Arc from a flyback transformer power supply

A Cornucopia Of High Voltage Sources

May 26, 2016 by Steven Dufresne 39 Comments

Having hacked away with high voltage for many years I’ve ended up using a large number of very different high voltage sources. I say sources and not power supplies because I’ve even powered a corona motor by rubbing a PVC pipe with a cotton cloth, making use of the triboelectric effect. But while the voltage from that is high, the current is too low for producing the necessary ion wind to make a lifter fly up off a tabletop. For that I use a flyback transformer and Cockcroft-Walton voltage multiplier power supply that’s plugged into a wall socket.

So yes, I have an unorthodox skillset when it comes to sourcing high voltage. It’s time I sat down and listed most of the power sources I’ve used over the years, including a bit about how they work, what their output is like and what they can be used for, as well as some idea of cost or ease of making. The order is from least powerful to most powerful so keep reading for the ones that really bite.

Triboelectric Effect

You’ve no doubt encountered this effect. It’s how your body is charged when you rub your feet on carpet and then get a shock from touching a door knob. When you rub two specific materials together there’s a transfer of electrons from one to the other. Not just any two materials will work. To find out which materials are good to use, have a look at a triboelectric series table.

Materials that are on the positive end of the table will become positively charged when rubbed against materials on the negative end of the table. Those materials will become negatively charged. The further apart they are in the table, the stronger the charging.

Powering corona motor with triboelectricity

An example of where I’ve used this is to power the corona motor shown here. I vigorously rub a PVC pipe with a cotton cloth, and as the pipe emerges from the cloth, a sharp wire a few millimeters away takes the charge from the pipe. You can see this corona motor being powered by other power sources in the video here.

This would be considered an electrostatic power source because charge is accumulated on surfaces. Being insulating materials, that charge can’t move around.

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Symmetry For Beginners – The Rubik’s Cube

May 24, 2016 by Will Sweatman 13 Comments

Symmetry is everywhere in our natural world. Just take a look at your hands, a butterfly, or a sunflower. It’s easy to pass off the idea of symmetry and symmetric structures as a simple quirk of existence, and to pay it little mind. If this is your view, I can assure you it will no longer be by the end of this series. If we force ourselves to look beyond the grade school applications of symmetry, we find a world rich in connections via many different types of symmetric identities. One of the most interesting is Gauge Symmetry, which lies at the heart of Quantum Electrodynamics, or QED (we’ll get into this a bit later in the series). Several branches of higher level mathematics study symmetry in detail, allowing a host of sciences, from physics to chemistry, to view difficult problems and theories from a different perspective.

The subject matter of the ideas explored in symmetry is complicated, and not well known outside of academia and the theoretical sciences. It is the goal of this series of articles to simplify some of the concepts that underpin the study of symmetry, so that the average hacker can gain a basic (and I mean basic) understanding of this fascinating body of knowledge, and put it to use in future projects. We’ll start things off by taking a look at a machine that has crossed the Hackaday server many times – those nifty Rubik’s Cube solvers. Just how do those things work anyway?

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Hackaday Dictionary: Lithium Ion Batteries

May 20, 2016 by Richard Baguley 36 Comments

Battery technology is a constant chemical war between the laws of physics and the desire of engineers to make devices smaller. On one side, the laws of physics declare that there are limits to how much energy you can store inside a battery, and on the other side are the engineers looking for ways to sneak around these laws. For many devices, the best compromise between these two sides is the lithium ion battery, usually abbreviated to Li-ion.

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Flying With Proportional – Integral – Derivative Control

May 18, 2016 by Rud Merriam 24 Comments

Your quad-copter is hovering nicely 100 feet north of you, its camera pointed exactly on target. The hover is doing so well all the RC transmitter controls are in the neutral position. The wind picks up a bit and now the ‘copter is 110 feet north. You adjust its position with your control stick but as you do the wind dies and you overshoot the correction. Another gust pushed it away from target in more than one direction as frustration passes your lips: ARGGGHH!! You promise yourself to get a new flight computer with position hold capability.

How do multicopters with smart controllers hold their position? They use a technique called Proportional – Integral – Derivative (PID) control. It’s a concept found in control systems of just about everything imaginable. To use PID your copter needs sensors that measure the current position and movement.

The typical sensors used for position control are a GPS receiver and an Inertial ~~Management~~ Measurement Unit (IMU) made up of an accelerometer, a gyroscope, and possibly a magnetometer (compass). Altitude control would require a barometer or some other means of measuring height above ground. Using sensor fusion techniques to combine the raw data, a computer can determine the position, movement, and altitude of the multicopter. But calculating corrections that will be just right, without over or undershooting the goal, is where PID comes into play. Continue reading “Flying With Proportional – Integral – Derivative Control” →

The Art And Science Of Bending Sheet Metal

May 18, 2016 by Moritz Walter 50 Comments

A motor mount. A sturdy enclosure. A 43.7° bracket. The average hack requires at least one angled metal part, and the best tool to make one is still the good ol’ press brake. Bending parts requires a few extra thoughts in the design and layout of the flat patterns, so if you want to know about bend allowances, bend deduction and how to bend accurate parts even without a press, read on.

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Two Guys, A Hotel Room And A Radio Fire

May 13, 2016 by Gregory L. Charvat 45 Comments

Can you build a HF SSB radio transciever in one weekend, while on the road, at parts from a swap meet? I can, but apparently not without setting something on fire.

Of course the swap meet I’m referring to is Hamvention, and Hamvention 2016 is coming up fast. In a previous trip to Hamvention, Scott Pastor (KC8KBK) and I challenged ourselves to restore tube radio gear in a dodgy Dayton-area hotel room where we repaired a WW2 era BC-224 and a Halicrafters receiver, scrounging parts from the Hamfest.

Our 2014 adventures were so much fun that it drove us to create our own hacking challenge in 2015 to cobble together a <$100 HF SSB transceiver (made in the USA for extra budget pressure), an ad-hoc antenna system, put this on the air, and make an out-of-state contact before the end of Hamvention using only parts and gear found at Hamvention. There’s no time to study manuals, antennas, EM theory, or vacuum tube circuitry. All you have are your whits, some basic tools, and all the Waffle House you can eat. But you have one thing on your side, the world’s largest collection of surplus electronics and radio junk in one place at one time. Can it be done?

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Tools Of The Trade – Component Placing

May 10, 2016 by Bob Baddeley 34 Comments

Recently we started a series on the components used to assemble a circuit board. The first issue was on dispensing solder paste. Moving down the assembly line, with the paste already on the board, the next step is getting the components onto the PCB. We’re just going to address SMT components in this issue, because the through hole assembly doesn’t take place until after the SMT components have gone through the process to affix them to the board.

SMT components will come in reels. These reels are paper or plastic with a clear plastic strip on top, and a reel typically has a few thousand components on it. Economies of scale really kick in with reels, especially passives. If you order SMT resistors in quantities of 1-10, they’re usually $.10 each. If you order a reel of 5000, it’s usually about $5 for the reel. It is cheaper to purchase a reel of 10 kOhm 0603 resistors and never have to order them again in your life than it is to order a few at a time. Plus the reel can be used on many pick-and-place machines, but the cut tape is often too short to use in automated processes.

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