we did for the TS100 iron a few years ago to see what you’re missing out on.

Photo via Wikimedia Commons

Microsoft Now Offering Parts And Repair Guides For Xbox Controllers

August 2, 2023 by 11 Comments

We’re big fans of repairable hardware here at Hackaday, so much so that when we see a company embracing the idea that their products should actually be serviced rather than thrown in the trash, we like to call attention to it. Yes, that even includes when it’s Microsoft.

This community has had a mixed relationship with the Redmond software giant, to say the least. But we’ve still got to give them credit when they do something positive. Not only are they offering a full selection of replacement parts for both the standard and Elite Xbox controllers, they’ve also provided written instructions and step-by-step video guides on how to install your new parts.

For those of you who stopped playing console games when the controllers still only had two buttons, this might not seem like such a big deal. But considering a new Xbox Elite Wireless Controller will set you back a dizzying $180, it’s not hard to see why some folks would be excited about the possibility of swapping out the guts of the thing for $50.

Of course, these parts were already available from third party sellers, and iFixit naturally has repair guides for all the different flavors of Xbox controllers. Nothing about what Microsoft is doing here makes the Xbox controller fundamentally any easier to repair than it was previously. But the fact that the company isn’t treating their customers like adversaries is a step in the right direction.

Valve has been similarly open about the internals of the Steam Deck, though their presentation was a bit dramatic, and even Sony provided an official teardown video for the PS5. We’re not sure why these companies are willing to pull back the curtain when it comes to gaming hardware. Whatever the reason, we’re certainly not complaining.

Continue reading “Microsoft Now Offering Parts And Repair Guides For Xbox Controllers” →

Truss-Braced Wings Could Bring New Look To Runways Worldwide

August 2, 2023 by 75 Comments

Airliners have looked largely the same for a long time now. The ongoing hunt for efficiency gains has seen the development of winglets, drag reducing films, and all manner of little aerodynamic tricks to save fuel, and hence money.

Boeing now has its eye on bigger, tastier goals. It believes by switching to a truss-braced wing design, it could net double-digit efficiency gains. It’s working together with NASA to see if this concept could change the face of commercial aviation in decades to come.

Aspect Ratio Matters

The ASH 31 glider features wings with an aspect ratio of 33.5, and a lift-to-drag ratio of 56. Credit: Manfred Munch, CC-BY-SA 3.0

The key goal of using a truss-braced wing is to enable an airliner to use a wing much thinner and narrower than usual. These “high aspect ratio” wings are far more efficient than the stubbier, wider wings currently common on modern airliners.  But why is aspect ratio so important, and how does it help

If you’ve ever looked at a glider, you will have noticed its incredibly long and narrow wings, which stand it apart from the shorter, wider wings used on airliners and conventional small aircraft. These wings are said to have a high aspect ratio, the ratio between the square of the wingspan and the projected area of the wing itself.

These wings are highly desirable for certain types of aircraft, as lift-to-drag ratio increases with aspect ratio. Any wing that generates lift also generates some drag, but this can be minimized through careful wing design. By making the wings longer and narrower, and thus higher in aspect ratio, the wing tip vortices generated by the wing are weakened. This reduces drag on the plane, and quite significantly so. Continue reading “Truss-Braced Wings Could Bring New Look To Runways Worldwide” →

An exploded view of an AirPods Pro case. The outer case consists of two long, capsule-shaped sections that enclose several smaller parts including the wireless charging cable, contacts for charging the AirPods themselves, and the top rounded protective piece for the buds that nestles into the top capsule. This version includes screws to fasten everything together instead of adhesives.

Fixing Some More Of Apple’s Design Mistakes

August 2, 2023 by 26 Comments

Love them or hate them, there’s no denying that Apple has strayed from the Woz’s original open platform ideal for the Apple II. [Ken Pillonel] is back for another round of fixing Apple’s repairability mistakes with a full complement of 3D printable replacement parts for the AirPods Pro case.

While modeling all of the parts would be handy enough for repairing a device with a 0/10 iFixit score, [Pillonel] modified the parts to go together with screws instead of adhesive so any future repairs don’t require cracking the plastic egg. He says, “By showcasing the potential for repairability, I hope to inspire both consumers and multi-billion dollar companies, like Apple, to embrace sustainable practices in their products.”

[Pillonel]’s repairability exploits may seem familiar to readers from his previous work on adding USB-C to the iPhone and the AirPods Pro case. If you just need to retrieve a lost AirPod, you might try an electromagnet, or you can make a Bluetooth receiver from a pair of knock-off buds.

