Crossed Wires Crash Rockets

On November 17th, a Vega rocket lifted off from French Guiana with its payload of two Earth observation satellites. The booster, coincidentally the 17th Vega to fly, performed perfectly: the solid-propellant rocket engines that make up its first three stages burned in succession. But soon after the fourth stage of the Vega ignited its liquid-fueled RD-843 engine, it became clear that something was very wrong. While telemetry showed the engine was operating as expected, the vehicle’s trajectory and acceleration started to deviate from the expected values.

There was no dramatic moment that would have indicated to the casual observer that the booster had failed. But by the time the mission clock had hit twelve minutes, there was no denying that the vehicle wasn’t going to make its intended orbit. While the live stream hosts continued extolling the virtues of the Vega rocket and the scientific payloads it carried, the screens behind them showed that the mission was doomed.

Displays behind the hosts clearly showed Vega wasn’t following the planned trajectory.

Unfortunately, there’s little room for error when it comes to spaceflight. Despite reaching a peak altitude of roughly 250 kilometers (155 miles), the Vega’s Attitude Vernier Upper Module (AVUM) failed to maintain the velocity and heading necessary to achieve orbit. Eventually the AVUM and the two satellites it carried came crashing back down to Earth, reportedly impacting an uninhabited area not far from where the third stage was expected to fall.

Although we’ve gotten a lot better at it, getting to space remains exceptionally difficult. It’s an inescapable reality that rockets will occasionally fail and their payloads will be lost. Yet the fact that Vega has had two failures in as many years is somewhat troubling, especially since the booster has only flown 17 missions so far. A success rate of 88% isn’t terrible, but it’s certainly on the lower end of the spectrum. For comparison, boosters such as the Soyuz, Falcon 9, and Atlas have success rates of 95% or higher.

Further failures could erode customer trust in the relatively new rocket, which has only been flying since 2012 and is facing stiff competition from commercial launch providers. If Vega is to become the European workhorse that operator Arianespace hopes, figuring out what went wrong on this launch and making sure it never happens again is of the utmost importance.

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Game Cartridges And The Technology To Make Data Last Forever

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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A Case For Project Part Numbers

Even when we share the design files for open source hardware, the step between digital files and a real-world mechatronics widget is still a big one. That’s why I set off on a personal vendetta to find ways to make that transfer step easier for newcomers to an open source mechantronics project.

Today, I want to spill the beans on one of these finds: part numbers, and showcase how they can help you share your project in a way that helps other reproduce it. Think of part numbers as being like version numbers for software, but on real objects.

I’ll showcase an example of putting part numbers to work on one of my projects, and then I’ll finish off by showing just how part numbers offer some powerful community-building aspects to your project.

A Tale Told with Jubilee

To give this idea some teeth, I put it to work on Jubilee, my open source toolchanging machine. Between October 2019 to November 2020, we’ve slowly grown the number of folks building Jubilees in the world from 1 to more than 50 chatting it up on the Discord server. Continue reading “A Case For Project Part Numbers”

The Dark Side Of Solar Power

Everybody loves solar power, right? It’s nice, clean, renewable energy that’s available pretty much everywhere the sun shines. If only the panels weren’t so expensive. Even better, solar is now the cheapest form of electricity for companies to build, according to the International Energy Agency. But solar isn’t all apples and sunshine — there’s a dark side you might not know about. Manufacturing solar panels is a dirty process from start to finish. Mining quartz for silicon causes the lung disease silicosis, and the production of solar cells uses a lot of energy, water, and toxic chemicals.

The other issue is that solar cells have a guanteed life expectancy of about 25 years, with average efficiency losses of 0.5% per year. If replacement begins after 25 years, time is running out for all the panels that were installed during the early 2000s boom. The International Renewable Energy Agency (IREA) projects that by 2050, we’ll be looking at 78 million metric tons of bulky e-waste. The IREA also believe that we’ll be generating six million metric tons of new solar e-waste every year by then, too. Unfortunately, there are hardly any measures in place to recycle solar panels, at least in the US.

How are solar panels made, anyway? And why is it so hard to recycle them? Let’s shed some light on the subject.

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Remoticon Video: How To Reverse Engineer A PCB

You hold in your hand a circuit board from a product you didn’t make. How does the thing work? What a daunting question, but it’s both solvable and approachable if you know what you’re doing. The good news is that Eric Schlaepfer knows exactly what he’s doing and boiled down the process of reverse engineering printed circuit boards into this excellent workshop. It was presented live during the 2020 Hackaday Remoticon, and the edited video, which you’ll find below, was just published. Slides for the talk have been published on the workshop project page.

Need proof that he has skills that we all want? Last year Eric successfully reverse-engineered the legendary Sound Blaster audio card and produced his own fully-functional drop-in replacement called the Snark Barker. And then re-engineered it to work with the ancient MCA bus architecture. Whoa.

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Spacing Out: Rocks From The Moon, Rocks From Mars, A Near Miss, And Some Interesting Launches

Sure, the SpaceX crew made it safely to the ISS, but there’s plenty happening beyond just that particular horizon. The Chinese National Space Administration have launched their Chang’e 5 mission to collect and return lunar rock samples, a collaboration between NASA and ESA to do the same with samples from Mars has passed its review, and a pair of satellites came uncomfortably close to each other in a near-miss that could have had significant orbital debris consequences. It’s time for Spacing Out!

