Infotainment system playing back from USB. (Folkert van Heusden)

Create Virtual USB Sticks With A Raspberry Pi Zero

March 9, 2024 by Maya Posch 28 Comments

Playing back music files from USB sticks is a common feature these days, and is built-into the infotainment system in [Folkert van Heusden]’s Opel Astra. Unfortunately such USB playback features often come with a range of limitations on things like audio codecs, and in the case of [Folkert]’s car, a 1000 file limit. This had him looking at an alternative to lugging a lot of USB sticks around to avoid the horror of hearing the same songs within a week while commuting. The solution? Make a Raspberry Pi Zero into a virtual USB mass storage device using the Mass Storage Gadget (MSG) driver in the Linux kernel.

Picking USB storage as the ideal option here comes mostly from the age of the infotainment system, which lacks Bluetooth, and the audio input jack is rather crackly. Of course, having the Raspberry Pi Zero pretend to be a storage device via the MSG driver wouldn’t solve the file limit, but to get around this two Python scripts were written: one which creates images from a folder of music files, and another which randomly picks one of the available images from the Zero’s SD card and configures the MSG driver to use it.

As for the list of future improvements, there is mounting the RPi Zero’s SD card as read-only to deal with the power-off when the car is shut down, and the creating of images requires to be run as root due to the use of loopback devices. As a Proof-of-Concept it does seem to be on the right track.

It’s not just the older infotainment systems that get to have all the fun. If you’re lucky enough to have Linux running in the dashboard, you might be little more than a Bash script away from bending the system to your will.

Extracting SecOC Keys From A 2021 Toyota RAV4 Prime

March 8, 2024 by Maya Posch 7 Comments

With the recently introduced SecOC (Secure Onboard Communication) standard, car manufacturers seek to make the CAN bus networks that form the backbone of modern day cars more secure. This standard adds a MAC (message authentication code) to the CAN messages, which can be used to validate that these messages come from a genuine part of the car, and not from a car thief or some third-party peripheral.

To check that it isn’t possible to circumvent SecOC, [Willem Melching] and [Greg Hogan] got their hands on the power steering (EPS) unit of a Toyota RAV4 Prime, as one of the first cars to implement this new security standard.

As noted by [Willem], the ultimate goal is to be able to run the open source driver assistance system openpilot on these SecOC-enabled cars, which would require either breaking SecOC, or following the official method of ‘rekeying’ the SecOC gateway.

After dumping the firmware of the EPS Renesas RH850/P1M-E MCU via a voltage fault injection, the AES-based encryption routines were identified, but no easy exploits found in the main application. This left the bootloader as the next target.

Ultimately they managed to reverse-engineer the bootloader to determine how the update procedure works, which enabled them to upload shellcode. This script then enabled them to extract the SecOC keys from RAM and send these over the CAN bus. With these keys the path is thus opened to allow any device to generate CAN messages with valid SecOC MACs, effectively breaking encryption. Naturally, there are many caveats with this discovery.

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How Much Longer Will Cars Have Cigarette Lighter Ports?

February 1, 2024 by Kristina Panos 106 Comments

Depending on the age of your car, it might contain a round 12 V power outlet in the dash, or possibly in the elbow compartment. And depending on your own age, you might know that as the cigarette lighter port. Whereas this thing used to have a single purpose — lighting cigars and cigarettes via hot coil — there are myriad uses today, from charging a phone to powering a dash camera to running one of those tire-inflating machines in a roadside emergency.

But how did it come to be a power source inside the vehicle? And how long will it stick around? With smoking on the decline for several decades, fewer and fewer people have the need for a cigarette lighter than do, say, a way to charge their phone. How long will the power source survive in this configuration?

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A black PCB with a cellular modem board piggy backed on top. It has a micro-USB and DB-type connector on the end facing the camera.

Open Vehicle Monitoring System Is The Window To Your EV’s Soul

January 25, 2024 by Navarre Bartz 14 Comments

Electric cars have more widgets than ever, but manufacturers would rather you don’t have direct access to them. The Open Vehicle Monitoring System intends to change that for the user. [via Transport Evolved]

As car manufacturers hoover up user data and require subscriptions for basic features, it can be a frustrating time to make such a big purchase. Begun in 2011, OVMS now interfaces with over a dozen different EVs and gives you access to (or helps you reverse engineer) all the data you could want from your vehicle. Depending on the vehicle, any number of functions can be accessed including remote climate start or cell-level battery statistics.

