EV History: The Lightning Precedes The Thunder

June 27, 2016 by Moritz Walter 39 Comments

In 1988, a bunch of engineers from Hotzenwald, Germany, came together and decided that it is time for the future of mobility: A new, more modern and environmentally friendly car should put an end to fossils and emissions while still being fun to drive. “It should become a new kind of car. Smaller, lighter, cleaner – and more beautiful” is how future CEO Thomas Albiez described his mission. For the first time in automotive history, this series car would be designed as an all-electric vehicle from the start and set a new standard for mobility. The project was given the codename “Hotzenblitz” (“Hotzen Bolt”) to indicate how the idea came to them: Like a lightning bolt. The snarky regional term also came with a double meaning: Imaginary lightning bolts, used for insurance fraud.

hotzenblitz_chassis — Hotzenblitz frame construction (origin unknown, image source)

Unnoticed by the rest of the world, they founded Hotzenblitz Mobile. Industrial Designer Harold Schurz was contracted to design the chassis for the Hotzenblitz, which was then modeled into a prototype chassis. The self-funded team moved fast. An external motorsports company helped to develop the tubular steel frame, and soon their vision took on shape. After the team had fitted a motor and transmission into the frame, CEO Thomas Albiez himself installed the traction battery and drive train. The team felt confident with the result, and in July 1990, during an open house day in the office, they somewhat spontaneously decided to call Green Tech entrepreneur and chocolate mogul Alfred Ritter.

Alfred Ritter had experienced financial losses after the Chernobyl Disaster. Many agricultural regions, including several hazelnut plantations that were vital to Alfred’s chocolate business, were irreversibly lost to the fallout contamination. It was then when he turned to the green energy business, founding the Paradigma group to manufacture solar collector systems and pellet heaters. When Thomas and the team called, Alfred jumped on the idea of an electric car. In the same year, Alfred Ritter and his sister Marli Hoppe-Ritter became shareholders in the company and helped to finance the future of the Hotzenblitz.

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Taming Robot Arm Jump With Accelerometers

June 24, 2016 by Rud Merriam 46 Comments

Last fall, I grabbed a robot arm from Robot Geeks when they were on sale at Thanksgiving. The arm uses servos to rotate the base and move the joints and gripper. These work well enough but I found one aspect of the arm frustrating. When you apply power, the software commands the servos to move to home position. The movement is sufficiently violent it can cause the entire arm to jump.

This jump occurs because there is no position feedback to the Arduino controller leaving it unable to know the positions of the arm’s servos and move them slowly to home. I pondered how to add this feedback using sensors, imposing the limitation that they couldn’t be large or require replacing existing parts. I decided to try adding accelerometers on each arm section.

Accelerometers, being affected by gravity when on a planet, provide an absolute reference because they always report the direction of down. With an accelerometer I can calculate the angle of an arm section with respect to the direction of gravitational acceleration.

Before discussing the accelerometers, take a look at the picture of the arm. An accelerometer would be added to each section of the arm between the controlling servos.

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Driving BB-8: More Than One Way To Move This Bot

June 24, 2016 by Steven Dufresne 30 Comments

BB-8 is the much loved new droid introduced in the 2016 movie Star Wars: The Force Awakens, though in my case from the very first trailer released in 2014 I liked it for the interesting engineering problems it posed. How would you make a robot that’s a ball that rolls along, but with a head that stays on top while the ball rolls under it?

BB-8 in 1st Star Wars: The Force Awakens trailer

Hamster in hamster wheel

To make the ball roll, the answer most people found obvious at first was to use the analogy of a hamster wheel. The hamster running inside makes the wheel turn. In the BB-8 building world, which is quite large, the drive mechanism has come to be called a hamster drive, or just a hamster.

For the head, it seemed obvious that there would be magnets inside the ball, perhaps held in place near the top of the ball by a post extending up from the hamster. Corresponding magnets in attraction would then be attached to the underside of the head, and balls (also mounted under the head) would keep the head moving smoothly over the ball.

