HALT In The Name Of Testing

July 1, 2016 by Adam Fabio 16 Comments

“Did I forget something?” It’s that nagging feeling every engineer has when their project is about to be deployed – it may be a product about to be ramped into production, a low volume product, or even a one off like a microsatellite. If you have the time and a few prototypes to spare though, there are ways to alleviate these worries. The key is a test method which has been used in aerospace, military, and other industries for years – Highly Accelerated Life Testing (HALT).

How to HALT

The idea behind HALT testing can be summed up in a couple of sentences:

Beat your product to death.
Figure out what broke.
Fix it, and fix the design.
Repeat.

Sounds barbaric, and in many cases it is. HALT testing is often associated with giant test chambers which are literally designed to torture anything inside them. Liquid nitrogen shock cools the chamber as low as -100°C. The Device Under Test (DUT) can soak at that temperature for hours. Powerful heaters then blast the chamber, causing temperature rises of up to 90°C per minute, topping off at up to 200°C. Pneumatic hammers beat on the chamber table causing vibrations at up to 90 Grms and 10 KHz. Corrosive sprays simulate years of rain and humidity. These chambers are literally hell on earth for any device unlucky enough to be placed inside them. It’s easy to see why this sort of testing is often referred to as “Shake and Bake”.

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Voja’s EEPROM Emulator From 1991

June 27, 2016 by Elliot Williams 22 Comments

We’re glad we’re not the only hacker-packrats out there! [Voja Antonic] recently stumbled on an EPROM emulator that he’d made way back in 1991. It’s a sweet build, so take your mind back 25 years if you can. Put on “Nevermind” and dig into a nicely done retro project.

The emulator is basically a PIC 16C54 microcontroller and some memory, with some buffers for input and output. On one side, it’s a plug-in replacement for an EPROM — the flash memory of a bygone era. On the other side, it connects via serial port to a PC. Instead of going through the tedious process of pulling the EPROM, erasing and reprogramming it, this device uploads new code in a jiffy.

No need to emulate ancient EPROMS? You should still check out this build — the mechanics are great! We love the serial-port backplane that is soldered on at a 90° angle. The joint is a card-edge connector electrically, but also into a nice little box, reminiscent of [Voja]’s other FR4 fabrication tricks. The drilled hole with the LED poking out is classy. We’re never going to make an EPROM emulator, but we’re absolutely going to steal some of the fabrication techniques.

[Voja] is a Hackaday contributor, badge-designer, mad hacker, inspired clock-builder, and developer of (then) Yugoslavia’s first DIY PC.

Make Math Real With This Analog Multiplier Primer

June 19, 2016 by Dan Maloney 11 Comments

Remember learning all about functions in algebra? Neither do we. Oh sure, most of us remember linear plots and the magic of understanding y=mx+b for the first time. But a lot of us managed to slide by with only a tenuous grasp of more complex functions like exponentials and conic sections. Luckily the functionally challenged among us can bolster their understanding with this demonstration using analog multipliers and op amps.

[devttys0]’s video tutorial is a great primer on analog multipliers and their many uses. Starting with a simple example that multiplies two input voltages together, he goes on to show circuits that output both the square and the cube of an input voltage. Seeing the output waveform of the cube of a ramped input voltage was what nailed the concept for us and transported us back to those seemingly wasted hours in algebra class many years ago. Further refinements by the addition of an op amp yield a circuit that outputs the square root of an input voltage, and eventually lead to a voltage controlled resistor that can attenuate an input signal depending on its voltage. Pretty powerful stuff for just a few chips.

The chip behind [devttys0]’s primer is the Analog Devices AD633, a pretty handy chip to have around. For more on this chip, check out [Bil Herd]’s post on analog computing.

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Simple Vacuum Tube Preamp Results In A Beautiful Build

June 19, 2016 by Dan Maloney 32 Comments

We have no intention of wading into the vacuum tube versus silicon debates audiophiles seem to thrive on. But we know a quality build when we see it, and this gorgeous tube preamp certainly looks like it sounds good.

The amp is an attempt by builder [Timothy Cose] to give a little something back to the online community of vacuum tube aficionados that guided him in his journey into the world of electrons under glass. Dubbed a “Muchedumbre” – Spanish for “crowd” or “mob”; we admit we don’t get the reference – the circuit is intended as a zero-gain preamp for matching impedance between line level sources and power amplifiers. Consisting of a single 12AU7 in a cathode-follower design and an EZ81 for rectification, where the amp really shines is in build quality. The aluminum and wood chassis looks great, and the point-to-point wiring is simple and neat. We especially appreciate the neatly bent component leads and the well-dressed connections on the terminal strips and octal sockets. There’s a nice photo gallery below with shots of the build.

As much as we appreciate the miracles that can be accomplished with silicon, there’s still magic aplenty with vacuum tubes. For more thermionic goodness, check out these minimalist homebrew vacuum tubes or these artisanal vacuum tubes.

