Engineering

597 Articles

All About USB-C: Pinecil Soldering Iron

January 31, 2023 by 79 Comments

As many people have pointed out, what matters with USB-C isn’t just the standard, it’s the implementations. After all, it’s the implementations that we actually have to deal with, and it’s where most of the problems with USB-C arise. There is some fault to the standard, like lack of cable markings from the get-go, but at this point, I’m convinced that the USB-C standard is a lot better than some people think.

I’d like to walk you through a few USB-C implementations in real, open-source, adjacent, and just interesting products. They’re all imperfect in some way – it can’t be otherwise, as they have to deal with the messy real world, where perfection is a rarity.

Today, let’s check out the Pinecil. A soldering iron by Pine64, released a few years ago, keeping the price low and quality high. It sports both a barrel jack and a USB-C port for its power input – a welcome departure from the Miniware iron strategy, where neither the barrel-jack-only TS100 nor the low-power proprietary-tip TS80 irons quite did it. And, given its design around TS100 T12-style tips, it’s no wonder Pinecil took a well-deserved spot in hobbyist world.

Can’t Just Pull The Trigger

Now, you might be thinking that Pinecil ought to be a simple device. The usual way to get high power out of a USB-C port is a Power Delivery (PD) trigger IC, and you could merely use that. However, if you’ve read the USB-C power article, you might remember the 45 W vs 60 W charger scenario, where such an arrangement would fail immediately. Overall, the configurability of trigger ICs is quite low, and when encountering a PD compatibility problem with some PSU, you can’t do anything about it except replace the IC with a slightly-different-logic IC- if a replacement even exists, and it usually does not. This is costly and limiting for a real-world use product. Continue reading “All About USB-C: Pinecil Soldering Iron” →

Machining With Electricity Explored In The Hack Chat

January 20, 2023 by 16 Comments

As a Hackaday reader, it’s safe to assume you’ve got a better than average understanding of electricity. There’s also an excellent chance you’re familiar with machining, and may even have a lathe or old mill in the workshop. But combining the two, and actually machining a piece of metal with electricity, isn’t something that many home gamers can boast first-hand experience with.

Daniel Herrington

Of course, that doesn’t mean there isn’t an interest. To help answer the burning (or at least, sparking) questions from the community, CEO and founder of Voxel Innovations Daniel Herrington stopped by this week’s Hack Chat to talk about the cutting edge of both electric discharge machining (EDM) and the closely related field of electrochemical machining (ECM). While his company uses the technology to produce components at incredible scales, Daniel got his start tinkering in the garage like so many of us, enabling him to provide both a professional and hobbyist prospective on the technologies.

Naturally, the first big question to be addressed was the difference between EDM and ECM. Put simply, electric discharge machining uses high-voltage to literally blast away material from the workpiece. The resulting finish is generally rough, and progress through the material tends to be slow, but it’s relatively simple to implement.

In contrast electrochemical machining could be thought of as a sort of reverse electroplating process, as the material being removed from the workpiece is dissolved and transferred to the cathode — though in practice the flow of pressurized electrolyte keeps it from actually plating the negatively charged tool. ECM is a faster process than EDM and allows for an exceptionally smooth surface finish, but is considerably more challenging from a technical perspective. Continue reading “Machining With Electricity Explored In The Hack Chat” →

Supercon 2022: All Aboard The SS MAPR With Sherry Chen

January 17, 2023 by 8 Comments

How do you figure out what is in a moving body of water over a mile wide? For those in charge of assessing the water quality of the Delaware river, this is a real problem. Collecting the data required to evaluate the water quality was expensive and time-consuming, taking over six years. Even then, the data was relatively sparse, with just a few water quality stations and only one surface sample for every six miles of river.

Sherry Chen, Quinn Wu, Vanessa Howell, Eunice Lee, Mia Mansour, and Frank Fan teamed up to create a solution, and the SS MAPR was the result. At Hackaday Supercon 2022, Sherry outlined the mission, why it was necessary, and their journey toward an autonomous robot boat. What follows is a fantastic guide and story of a massive project coming together. There are plans, evaluations, and tests for each component.

