Dissecting The Elusive Wax Motor

June 18, 2018 by Tom Nardi 34 Comments

We’d wager most readers aren’t intimately acquainted with wax motors. In fact, a good deal of you have probably never heard of them, let alone used one in a project. Which isn’t exactly surprising, as they’re very niche and rarely used outside of HVAC systems and some appliances. But they’re fascinating devices, and once you’ve seen how they work, you might just figure out an application for one.

[AvE] recently did a complete teardown on a typical wax motor, going as far as cutting the thing in half to show the inner workings. Now we’ve seen some readers commenting that everyone’s favorite foul-mouthed destroyer of consumer goods has lost his edge, that his newer videos are more about goofing off than anything. Well we can’t necessarily defend his signature linguistic repertoire, but we can confidently say this video does an excellent job of explaining these little-known gadgets.

The short version is that a wax motor, which is really a linear actuator, operates on the principle that wax expands when it melts. If a solid block of wax is placed in a cylinder, it can push on a piston during the phase change from solid to liquid. As the liquid wax resists compression, the wax motor has an exceptionally high output force for such a small device. The downside is, the stroke length is usually rather short: for the one [AvE] demonstrates, it’s on the order of 2 mm.

By turning heat directly into mechanical energy, wax motors are often used to open valves and vents when they’ve reached a specific temperature. The common automotive engine thermostat is a classic example of a wax motor, and they’re commonly found inside of dishwashers as a way to open the soap dispenser at the proper time during the cycle.

This actually isn’t the first time we’ve featured an in-depth look at wax motors, but [AvE] actually cutting this one in half combined with the fact that the video doesn’t look like it was filmed on a 1980’s camera makes it worth revisiting the subject. Who is going to build a wax motor power device for the Power Harvesting Challenge in the 2018 Hackaday Prize?

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Poetry Is The Fruit Of This Loom

June 14, 2018 by Tom Nardi 14 Comments

We’d wager that most people reading these words have never used a loom before. Nor have most of you churned butter, or ridden in a horse-drawn wagon. Despite these things being state of the art technology at one point, today the average person is only dimly aware of their existence. In the developed world, life has moved on. We don’t make our own clothes or grow our own crops. We consume, but the where and how of production has become nebulous to us.

[David Heisserer] and his wife [Danielle Everine], believe this modern separation between consumption and production is a mistake. How can we appreciate where our clothing comes from, much less the people who make it, without understanding the domestic labor that was once required to produce even a simple garment? In an effort to educate the public on textile production in a fun and meaningful way, they’ve created a poetry printing loom called Meme Weaver.

The Meme Weaver will be cranking out words of woolen wisdom at the Northern Spark Festival taking place June 15th and 16th in downtown Minneapolis. If any Hackaday readers in the area get a chance to check out the machine, we’d love to hear about it in the comments. Take photos! Just don’t blame us if you have a sudden urge to make all of your clothing afterwards.
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Unlocking Animal Crossing’s Debug Mode

June 13, 2018 by Tom Nardi 8 Comments

Originally released on the Nintendo 64 in 2001, Animal Crossing was the first entry into what has become a massively successful franchise. But while the game has appeared on more modern Nintendo consoles, most recently Android and iOS, the version released on the GameCube holds a special place in many fan’s hearts. The GameCube version was the first time those outside of Japan got a taste of the unique community simulation offered by Animal Crossing, and maintains a following nearly 20 years after its release.

[James Chambers] has recently been investigating creating mods for the GameCube version of Animal Crossing, and in the process uncovered some interesting references to a debug mode. That launched a deep dive into the game’s assembly code in an attempt to find what the debug functions did and if they could be enabled without having to patch the game ROM. In the end, he was able to find a push button code that enables debug mode on the retail copy of the game.

[James] starts by using the debugger provided by the Dolphin GameCube emulator to poke around and figure out exactly what flags need to be modified to activate the debug mode. This leads to a few interesting finds, such as being able to pop up a performance monitor graph and some build info. Eventually he finds the proper incantation to bring up a functional debug display in the game, but there was still the mystery of how you do it on the real hardware with a retail copy of the game.

It wouldn’t be unreasonable to think that some special dongle or development version of the GameCube would be required to kick the game into debug mode. But through careful examination of the code path, [James] was able to figure out that hitting a specific combination of buttons on the controller was all that was required to use the debug mode on the stock game. Once the debug mode is started, a controller plugged into the second port allows the user to navigate through options and perform tasks. Not everything is currently understood, but some progress has been made, such as figuring out how to add items to your inventory.

It’s hardly Nintendo’s most popular console, but there’s still a healthy interest in GameCube hacking as the machine approaches its 20th anniversary. We recently saw some impressive work being done to reverse engineer the system’s wireless controllers, though some people are more interested in just cutting the thing in half.

[Thanks to Tim Trzepacz for the tip.]

555 Ways To Speed Control A DC Motor

June 12, 2018 by Lewin Day 20 Comments

The 555 timer IC is a handful of active components all baked into one beautifully useful 8 pin package. Originally designed for timing purposes, they became ubiquitous parts that can achieve almost anything. In this case, they’re being used to create a basic PWM motor controller.