The magnet approach for the head has turned out to be the method used by all BB-8 builders that I’ve seen. However, the hamster has turned out to be only one of multiple solutions. Since the original debut many different methods have been used in builds and we’re going to have a lot of fun looking at each separate approach. It’s almost like revealing a magic trick; but really it’s all just clever engineering.

Note that for the actual movie, a combination of 7 or 8 props and CGI were used. The official working BB-8s that are shown at various promotional events were built after the movie was made and as of this writing, few details of their construction have been released. One notable detail, however, is that they aren’t using hamster drives.

Below are details of all the different BB-8 drive systems I’ve seen so far that have been built along with how they work.

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150,000 Members Strong, Hackaday.io Flies Past Another Milestone

June 23, 2016 by Mike Szczys 21 Comments

We’re growing so fast that soon your mom will be on Hackaday.io. That’s fine, everyone who loves hardware is welcome. 150,000 members have made Hackaday.io a home for their creativity — looking for inspiration in the work of others, sharing successes and temporary failures, and building their dream team to take on amazing new challenges. There is no place in the world that can come close to matching the Open Hardware ecosystem that is Hackaday.io.

What is in that one number, 150k? It is a monumental chunk of a much bigger picture: the thriving Hackaday ecosystem that spans from staking down your own workshop full of projects and skills, to following the editorial pulse of hardware used in new and creative ways. Looking over the last twelve months on all of the Hackaday sites we’ve seen about 18.5 Million visitors and registered nearly 85 Million views. Hackaday is not a passive community. We all have an insatiable hunger to delve into the next big trick, and to celebrate the accomplishments that made it happen.

Want to find a new and unique way to use the tech you find most interesting? Your leap forward needs input to pollinate the idea. Hackaday has a critical mass of hackers, designers, and engineers waiting with excitement to hear and help out in exploring and expanding the frontier. These interaction are what has packed Hackaday.io with interesting people. Most would say: I came for a specific hack or to see what a particular hacker was up to, but then I felt at home and decided to stick around and share what I’ve spent way to much time doing (but I wouldn’t have it any other way).

As we continue to knock down one membership milestone after another I want to thank you all for being involved, for valuing the free and open sharing of information and ideas, and for sharing your own time and talent. You are what moves this community of hardware hackers to dizzying heights of excellence and awesome.

This is all too good to be a secret. Talk to your hardware-loving friends, colleagues, family, and acquaintances and invite them to Hackaday.io if they’re not already with us.

What Could Go Wrong: Asynchronous Serial Edition

June 22, 2016 by Elliot Williams 50 Comments

It’s the easiest thing in the world — simple, straightforward serial data. It’s the fallback communication protocol for nearly every embedded system out there, and so it’s one that you really want to work when the chips are down. And yet! When you need it most, you may discover that even asynchronous serial can cost you a few hours of debugging time and add a few gray hairs to your scalp.

In this article, I’m going to cover most (all?) of the things that can go wrong with asynchronous serial protocols, and how to diagnose and debug this most useful of data transfer methods. The goal is to make you aware enough of what can go wrong that when it does, you’ll troubleshoot it systematically in a few minutes instead of wasting a few hours.

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A Hacker’s Guide To Getting Old

June 22, 2016 by Dan Maloney 95 Comments

It’s no surprise that things change as we age, and that tasks that were once trivial become difficult. Case in point: my son asked for help with the cord on his gaming headset the other night. The cable had broken and we could see frayed conductors exposed. When I got it apart, I found that I could barely see the ultra-fine wires to resolder them after cutting out the bad section. I managed to do it, but just barely.

This experience got me thinking about how to deal with the inevitable. How do you stay active as a hacker once your body starts to fight you more than it helps you? I’m interested mostly in dealing with changes in vision, but also in loss of dexterity and fine motor skills, and dealing with cognitive changes. This isn’t a comprehensive list of the ravages of time, but they’re probably the big ones that impact any hacker-related hobby. I enlisted a couple of my more seasoned Hackaday colleagues, [Bil] and [Rud], for their tips and tricks to deal with these issues.

