Vintage Aircraft Controls Turned USB Button Box

July 25, 2020 by Tom Nardi 4 Comments

The Gables Engineering G-2789 audio selector panels aren’t good for much outside of the aircraft they were installed in, that is, until [MelkorsGreatestHits] replaced most of the internals with a Teensy 3.2. Now they are multi-functional USB input devices for…well, whatever it is you’d do with a bunch of toggle switches and momentary push buttons hanging off your computer.

With the Teensy going its best impression of a USB game controller, the host operating system has access to seven momentary buttons, twelve toggles, and one rotary axis for the volume knob.

Right now [MelkorsGreatestHits] says the code is set up so the computer sees a button press on each state change; in other words, the button assigned to the toggle switch will get “pressed” once when it goes up and again when it’s flicked back down. But of course that could be modified depending on what sort of software you wanted to interface the device with.

As we’ve seen with other pieces of vintage aircraft instrumentation, lighting on the G-2789 was provided by a series of incandescent bulbs that shine through the opaque front panel material. [MelkorsGreatestHits] replaced those lamps with white LEDs, but unfortunately the resulting light was a bit too harsh. As a quick fix, the LEDs received a few coats of yellow and orange paint until the light was more of an amber color. Using RGB LEDs would have been a nice touch, but you work with what you’ve got.

This isn’t the first time that [MelkorsGreatestHits] has turned an old aircraft cockpit module into a USB input device, and we’re certainly interested in seeing what the next project will look like. Though we’re perhaps more interested in finding out where all all these old school airplane parts are coming from…

USB-C Where It Was Never Intended To Be

July 24, 2020 by Jenny List 25 Comments

The USB-C revolution is well under way, as first your new phone, then your single-board computer, and now your laptop are likely so sport the familiar reversible round-cornered connector. We’re still in the crossover period of requiring to keep micro USB, proprietary laptop, and USB-C power supplies at hand, but the promise of a USB-C-only world is tantalisingly close. For [Purkkaviritys] that’s a little bit closer now, as he’s modified his Thinkpad T440s to take a USB charger instead of its proprietary Lenovo square-plug part. (Video, embedded below.)

At its heart is a USB-PD emulator module that does all the hard work of negotiation with the power supply, giving the laptop the DC voltage it needs. It’s not quite that simple though, because a resistor is required to reassure the laptop that it’s got a genuine power supply. The module is encased in a carefully-designed surround that neatly takes the space vacated by the original connector, and since this laptop has its internal power connector on a short cable it is made very straightforward to fit into the case. If you didn’t know it was a home-made upgrade, you could be forgiven for thinking that this laptop left the factory with a USB-C power socket.

The USB-C module used here is a versatile part. We’ve previously seen it in a soldering iron conversion.

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TinyPilot Provides KVM-over-IP, With Low Cost And Even Lower Latency

July 24, 2020 by Donald Papp 45 Comments

Remote access is great, but if the machine stops booting, ceases to connect to the network, or needs low-level interaction like BIOS settings or boot management, remote access is worthless because it’s only available once the host computer is up and running. The usual solution is to drag a keyboard and monitor to the machine in question for physical access.

Ubuntu laptop (right) being accessed over IP, via web browser on the left.

For most people, swapping cables in this way is an infrequent task at best. But for those who work more closely with managing hardware or developing software, the need to plug and unplug a keyboard and monitor into machines that otherwise run headless can get tiresome. The modern solution is KVM (keyboard, video, mouse) over IP, but commercial options are expensive. [Michael Lynch]’s TinyPilot on the other hand clocks in at roughly $100 of parts, including a Raspberry Pi and USB HDMI capture device. It does have to drop the ‘M’ from KVM (meaning it does not support a mouse yet) but the rest of it hits all the bases, and does it all from a web browser.

What exactly does TinyPilot do? It provides remote access via web browser, but the device is an independent piece of hardware that — from the host computer’s point of view — is no different from a physical keyboard and monitor. That means keyboard and video access works before the host machine even boots, so even changing something like BIOS settings is no problem.

[Michael] demonstrates his design in the video embedded below, but we encourage you to check out the project page for a fascinating exploration of all the challenges that were part of TinyPilot’s development.

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Die Lapping For Better CPU Performance

July 21, 2020 by Lewin Day 59 Comments

CPUs generate their heat in the silicon die that does all those wonderful calculations which make our computers work. But silicon conducts heat fairly poorly, so the thinner your CPU die, the better it will conduct heat out to the heatsink. This theoretically promises better cooling and thus more scope for performance. Thus, it follows that some overclockers have taken to lapping down their CPU dies to try and make a performance gain.

