Handling Bulk Material: Why Does My Cat Food Get Stuck?

May 24, 2022 by Anne Ogborn 44 Comments

Bulk material is stuff handled ‘in bulk’. One LEGO piece is a brick but 1,000 poured into a bag is bulk material. Corn starch, sand, flour, powder-coat powder, gravel, cat food, Cap’n Crunch, coins, screws, Styrofoam beads, lead shot, and gummy worms are bulk materials.

Applications abound where you need to move stuff in bulk. Selective sintering 3D printers, animal feeders, DIY injection molders, toner based PCB makers, home powder coating, automatic LEGO/domino/whatever sorters or assemblers, automated gardeners, airsoft accessories – handling bulk material is part of hacking. College science classes cover solids and liquids, but rarely bulk materials.

Most hackers just pray it works and tap the bin when it doesn’t. Industry does better, but the slang term “bin rash”, the long term result of tapping a 300 ton bin with sledgehammers (video), shows they don’t get it right all the time either. At the same time, it’s a fun area you can experiment with using kitchen items. So come along with us for a short series on the basics of bulk material handling. Continue reading “Handling Bulk Material: Why Does My Cat Food Get Stuck?” →

Large Scale Carbon Capture Without The Technology

May 10, 2022 by Jenny List 213 Comments

We humans are in something of a pickle, as we’ve put too much carbon dioxide in the atmosphere and caused climate change that might even wipe us out. There may still be people to whom that’s a controversial statement, but knowing something needs to be done about it should be a position for which you don’t necessarily have to be a climate change activist glueing yourself to the gates of a refinery.

It’s obvious that we can reduce our CO2 emissions to tackle the problem, but that’s not the only way that atmospheric CO2 can be reduced. How about removing it from the air? It’s an approach that’s being taken seriously enough for a number of industrial carbon capture solutions to be proposed, and even for a pilot plant to be constructed in Iceland. The most promising idea is that CO2 from power stations can be injected into porous basalt rock where it can react to form calcium carbonate. All of which is very impressive, but is there not a way that this can be achieved without resorting to too much technology? Time for Hackaday to pull out the back-of-envelope calculator, and take a look. Continue reading “Large Scale Carbon Capture Without The Technology” →

About As Cold As It Gets: The Webb Telescope’s Cryocooler

May 5, 2022 by Dan Maloney 26 Comments

If you were asked to name the coldest spot in the solar system, chances are pretty good you’d think it would be somewhere as far as possible from the ultimate source of all the system’s energy — the Sun. It stands to reason that the further away you get from something hot, the more the heat spreads out. And so Pluto, planet or not, might be a good guess for the record low temperature.

But, for as cold as Pluto gets — down to 40 Kelvin — there’s a place that much, much colder than that, and paradoxically, much closer to home. In fact, it’s only about a million miles away, and right now, sitting at a mere 6 Kelvin, the chunk of silicon at the focal plane of one of the main instruments aboard the James Webb Space telescope makes the surface of Pluto look downright balmy.

The depth of cold on Webb is all the more amazing given that mere meters away, the temperature is a sizzling 324 K (123 F, 51 C). The hows and whys of Webb’s cooling systems are chock full of interesting engineering tidbits and worth an in-depth look as the world’s newest space telescope gears up for observations.

Continue reading “About As Cold As It Gets: The Webb Telescope’s Cryocooler” →

EV Charging Connectors Come In Many Shapes And Sizes

April 28, 2022 by Lewin Day 69 Comments

Electric vehicles are now commonplace on our roads, and charging infrastructure is being built out across the world to serve them. It’s the electric equivalent of the gas station, and soon enough, they’re going to be everywhere.

However, it raises an interesting problem. Gas pumps simply pour a liquid into a hole, and have been largely standardized for quite some time. That’s not quite the case in the world of EV chargers, so let’s dive in and check out the current state of play.

AC, DC, Fast, or Slow?

Since becoming more mainstream over the past decade or so, EV technology has undergone rapid development. With most EVs still somewhat limited in range, automakers have developed ever-faster charging vehicles over the years to improve practicality. This has come through improvements to batteries, controller hardware, and software. Charging tech has evolved to the point where the latest EVs can now add hundreds of miles of range in under 20 minutes.