Sherry and the team first started by defining what was needed. It needed to be cheap, easy to use, and able to sample from various depths in a well-confined bounding box. It needed to run for four hours, be operated by a single person, and take ten samples across a 1-mile (2 km) section of the river. Some of the commercial solutions were evaluated, but they found none of them met the requirements, even ignoring their high costs. They selected a multi-hull style boat with off-the-shelf pontoons for stability and cost reasons.
Continue reading “Supercon 2022: All Aboard The SS MAPR With Sherry Chen” →

Wear Your Fave Cassette Tapes As A Necklace With This 3D Printed Adapter

December 29, 2022 by 47 Comments

While packing merch for a recent gig, I realised I had the opportunity to do something a little fun. I’d released an album on tape, and spent a little extra to ensure the cassette itself was a thing of beauty. It deserved to be seen, rather than hidden away in a case on a shelf. I wanted to turn this piece of musical media into a necklace.

Of course, cassette tapes aren’t meant to be used in this way. Simply throwing a chain through the cassette would lead to tape reeling out everywhere. Thus, I fired up some CAD software and engineered a solution to do the job! Here’s how I built an adapter to turn any cassette tape into a cool necklace.

Find the design on Thingiverse, and more details below!

Continue reading “Wear Your Fave Cassette Tapes As A Necklace With This 3D Printed Adapter” →

Supercon 2022: Mooneer Salem Goes Ham With An ESP32

December 28, 2022 by 10 Comments

After being licensed as a ham radio operator since the early 2000s, you tend to start thinking about combining your love for the radio with other talents. In a 20-minute talk at Hackaday Supercon 2022, [Mooneer Salem] tells the story of one such passion project that combined software and radio to miniaturize a digital ham radio modulator.

[Mooneer] works as a software developer and contributes to a project called FreeDV (free digital voice), a digital voice mode for HF radio. FreeDV first compresses the digital audio stream, then converts it into a modulation scheme sent out over a radio. The appeal is that this can be understandable down to very low signal-to-noise ratios and includes metadata and all the other niceties that digital signals bring.

Traditionally, this has required a computer to compress the audio and modulate the signal in addition to two sound cards. One card processes the audio in and out of your headset, and another for the audio coming in and out of the radio. [David Rowe] and [Rick Barnich] developed the SM1000, a portable FreeDV adapter based around the STM32F4 microcontroller. However, flash space was running low, and the cost was more than they wanted. Continue reading “Supercon 2022: Mooneer Salem Goes Ham With An ESP32” →

Big Chemistry: Liquefied Natural Gas

December 21, 2022 by 44 Comments

The topic of energy has been top-of-mind for us since the first of our ancestors came down out of the trees looking for something to eat that wouldn’t eat them. But in a world where the neverending struggle for energy has been abstracted away to the flick of a finger on a light switch or thermostat, thanks to geopolitical forces many of us are now facing the wrath of winter with a completely different outlook on what it takes to stay warm.

The problem isn’t necessarily that we don’t have enough energy, it’s more that what we have is neither evenly distributed nor easily obtained. Moving energy from where it’s produced to where it’s needed is rarely a simple matter, and often poses significant and interesting engineering challenges. This is especially true for sources of energy that don’t pack a lot of punch into a small space, like natural gas. Getting it across a continent is challenging enough; getting it across an ocean is another thing altogether, and that’s where liquefied natural gas, or LNG, comes into the picture.

Continue reading “Big Chemistry: Liquefied Natural Gas” →

Battery Engineering Hack Chat Gets Charged Up

December 16, 2022 by 9 Comments

Turn the clock back a couple of decades, and the only time the average person would have given much thought to batteries was when the power would go out, and they suddenly needed to juice up their flashlight or portable radio.  But today, high-capacity batteries have become part and parcel to our increasingly digital lifestyle. In fact, there’s an excellent chance the device your reading this on is currently running on battery power, or at least, is capable of it.

So let’s get to know batteries better. What’s the chemical process that allows them to work? For that matter, what even is a battery in the first place?

It’s these questions, and more, that made up this week’s Battery Engineering Hack Chat with Dave Sopchak. Our last Hack Chat of 2022 ended up being one of the longest in recent memory, with the conversation starting over an hour before the scheduled kickoff and running another half hour beyond when emcee Dan Maloney officially made his closing remarks. Not bad for a topic that so often gets taken for granted.

Continue reading “Battery Engineering Hack Chat Gets Charged Up” →