Continue reading “Fixing Some More Of Apple’s Design Mistakes” →

Clipper Windpower: Solutions In Search Of Problems

August 2, 2023 by 69 Comments

The first modern wind turbines designed for bulk electricity generation came online gradually throughout the 80s and early 90s. By today’s standards these turbines are barely recognizable. They were small, had low power ratings often in the range of tens to hundreds of kilowatts, and had tiny blades that had to rotate extremely quickly.

When comparing one of these tiny machines next to a modern turbine with a power rating of 10 or more megawatts with blades with lengths on the order of a hundred meters, one might wonder if there is anything in common at all. In fact, plenty of turbines across the decades share fundamental similarities including a three-blade design, a fairly simple gearbox, and a single electric generator. While more modern turbines are increasingly using direct-drive systems that eliminate the need for a gearbox and the maintenance associated with them, in the early 2000s an American wind turbine manufacturer named Clipper Windpower went in the opposite direction, manufacturing wind turbines with an elaborate, expensive, and heavy gearbox that supported four generators in each turbine. This ended up sealing the company’s fate only a few years after the turbines were delivered to wind farms.

Some history: the largest terrestrial wind turbines were approaching the neighborhood of 2 megawatts, but some manufacturers were getting to these milestones essentially by slapping on larger blades and generators to existing designs rather than re-designing their turbines from the ground up to host these larger components. This was leading to diminishing returns, as well as an increased amount of mechanical issues in the turbines themselves, and it was only a matter of time before the existing designs wouldn’t support this trend further. Besides increased weight and other mechanical stresses on the structure itself, another major concern was finding (and paying for) cranes with enough capacity to hoist these larger components to ever-increasing heights, especially in the remote locations that wind farms are typically located. And cranes aren’t needed just for construction; they are also used whenever a large component like a generator or blade needs to be repaired or replaced. Continue reading “Clipper Windpower: Solutions In Search Of Problems” →

Solar Power Your Pi

August 2, 2023 by 9 Comments

Running a Raspberry Pi with solar power sounds easy. Of course, like most things, the details are what get you. About a year ago, [Bystroushaa] tried it without success. But the second time turned out to be the charm.

Of course, success is a relative term. It does work, but there is concern that it won’t be sufficient in the winter. In addition, if the battery dies, everything doesn’t restart automatically. Still, it is usable, and there should be ways to solve those problems.

The original attempt used a PiJuice hat and solar panel. This time, the design didn’t use these, opting instead for a LiFePO4 battery, a solar regulator, and a solar panel. The rest of it comes down to mechanical and physical mounting. The cheap regulator has some drawbacks. For example, it doesn’t allow for monitoring like more expensive units. It also cannot balance the cells periodically, although that could be done with an external controller.

We’ve seen solar-powered Pi boards before. Or, try a Game Boy.

Heartbeat packets of LKV373

Audio, Not Video Over The LKV373 HDMI Extender

August 2, 2023 by 11 Comments

[eta] found herself in a flat with several LKV373 HDMI extenders. Find the corresponding transmitter, plug it into your device, and you’ve got a connection to the TV/sound system, no fussing with wires behind the TV. However, [eta] wanted to get rid of the need to plug in a laptop and start sending packets directly to play music. As her flatmate [dan] had already reverse-engineered the receiver, she tested her prototype against their virtualized receiver, de-ip-hmdi.

The actual sending of images was surprisingly straightforward — just a JPEG sliced into 1024 bytes chunks and sent over. However, early testing showed nothing on the receiver. The end of a frame needed marking by setting the most-significant bit of the chunk number to one. Now de-ip-hdmi showed the image, but the actual hardware would not. With something missing, [eta] returned to Wireshark to scan packets. Noticing some strange packets on port 2067, she analyzed the pattern to reveal it sent another packet just before a new frame and included the frame number. With this tweak, it was still not enough. Ultimately, heartbeat packets sent every second synchronize things, but compared to the noise of the video packets, they were easy to miss. Now [eta] had some functioning video streaming rust code.

In theory, audio for the LKV373 followed the same thought process as video. Two channels of 32-bit big Endian integers at 44,100 hz chunked into 992-byte sections and sent as a packet formed the audio stream. With only 992 bytes, two streams, and 4 bytes per sample, each packet only held 2.812 milliseconds of sound. The first tests resulted in no audio output or distorted crunchy sound. Of course, this was every audio engineer’s worst nightmare: jitter. With a spin loop and an efficient ring buffer, the audio packets were soon slinging across the network reliably.

The code is available on a hosted version of GitLab. It’s a beautiful journey through reverse engineering some obscure but relatively cheap hardware. Along the way, there is nicely annotated Rust code, which makes it all the better.