Engineering

583 Articles

How To Get Into Cars: Drifting Mods

January 4, 2021 by 31 Comments

Drifting is a hugely popular motorsport unlike any other, focusing on style and getting sideways rather than the pursuit of the fastest time between two points. It’s a challenge that places great demands on car and driver, and proper attention to setup to truly succeed. Here’s a guide to get your first drift build coming together.

Getting Sideways (And Back Again)

Drift cars are specialised beasts, and like any motorsport discipline, the demands of the sport shape the vehicle to suit. If you’re looking to drift, you’ll want to choose a project car with a front-engined, rear-wheel drive layout. While it’s somewhat possible to drift with other layouts, the act of kicking out the tail and holding a slide at speed is best achieved with the handling characteristics of such a vehicle. It all comes down to weight transfer and breaking traction at will. Of course, over the years, certain cars have become expensive on the second-hand market due to their drift prowess, so you may have to get creative if your first choice isn’t available at your budget. It pays to talk to the drifters down at your local track to get an idea of which cars in your area are the best bet for a drift build. Once you’ve got yourself a car, you can get down to installing mods!

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Still Working After All These Years: The Voyager Plasma Wave Subsystem

December 31, 2020 by 49 Comments

NASA is always keen to highlight the space agency’s many successes, and rightly so — those who pay for these expensive projects have a right to know what they’re getting for their money. And so the news was recently sprinkled with stories of the discovery of electron bursts beyond the edge of our solar system, caused by shock waves from coronal mass ejection (CME) from our Sun reflecting and accelerating electrons in interstellar plasmas. It’s a novel mechanism and an exciting discovery that changes a lot of assumptions about what happens out in the lonely space outside of the Sun’s influence.

The recent discovery is impressive in its own right, but it’s even more stunning when you dig into the details of how it was made: by the 43-year-old Voyager spacecraft, each now about 17 light-hours away from Earth, and each carrying an instrument so simple and efficient that they’re still working all after this time — and which very nearly were left out of the mission’s science payload.

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Water And Molten Aluminium Is A Dangerous Combination

December 30, 2020 by 70 Comments

It is not uncommon for a Hackaday writer to trawl the comments section of a given article, looking for insights or to learn something new. Often, those with experience in various fields will share kernels of knowledge or raise questions on a particular topic. Recently, I happened to be glazing over an article on aluminium casting with interest, given my own experience in the field. One comment in particular caught my eye.

 And no, the water won’t cause a steam explosion. There’s a guy on youtube (myfordlover, I think) who disproves that myth with molten iron, pouring the iron into water, pouring water into a ladle of molten iron and so on. We’ll be happy to do a video demonstrating this with aluminum if so desired.

Having worked for some time in an aluminium die casting plant, I sincerely hope [John] did not attempt this feat. While there are a number of YouTube videos showing that this can be done without calamity, there are many showing the exact opposite. Mixing molten aluminium and water often ends very poorly, causing serious injury or even fatalities in the workplace. Let’s dive deeper to see why that is.

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The High-Tech Valor Glass Vials Used To Deliver The Coronavirus Vaccine

December 28, 2020 by 70 Comments

As the world waits for COVID-19 vaccines, some pharmaceutical companies stand armed and ready with an exciting improvement: better vials to hold the doses. Vials haven’t changed much in the last 100 years, but in 2011, Corning decided to do something about that. They started developing an alternative glass that is able to resist damage and prevent cracks. It’s called Valor glass, and it’s amazingly strong stuff. Think Gorilla glass for the medical industry.

Traditionally, pharmaceutical vials have been made from borosilicate glass, which is the same laboratory-safe material as Corning’s Pyrex. Borosilicate glass gets its strength from the addition of boron. Although borosilicate glass is pretty tough, it comes with some issues. Any type of glass is only as strong as its flaws, and borosilicate glasses are prone to some particularly strength-limiting flaws. Pharmaceutical glass must stand up to extreme temperatures, from the high heat of the vial-making process to the bitterly cold freeze-drying process and storing temperature required by the fragile viral RNA of some COVID-19 vaccines. Let’s take a look at how Valor glass vials tackle these challenges.

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Tracking Satellites: The Nitty Gritty Details

December 16, 2020 by 18 Comments

If you want to listen to satellites, you have to be able to track them as they pass over the sky. When I first started tracking amateur satellites, computing the satellite’s location in the sky was a part of the challenge. Nowadays, that’s trivial. What’s left over are all the extremely important real-world details.  Let’s take a look at a typical ham satellite tracking setup and see how it all ties together.

Rotators for Steering

The popularity of robotics, 3D printing, and CNC machines has resulted in a deluge of affordable electric motors and drivers. It’s hard to imagine that an electric motor for rotating an antenna would be anything special, but in fact, antenna rotators are non-trivial engineering designs. Most of the challenges are mechanical, not electrical — the antennas that they drive can be huge, have significant wind loading and rotational inertial, and just downright weigh a lot. A rotator design has to consider bearings, weather exposure, all kinds of loads, not just rotational. And usually a brake is required to keep the antenna pointed in windy conditions.

There’s been a 70-some year history of these mechanisms from back in the 1950s when Cornell Dubilier Electronics, the company you know as a capcacitor manufacturer, began making these rotators for television antennas in the 1950s. I was a little surprised to see that the rotator systems you can buy today are not very different from the ones we used in the 1980s, other than improved electronic controls. Continue reading “Tracking Satellites: The Nitty Gritty Details” →

Peeking Inside A VW Gearbox Reveals Die Casting Truths

December 14, 2020 by 70 Comments

Recently, I was offered a 1997 Volkswagen Golf for the low, low price of free — assuming I could haul it away, as it suffered from a thoroughly borked automatic transmission. Being incapable of saying no to such an opportunity, I set about trailering the poor convertible home and immediately tore into the mechanicals to see what was wrong.

Alas, I have thus far failed to resurrect the beast from Wolfsburg, but while I was wrist deep in transmission fluid, I spotted something that caught my eye. Come along for a look at the nitty-gritty of transmission manufacturing!

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Game Cartridges And The Technology To Make Data Last Forever

December 3, 2020 by 69 Comments

Game cartridges are perhaps the hardiest of all common storage schemes. Short of blunt traumatic force or application of electrical surges to the cartridge’s edge connectors, damaging a game cartridge is hard to do by accident. The same is also true for the data on them, whether one talks about an Atari 2006 cartridge from the late 1970s or a 1990s Nintendo 64 cartridge.

The secret sauce here are mask ROMs (MROM), which are read-only memory chips that literally have the software turned into a hardware memory device. A mask layer unique to each data set is used when metalizing the interconnects during chip fabrication. This means that the data stored on them is as durable as the processor in the game console itself. Yet this is not a technology that we can use in our own hobby projects, and it’s not available for personal long-term data storage due to the costs associated with manufacturing what is essentially a custom chip.

Despite its value as truly persistent storage, MROM has fallen out of favor over the decades. You may be surprised to find a lot of what’s currently used in the consumer market is prone to data corruption over time spans as short as one year to one decade depending on environmental conditions.

So what are we to do if we need to have read-only data that should remain readable for the coming decades?

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