It’s not a simple process, as the team at [Linus Tech Tips] found out. First, the CPU must be decapped, which on the Intel chip in question requires heating to release the intermediate heat spreader. A special jig is also required to do the job accurately. Once the bare CPU is cleaned of all residual glue and heat compounds, it can then be delicately lapped with a second jig designed to avoid over-sanding the CPU.

After much delicate disassembly, lapping, and reassembly, the CPU appears to drop 3-4 degrees C in benchmarks. In overclocking terms, that’s not a whole lot. While the process is risky and complicated for little gain, the underlying premise has merit – Intel thinned things out in later chips to make minor gains themselves. Video after the break.

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Quickly Mute And Unmute Yourself Using The Physical Mute Button

July 15, 2020 by Orlando Hoilett 52 Comments

With many conferences moving to fully virtual this year, video conferencing will continue to be a mainstay in our lives for the foreseeable future. [Elliot] wanted to spice up his video conferencing experience just a bit and make his experience a bit more ergonomic. We’ve all had the problem of looking for our Zoom window buried behind any number of other applications, desperately searching for the mute button. Furthermore, when we get called on, we’re desperately trying to give the impression that we’ve been paying attention the entire time, even when we haven’t been.

To solve all these problems, he built a physical mute button to easily toggle the mute option on and off during Zoom calls. The device takes advantage of the native USB feature of his Digispark board, and a few built-in keyboard shortcuts in Zoom. With native USB, the Digispark board can act like a keyboard, making it really simple to emulate keyboard presses using the microcontroller. Throw in an arcade-style button and do a bit of handcrafting and you have yourself your own physical mute button.

We were really impressed by the simplicity of the design as well as the elegance of the mechanical assembly. [Elliot] even made a revamped version with a second button allowing him to control his video as well. Cool button(s) [Elliot]!

What’s your favorite work-from-home hack? Check out some of our favorites here on Hackaday.

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Tales From The Sysadmin: Impending Hard Drive Doom

July 14, 2020 by Jonathan Bennett 70 Comments

It should have been another fine day, but not all was well in paradise. Few things bring a creeping feeling of doom like a computer that hardlocks and then refuses to boot. The clicking sound coming from the tower probably isn’t a good sign either. Those backups are up to date, right? Right?

There are some legends and old stories about hard drive repair. One of my favorites is the official solution to stiction for old drives: Smack it with a mallet. Another trick I’ve heard repeatedly is to freeze a hard drive before trying to read data off of it. This could actually be useful in a couple instances. The temperature change can help with stiction, and freezing the drive could potentially help an overheating drive last a bit longer. The downside is the potential for condensation inside the drive. Don’t turn to one of these questionable fixes unless you’ve exhausted the safer options.

For the purpose of this article, we’ll assume the problem is the hard drive, and not another component like a power supply or SATA cable causing problems. A truly dead drive is a topic for another time, but if the drive is alive enough to show up as a block device when plugged in, then there’s hope for recovering the data. One of the USB to SATA cables available on your favorite online store is a great way to recover data. Another option is booting off a Linux DVD or flash drive, and accessing the drive in place. If you’re lucky, you can just copy your files and call it a day. If the file transfer fails because of the dying drive, or you need a full disk image, it’s time to pull out some tools and get to work. Continue reading “Tales From The Sysadmin: Impending Hard Drive Doom” →

Hacked Case Fan Follows The Leader With IR Sensor

July 10, 2020 by Tom Nardi 22 Comments

Adding an additional fan to your PC is usually pretty straightforward, but as [Randy Elwin] found, this isn’t always the case with the newer Small Form Factor (SFF) machines. Not only was the standard 80 mm fan too large to fit inside of the case, but there wasn’t even a spot to plug it in. So he had to come up with his own way to power it up and control its speed.

Now if he only needed power, that wouldn’t have been a problem. You could certainly tap into one of the wires coming from the PSU and get 12 V to spin the fan. But that would mean it was running at max speed the whole time; fine in a pinch, but not exactly ideal for a daily driver.

Note the SATA connector pulled from a dead HDD.

To get speed control, [Randy] put together a little circuit using an ATtiny85, an IR LED, and a LTR-306 phototransistor. The optical components are used to detect the GPU fan’s current speed, which itself is controlled based on system temperature. Using the GPU fan RPM as an input, a lookup table on the microcontroller sets an appropriate speed for the 80 mm case fan.

One could argue that it would have been easier to connect a temperature sensor to the ATtiny85, but by synchronizing the case fan to the computer-controlled GPU fan, [Randy] is able to manually control them both from software if necessary. Rather than waiting on the case temperature to rise, he can peg the GPU fan and have the external fan speed up to match when the system is under heavy load.

You may think this is overkill for a simple case fan, but compared to some of the cooling hacks we’ve seen in the past, it’s pretty tame.