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FAA Finalizes Rules For Drones, UAS, And Model Aircraft

June 21, 2016 by Brian Benchoff 20 Comments

The FAA and DOT have finalized their rules for small Unmanned Aircraft Systems (UAS, or drones), and clarified rules for model aircraft. This is the end of a long process the FAA undertook last year that has included a registry system for model aircraft, and input from members of UAS and model aircraft industry including the Academy of Model Aeronautics and 3D Robotics.

Model Aircraft

Since the FAA began drafting the rules for unmanned aircraft systems, it has been necessary to point out the distinction between a UAS and a model aircraft. Thanks to the amazing advances in battery, brushless motor, and flight controller technology over the past decade, the line between a drone and a model aircraft has been fuzzed, and onboard video systems and FPV flying have only blurred the distinction.

The distinction between a UAS and model aircraft is an important one. Thanks to the FAA Reauthorization Act of 2012, the FAA, “may not promulgate any rule or regulation regarding a model aircraft” under certain conditions. These conditions include aircraft flown strictly for hobby or recreational use, operated in accordance with a community-based set of safety guidelines (read: the safety guidelines set by the Academy of Model Aeronautics), weighs less than 55 pounds, gives way to manned aircraft, and notifies the operator of an airport when flown within five miles of a control tower.

Despite laws enacted by congress, the FAA saw it necessary to create rules and regulations for model aircraft weighing less than 55 pounds, and operated in accordance with a community-based set of safety guidelines. The FAA’s drone registration system doesn’t make sense, and there is at least one pending court case objecting to these rules.

The FAA’s final rules for UAS, drones, and model airplanes change nothing from the regulations made over the past year. If your drone weighs more than 250 grams, you must register it. For model aircraft, and unmanned aircraft systems conducting ‘hobbyist operations’, nothing has changed.

Unmanned Aerial Systems

The finalized rule introduced today concerns only unmanned aircraft systems weighing less than 55 pounds conducting non-hobbyist operations. The person flying the drone must be at least 16 years old and hold a remote pilot certificate with a small UAS rating. This remote pilot certificate may be obtained by passing an aeronautical knowledge test, or by holding a non-student Part 61 pilot certificate (the kind you would get if you’d like to fly a Cessna on the weekends)

What this means

Under the new regulations, nothing for model aircraft has changed. The guys flying foam board planes will still have to deal with a registration system of questionable legality.

For professional drone pilots – those taking aerial pictures, farmers, or pilots contracting their services out to real estate agents – the situation has vastly improved. A pilot’s license is no longer needed for these operations, and these aircraft may be operated in class G airspace without restriction. Drone use for commercial purposes is now possible without a pilot’s license. This is huge for many industries.

These rules do not cover autonomous flight. This is, by far, the greatest shortcoming of the new regulations. The most interesting applications of drones and unmanned aircraft is autonomous flight. With autonomous drones, farmers could monitor their fields. Amazon could deliver beer to your backyard. There are no regulations regarding autonomous flight from the FAA, and any business plans that hinge on pilot-less aircraft will be unrealized in the near term.

DJI Phantoms are now ‘drones’

This is a quick aside, but I must point out the FAA press release was written by someone with one of two possible attributes. Either the author of this press release paid zero attention to detail, or the FAA has a desire to call all unmanned aircraft systems ‘drones’.

The use of the word ‘drone’ in the model aircraft community has been contentious, with quadcopter enthusiasts making a plain distinction between a DJI Phantom and a Predator drone. Drones, some say, have the negative connotation of firing hellfire missiles into wedding parties and killing American citizens in foreign lands without due process, violating the 5th amendment. Others have classified ‘drones’ as having autonomous capability.

This linguistic puzzle has now been solved by the FAA. In several places in this press release, the FAA equates ‘unmanned aircraft systems’ with drones, and even invents the phrase, ‘unmanned aircraft drone’. Language is not defined by commenters on fringe tech blogs, it is defined by common parlance. Now the definition of ‘drone’ is settled: it is an unmanned, non-autonomous, remote-controlled flying machine not flown for hobby or recreational use.

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