Bringing Alien Rocks to Earth

The Chang'e 5 mission on the launch pad. China News Service, CC BY 3.0.
The Chang’e 5 mission on the launch pad. China News Service, CC BY 3.0.

Ever since the NASA and Soviet lunar launches at the height of the Space Race, there have been no new missions to collect material from the Lunar surface and return it to Earth. That changed last week.

The Chang’e 5 mission launched in China on November 23rd will deliver moon rocks to earth, and as this is being written it has already entered Lunar orbit and separated into its constituent parts in preparation for landing. It’s a four-craft mission, with a lunar lander and ascent module going to the surface, and a service module and Earth return craft remaining in orbit to receive the samples and send them back to the planet for re-entry and retrieval. The hurdles facing the mission scientists and engineers are immense, and a safe sample return in mid-December will be an extremely impressive achievement.

Happily Chang’e 5 even has a hacker angle, as its telemetry has offered a bonanza to satellite-watchers who have turned their dishes skyward to capture the event. Daniel Estévez EA4GPZ has posted a collected analysis of data telemetry work by a variety of people worldwide, but the eye-candy prize goes to r00t.cz, who has successfully decoded image stream data to the extent that they have assembled a fragment of video captured from the craft during its journey.

Not to be outdone in the field of ambitious sample return missions, NASA and ESA’s joint plan to collect and return rock core samples from Mars has met with the approval of the independent review board set up to examine it. This will involve multiple craft from both agencies, with NASA’s already launched Perseverance rover collecting and containing the samples before leaving them on the surface for eventual collection by a future ESA rover. This will then pass them to a NASA ascent craft which will take them to Martian orbit and rendezvous with an ESA craft that will return them to Earth. We space-watchers are in for an exciting decade.

That Was a Close One!

Anyone who has seen the film Gravity will be familiar with the Kessler syndrome, in which collisions between spacecraft and or debris could create a chain reaction of further collisions and render entire orbital spheres unusable to future craft because of the collision hazard presented by the resulting cloud of space debris. Because of this, spacecraft operators devote considerable resources towards avoiding such collisions, and it is not uncommon for slight orbital adjustments to be made to avoid proximity with other orbiting man-made objects.

On the 27th of November it seems that these efforts failed, with a terse announcement from Roscosmos of a near-miss between their Kanopus-V craft and the Indian CARTOSAT 2F. The two remote-imaging satellites passed as close as 224 metres from each other, which in space terms given their likely closing speeds would have been significantly too close for comfort. The announcement appears worded to suggest that the Indian craft was at fault, however it’s probably a fairer conclusion that both space agencies should have seen the other’s satellite coming. Fortunately we escaped a catastrophe this time, but it is to be hoped that all operators of such satellites will take note.

RocketLab Joins the Reusable Booster Club

Other recent launches that might excite the interest of readers are the New Zealand-based RocketLab launching their Electron rocket with  30 small satellites on board before for the first time retrieving their booster stage, and the Japanese Mitsubish Electric sending their JDRS-1 satellite to geosynchronous orbit. This last craft is of interest because it carries an optical data link rather than the more usual RF, and could prove the technology for future launches.

The coming weeks should be full of news from China on Chang’e 5’s progress. Getting a craft to the moon and returning it will be a huge achievement, and we hope nothing fails and we’ll see pictures of the first new Moon rocks on Earth since the 1970s. We don’t know how to say “Good luck and a successful mission!” in Chinese, so we’ll say it in English.

Lithium: What Is It And Do We Have Enough?

Lithium (from Greek lithos or stone) is a silvery-white alkali metal that is the lightest solid element. Just one atomic step up from Helium, this magic metal seems to be in everything these days. In addition to forming the backbone of many kinds of batteries, it also is used in lubricants, mood-stabilizing drugs, and serves as an important additive in iron, steel, and aluminum production. Increasingly, the world is looking to store more and more power as phones, solar grids, and electric cars continue to rise in popularity, each equipped with lithium-based batteries. This translates to an ever-growing need for more lithium. So far production has struggled to keep pace with demand. This leads to the question, do we have enough lithium for everyone?

It takes around 138 lbs (63 kg) of 99.5% pure lithium to make a 70 kWh Tesla Model S battery pack. In 2016, OICA estimated that the world had 1.3 billion cars in use. If we replace every car with an electric version, we would need 179 billion pounds or 89.5 million tons (81 million tonnes) of lithium. That’s just the cars. That doesn’t include smartphones, laptops, home power systems, massive grid storage projects, and thousands of other products that use lithium batteries.

In 2019 the US Geological Survey estimated the world reserves of identified lithium was 17 million tonnes. Including the unidentified, the estimated total worldwide lithium was 62 million tonnes. While neither of these estimates is at that 89 million ton mark, why is there such a large gap between the identified and estimated total? And given the general rule of thumb that the lighter a nucleus is, the more abundant the element is, shouldn’t there be more lithium reserves? After all, the US Geological Survey estimates there are around 2.1 billion tonnes of identified copper and an additional 3.5 billion tonnes that have yet to be discovered. Why is there a factor of 100x separating these two elements?

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