Engineering

603 Articles

How Does The James Webb Telescope Phone Home?

July 25, 2022 by 31 Comments

When it comes to an engineering marvel like the James Webb Space Telescope, the technology involved is so specialized that there’s precious little the average person can truly relate to. We’re talking about an infrared observatory that cost $10 billion to build and operates at a temperature of 50 K (−223 °C; −370 °F), 1.5 million kilometers (930,000 mi) from Earth — you wouldn’t exactly expect it to share any parts with your run-of-the-mill laptop.

But it would be a lot easier for the public to understand if it did. So it’s really no surprise that this week we saw several tech sites running headlines about the “tiny solid state drive” inside the James Webb Space Telescope. They marveled at the observatory’s ability to deliver such incredible images with only 68 gigabytes of onboard storage, a figure below what you’d expect to see on a mid-tier smartphone these days. Focusing on the solid state drive (SSD) and its relatively meager capacity gave these articles a touchstone that was easy to grasp by a mainstream audience. Even if it was a flawed comparison, readers came away with a fun fact for the water cooler — “My computer’s got a bigger drive than the James Webb.”

Of course, we know that NASA didn’t hit up eBay for an outdated Samsung EVO SSD to slap into their next-generation space observatory. The reality is that the solid state drive, known officially as the Solid State Recorder (SSR), was custom built to meet the exact requirements of the JWST’s mission; just like every other component on the spacecraft. Likewise, its somewhat unusual 68 GB capacity isn’t just some arbitrary number, it was precisely calculated given the needs of the scientific instruments onboard.

With so much buzz about the James Webb Space Telescope’s storage capacity, or lack thereof, in the news, it seemed like an excellent time to dive a bit deeper into this particular subsystem of the observatory. How is the SSR utilized, how did engineers land on that specific capacity, and how does its design compare to previous space telescopes such as the Hubble?

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Working With BGAs: Design And Layout

June 20, 2022 by 27 Comments

The Ball Grid Array, or BGA package is no longer the exclusive preserve of large, complex chips on computer motherboards: today even simple microcontrollers are available with those little solder balls. Still, many hobbyists prefer to stay with QFP and QFN packages because they’re easier to solder. While that is a fair point, BGA packages can offer significant space savings, and are sometimes the only choice: with the ongoing chip shortage, some other package versions might simply be unavailable. Even soldering doesn’t have to be complicated: if you’re already comfortable with solder paste and reflow profiles, adding a BGA or two into the mix is pretty easy.

In this article we’ll show that working with BGA chips is not as difficult as it may seem. The focus will be on printed circuit board design: how to draw proper footprints, how to route lots of signals and what capabilities your PCB manufacturer should have. We’ll cover soldering and rework techniques in a future article, but first let’s take a look at why BGAs are used at all.

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Revolving Doors Aren’t Just Annoying, They’re Energy Saving Too

June 9, 2022 by 43 Comments

While most of us have been content with swing and sliding doors for the vast majority of our needs around the home, the revolving door remains popular in a wide variety of contexts.

It’s a confounding contraption that always feels ready to snatch and ensnare the unwary user. However, these doors do have certain benefits that have allowed them to retain popularity in many public buildings around the world. Let’s dive in to why below.

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

May 24, 2022 by 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 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 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.

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EV Charging Connectors Come In Many Shapes And Sizes

April 28, 2022 by 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” →