The trick is to set the 555 up in astable mode, and use diodes and a potentiometer in the charge/discharge loop. By hanging a diode off either side of a potentiometer, leading to the charge and discharge pins, and connecting the center lug to the main capacitor, you can vary the resistance seen by the capacitor during charge and discharge. By making charging take longer, you increase the pulse width, and by making discharge take longer, you reduce the pulse width. The actual frequency itself is determined largely by the capacitor and total resistance of the potentiometer itself.

This is a very old-school way to generate a PWM signal, which could be used to vary intensity of a light or make noise on a buzzer. However, in this case, the output of the 555 is connected to a MOSFET which is used to vary the speed of a computer fan motor.

It’s an excellent way to learn about both PWM motor control and the use of 555 timers, all with a very low parts cost and readily available components. We’ve seen such setups before, used as easy-to-build dimmer switches, too.

Tricking A Vintage Clock Chip Into Working On 50-Hz Power

June 11, 2018 by Dan Maloney 32 Comments

Thanks to microcontrollers, RTC modules, and a plethora of cheap and interesting display options, digital clock projects have become pretty easy. Choose to base a clock build around a chip sporting a date code from the late 70s, though, and your build is bound to be more than run-of-the-mill.

This is the boat that [Fran Blanche] finds herself in with one of her ongoing projects. The chip in question is a Mostek MK50250 digital alarm clock chip, and her first hurdle was find a way to run the clock on 50 Hertz with North American 60-Hertz power. The reason for this is a lesson in the compromises engineers sometimes have to make during the design process, and how that sometimes leads to false assumptions. It seems that the Mostek designers assumed that a 24-hour display would only ever be needed in locales where the line frequency is 50 Hz. [Fran], however, wants military time at 60 Hz, so she came up with a circuit to fool the chip. It uses a 4017 decade counter to divide the 60-Hz signal by 10, and uses the 6-Hz output to turn on a transistor that pulls the 60-Hz output low for one pulse. The result is one dropped pulse out of every six, which gives the Mostek the 50-Hz signal it needs. Sure, the pulse chain is asymmetric, but the chip won’t care, and [Fran] gets the clock she wants. Pretty clever.

[Fran] has been teasing this clock build for a while, and we’re keen to see what it looks like. We hope she’ll be using these outsized not-quite-a-light-pipe LED displays or something similar.

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Restoring An Atari 800 XL That’s Beyond Restoring

June 9, 2018 by Tom Nardi 24 Comments

Sometimes the best way to get a hacker to do something is to tell them that they shouldn’t, or even better can’t, do it. Nothing inspires the inquisitive mind quite like the idea that they are heading down the road less traveled, if for nothing else to say that they did it. A thrown gauntlet and caffeine is often all that stands between the possible and the impossible.

So when [Drygol] heard a friend comment he had an old Atari 800 XL that was such poor shape it couldn’t be repaired, he took on the challenge of restoring the machine sight unseen. Luckily for us, his pride kept him from backing down when he saw the twisted and dirty mess of a computer in person. He’s started documenting the process on his blog, and while this is only the first phase of the restoration, the work he’s done already is impressive enough that we think you’ll want to follow him along on his quest.

There’s no word on what happened to this miserable looking Atari, but we wouldn’t be surprised if it was run over by a truck. The board was cracked and twisted, with some components missing entirely. The first step in this impossible restoration was straightening the PCB, which [Drygol] did by clamping it to some aluminum bar stock and heating the whole board up to 40C (104F) for a few days. Once the got most of the bend out, he used a small drill bit to put holes in the PCB laminate and inject epoxy to add some strength. It’s an interesting technique, and the results seem to speak for themselves.

Once the board was straight, he went through replacing blown passive components and broken chip sockets. All the ICs were pulled and treated to an isopropyl alcohol and acetone bath in an ultrasonic cleaner to get them looking like new again. The CPU was cooked and needed to get swapped out, but otherwise it was smooth sailing, and before long he had the machine booted up. While most would have been satisfied to just get this far, [Drygol] considers this to be the easy part.

He next straightened out the metal shielding with a mallet, sanded it down, and sprayed it with a new zinc coating. The plastic around the keyboard and the metal trim pieces were also removed, cleaned, and refinished where necessary. Rather than going for perfection, [Drygol] intentionally left some issues so the machine didn’t look 100% pristine. It’s supposed to be a functional computer, not a museum piece behind glass.

We’ll have to wait until the next entry in this series to see how he repairs the absolutely devastated case. Any rational person would just use a case from a donor machine, but we’ve got a feeling [Drygol] might have something a little more impressive in mind.

In the meantime we’ve got plenty of incredible restorations to keep you occupied, from this sunken VIC-20 to a Pi-packing Osborne.

VCF East 2018: SDR On The Altair 8800

June 8, 2018 by Tom Nardi 34 Comments

You’d be forgiven if you thought software defined radio (SDR) was a relatively recent discovery. After all, few outside of the hardcore amateur radio circles were even familiar with the concept until it was discovered that cheap USB TV tuners could be used as fairly decent receivers from a few hundred MHz all the way up into the GHz range. The advent of the RTL-SDR project in 2012 brought the cost of entry level SDR hardware from hundreds of dollars to tens of dollars effectively overnight. Today there’s more hackers cruising the airwaves via software trickery than there’s ever been before.

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