However, charging EVs at this pace requires huge amounts of power. Thus, automakers and industry groups have worked to develop new charging standards that can deliver high current to top vehicle batteries off as quickly as possible.

As a guide, a typical home outlet in the US can deliver 1.8 kW of power. It would take an excruciating 48 hours or more to charge a modern EV from a home socket like this.

In contrast, modern EV charge ports can carry anywhere from 2 kW up to 350 kW in some cases, and require highly specialized connectors to do so. Various standards have come about over the years as automakers look to pump more electricity into a vehicle at greater speed. Let’s take a look at the most common options out in the wild today. Continue reading “EV Charging Connectors Come In Many Shapes And Sizes” →

Noor III Solar Tower of the Ouarzazate Power Station, at dusk. (Credit: Marc Lacoste)

The Future Of Energy Storage On Both Sides Of The Meter

April 13, 2022 by Maya Posch 81 Comments

That energy storage is a hot topic is hardly a surprise to anyone these days. Even so, energy storage can take a lot of different forms, some of which are more relevant to the utility provider (like grid-level storage), while others are relevant to business and home owners (e.g. whole-house storage), and yet other technologies live in this tense zone between utility and personal interest, such as (electric) vehicle-to-grid.

For utilities a lot of noise is being made about shiny new technologies, such as hydrogen-based storage, while home- and business owners are pondering on the benefits of relying solely on the utility’s generosity with feed-in tariffs, versus charging a big battery from the solar panels on the roof and using the produced power themselves. Ultimately the questions here are which technologies will indeed live up to their promises, and which a home owner may want to invest in.

Continue reading “The Future Of Energy Storage On Both Sides Of The Meter” →

Bath County Pumped Storage Station (Credit: CHA)

Grid-Level Energy Storage And The Challenge Of Storing Energy Efficiently

April 6, 2022 by Maya Posch 118 Comments

Although every electrical grid begins with the production of electricity, there are times when storing this power in some form instead of using it immediately is highly convenient. Today’s battery-powered gadgets are an obvious example of such time-shifting, but energy storage plays a major role on the grid itself, too, whether in electrochemical, mechanical or in some other form.

Utility-level energy storage is essential for not only stabilizing the grid, but also to time-shift excess energy and provide a way to deal with sudden spikes in demand (peak-shaving) plus demand drops by absorbing the excess energy. The health of the grid can essentially be regarded as a function of its alternating current (AC) frequency, with strong deviations potentially leading to a collapse of the grid.

Naturally, such energy storage is not free, and the benefits of adding it to the grid have to be considered against the expense, as well as potential alternatives. With the rapid increase of highly volatile electrical generators on the grid in the form of non-dispatchable variable renewable energy, e.g. wind turbines and PV solar, there has been a push to store more excess power rather than curtailing it, in addition to using energy storage for general grid health.

Continue reading “Grid-Level Energy Storage And The Challenge Of Storing Energy Efficiently” →

Circuit VR: The Wheatstone Bridge Analog Computer

March 31, 2022 by Al Williams 13 Comments

We are always impressed with something so simple can actually be so complex. For example, what would you think goes into an analog computer? Of course, a “real” analog computer has opamps that can do logarithms, square roots, multiply, and divide. But would it surprise you that you can make an analog device like a slide rule using a Wheatstone bridge — essentially two voltage dividers. You don’t even need any active devices at all. It is an old idea and one that used to show up in electronic magazines now and again. I’ll show you how they work and simulate the device so you don’t have to build it unless you just want to.

A voltage divider is one of the easiest circuits in the world to analyze. Consider two resistors Ra and Rb in series. Voltage comes in at the top of Ra and the bottom of Rb is grounded. The node connecting Ra and Rb — let’s call it Z — is what we’ll consider the output.

Let’s say we have a 10 V battery feeding A and a perfect voltmeter that doesn’t load the circuit connected to Z. By Kirchoff’s current law we know the current through Ra and Rb must be the same. After all, there’s nowhere else for it to go. We also know the voltage drop across Ra plus the voltage drop across Rb must equal to 10 V. Kirchoff, conservation of energy, whatever you want to call it. Let’s call these quantities I, Va, and Vb. Continue reading “Circuit VR: The Wheatstone Bridge Analog Computer” →