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Denver Mini Maker Faire: Fun With Pinball

June 17, 2016 by Kristina Panos 5 Comments

[Mark Gibson] probably has nothing against silicon. He just knows that a lot that can be done with simple switches, relays, and solenoids and wants to share that knowledge with the world. This was made abundantly clear to me during repeat visits to his expansive booth at Denver Mini Maker Faire last weekend.

In the sunlight-filled atrium of the Museum of Nature and Science, [Mark] sat behind several long tables covered with his creations made from mid-century pinball machines. There are about two dozen pieces in his interactive exhibit, which made its debut at the first-ever Northern Colorado Maker Faire in 2013. [Mark] was motivated to build these boards because he wanted to get people interested in the way things work through interaction and discovery of pinball mechanisms.

Most of the pieces he has built are single units and simple systems from pinball machines—flippers, chime units, targets, bumpers, and so on—that he affixed to wooden boards so that people can explore them without breaking anything. All of the units are operated using large and inviting push buttons that have been screwed down tight. Each of the systems also has a display card with an engineering drawing of the mechanism and a short explanation of how it works.

[Mark] also brought some of the original games he has created by combining several systems from different machines, like a horse derby and a baseball game. Both of these were built with education in mind; all of the guts including the original fabric-wrapped wires are prominently displayed. The derby game wasn’t working, but I managed to load the bases and get a grand slam in the baseball game. Probably couldn’t do that again in a million summers.

fun with pinball baseball game — Take me out to the Maker Faire! Click to embiggen.

About five years ago, we covered [Mark]’s build of an atomic clock from pinball machine parts. It’s about time we featured his work again. We have shared a lot of pinball-related builds over the years from the immersive to the gigantic to the dankest of the dank.

Micro Tesla Turbine Is An Engineering Tour De Force

June 17, 2016 by Dan Maloney 64 Comments

A corollary to Godwin’s Law ought to be that any Hackaday post that mentions Nikola Tesla will have a long and colorful comment thread. We hope this one does too, but with any luck it’ll concentrate on the engineering behind this tiny custom-built Telsa turbine.

For those not familiar with Mr. Tesla’s favorite invention, the turbine is a super-efficient design that has no blades, relying instead on smooth, closely spaced discs that get dragged along by the friction of a moving fluid. [johnnyq90]’s micro version of the turbine is a very accomplished feat of machining. Although at first the build appears a bit janky, as it progresses we see some real craftsmanship – if you ever doubt that soda can aluminum can be turned, watch the video below. The precision 25mm rotor goes into a CNC machined aluminum housing; the way the turned cover snaps onto the housing is oddly satisfying. It looks like the only off-the-shelf parts are the rotor bearings; everything else is scratch-made. The second video ends with a test spool-up that sounds pretty good. We can’t wait for part 3 to find out how fast this turbine can turn.

Size matters, and in this case, small is pretty darn impressive. For a larger treatment of a Tesla turbine, see this one made of old hard drive platters.

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A Slide Viewer Makes An Excellent Case For An OLED Project

June 17, 2016 by Jenny List 17 Comments

Sometimes when browsing the websites of our global hackspace community you notice a project that’s attractive not necessarily because of what it does or its technology but because of its presentation. So it is with the subject of this article, [Kris] needed a house temperature monitor and found a 1960s slide viewer made an excellent choice for its housing.

The monitor itself is a fairly straightforward Arduino build using a couple of DS18B20 1-wire temperature sensors and a real-time-clock module and displaying their readings on a small OLED screen. Its code can be found on this mailing list thread if you are interested. The display presented a problem as it needed to be reasonably large, yet fairly dim so it could be read at night without being bright enough to interrupt sleep.

A variety of projection techniques were tried, involving lenses from a projection clock, a magnifying glass, and a Google Cardboard clone. Sadly none of these lenses had the required focal length. Eventually the slide viewer was chosen because it was pointed out that the OLED screen was about the same size as a photographic slide.

Slide viewers are part of the familiar ephemera of the analog era that most people over 60 may still have taking up drawer space somewhere but may well be completely alien to anyone under about 30. They were a magnification system packaged up into a console usually styled to look something like a small portable TV of the day, and different models had built-in battery lights, or collected ambient light with a mirror. The screen was usually a large rectangular lens about 100mm(4″) diagonal.

[Kris]’s Vistarama slide viewer came via eBay. It’s not the smallest of viewers, other models folded their light paths with mirrors, however the extra space meant that the Arduino fit easily. The OLED was placed where the slide would go, and its display appeared at just the right magnification and brightness. Job done, and looking rather stylish!

We’ve not featured a slide viewer before here at Hackaday, though we did recently feature a similar hack on an Ikea toy projector. We have however featured more than one digital conversion on a classic slide projector using LCD screens in place of the slide.

Via Robots and Dinosaurs makerspace, Sydney.