The hardware connects to your car’s OBDII port and uses an ESP32 microcontroller connected to a SIMCOM SIM7600G modem (including GPS) to provide support for 3 CAN buses as well as Wi-Fi and Bluetooth connections. This can be particularly useful for remote access to data for vehicles that can no longer phone home via their originally included cellular modems as older networks shut down.

Do you wish EVs weren’t so complicated? Read our Minimal Motoring Manifesto.

A black plastic trim piece from a vehicle interior. It has slight flecking in its texture. It is sitting on an off-white bench overlooking a workshop.

Can Car Parts Grow On Trees?

January 19, 2024 by Navarre Bartz 27 Comments

Cars don’t grow on trees, but Ford is designing car parts from olive tree cuttings. [via Electrek]

Ford is no stranger to designing parts from plants for their vehicles. Henry famously liked to beat on the Soy Bean Car with a blunted axe to tout the benefits of bioplastic panels. Researchers at Ford’s Cologne, Germany facility have detailed their work to use waste from olive orchards as part of a new biocomposite from the LIVE COMPOLIVE program.

Fibers from the olive tree cuttings are mixed with recycled plastic and injection molded to form panels. The video below features interior panels that are currently made with traditional plastics that could be swapped over to the new composite. Since these cuttings are a waste product from food production, there isn’t the tension akin to that presented via biofuels vs food. We’re curious what Precious Plastics could do with this, especially if the fibers are able to reinforce the matrix.

If you want to see some other unusual uses for waste wood, why not checkout a “paper” bottle or 3D printing with sawdust?

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Tesla’s Plug Moves Another Step Closer To Dominance

December 21, 2023 by Navarre Bartz 46 Comments

Charging an EV currently means making sure you find a station with the right plug. SAE International has now published what could be the end to the mishmash of standards in North America with the J3400 North American Charging Standard.

The SAE J3400TM North American Charging Standard (NACS) Electric Vehicle Coupler Technical Information Report (TIR), which just rolls off the tongue, details the standard formerly only available on Tesla vehicles. We previously talked about the avalanche of support from other automakers this year for the connector, and now that the independent SAE standard has come through, the only major holdout is Stellantis.

Among the advantages of the NACS standard over the Combined Charging System (CCS) or CHAdeMO is a smaller number of conductors given the plug’s ability to carry DC or AC over the same wires. Another benefit is the standard using 277 V which means that three separate Level 2 chargers can be placed on a single 3-phase commercial line with no additional step down required. Street parkers can also rejoice, as the standard includes provisions for lampost-based charger installations with a charge receptacle plug instead of the attached cable required by J1772 which leads to maintenance, clutter, and ADA concerns.

Now that J3400/NACS is no longer under the purview of a single company, the Federal Highway Administration has announced that it will be looking into amending the requirements for federal charger installation subsidies. Current rules require CCS plugs be part of the installation to qualify for funds from the Bipartisan Infrastructure Bill.

If you want to see how to spice up charging an EV at home, how about this charging robot or maybe try fast charging an e-bike from an electric car plug?

An image of the inside of a vehicle wheel. An outer ring gear is attached to two articulated sets of three small helical gears attached to a central sun gear. A shaft from the right side enters into the sun gear.

A Revolution In Vehicle Drivetrains?

December 6, 2023 by Navarre Bartz 47 Comments

Power delivery in passenger vehicle drivetrains hasn’t changed much since the introduction of the constant velocity (CV) joint in the 1930s. Most electric vehicles still deliver power via the same system used by internal combustion cars. Hyundai/Kia has now revealed a system they think will provide a new paradigm with their Universal Wheel Drive System (Uni Wheel). [via Electrek]

What appears at first to be a hub motor is in fact a geared wheel that keeps the motor close without the problem of high unsprung weight. Power is fed into a sun gear which can move independently of the wheel allowing the system to maintain a more consistent driveline and avoid power variability over the range of suspension travel like you’d find in a CV joint experiencing high deflection.

We have some concerns about the durability of such a system when compared with the KISS and long development history of CV joints, but we can’t deny that moving the motors of an electric vehicle out to the corners would allow more packaging flexibility for the cargo and passenger areas. We’re also excited to see open source replicas make their way into smaller robotics projects now that the images have been released. If you’ve already made one in CAD, send us a tip at tips@hackaday.com.

Looking for more interesting innovations in electric cars? How about an off-grid camper van? If you think automakers are overcomplicating something that should be simple, read the Minimal Motoring Manifesto.

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