What On Earth Is A Pickle Fork And Why Is It Adding To Boeing’s 737 Woes?

September 30, 2019 by Jenny List 89 Comments

It’s fair to say that 2019 has not been a good year for the aircraft manufacturer Boeing, as its new 737 MAX aircraft has been revealed to contain a software fault that could cause the aircraft to enter a dive and crash. Now stories are circulating of another issue with the 737, some of the so-called “Pickle forks” in the earlier 737NG aircraft have been found to develop cracks.

It’s a concerning story and there are myriad theories surrounding its origin but it should also have a reassuring angle: the painstaking system of maintenance checks that underpins the aviation industry has worked as intended. This problem has been identified before any catastrophic failures have occurred. It’s not the story Boeing needs at the moment, but they and the regulators will no doubt be working hard to produce a new design and ensure that it is fitted to aircraft.

The Role of the Pickle Fork

For those of us who do not work in aviation though it presents a question: what on earth is a pickle fork? The coverage of the story tells us it’s something to do with attaching the wing to the fuselage, but without a handy 737 to open up and take a look at we’re none the wiser.

Fortunately there’s a comprehensive description of one along with a review of wing attachment technologies from Boeing themselves, and it can be found in one of their patents. US9399508B2 is concerned with an active suspension system for wing-fuselage mounts and is a fascinating read in itself, but the part we are concerned with is a description of existing wing fixtures on page 12 of the patent PDF.

A cross-section of the aircraft wing fixing, in which we've highlighted the role of the pickle forks. (Boeing) — A cross-section of the aircraft wing fixing, in which we’ve highlighted the role of the pickle forks. (Boeing)

The pickle fork is an assembly so named because of its resemblance to the kitchen utensil, which attaches firmly to each side of the fuselage and has two prongs that extend below it where they are attached to the wing spar.

For the curious engineer with no aviation experience the question is further answered by the patent’s figure 2, which provides a handy cross-section. The other wing attachment they discuss involves the use of pins, leading to the point of the patented invention. Conventional wing fixings transmit the forces from the wing to the fuselage as a rigid unit, requiring the fuselage to be substantial enough to handle those forces and presenting a problem for designers of larger aircraft. The active suspension system is designed to mitigate this, and we’d be fascinated to hear from any readers in the comments who might be able to tell us more.

We think it’s empowering that a science-minded general public can look more deeply at a component singled out in a news report by digging into the explanation in the Boeing patent. We don’t envy the Boeing engineers in their task as they work to produce a replacement, and we hope to hear of their solution as it appears.

[via Hacker News]

[Header image: AMX Boeing 737 XA-PAM by Jean-Philippe Boulet CC-BY 3.0]

The Future Of Diesel Is On Shaky Ground

September 26, 2019 by Zoe Skyforest 251 Comments

Diesel is a fuel that has had a mixed history, with varying levels of take-up by consumers around the world. In the world of transport, diesel engines have offered better fuel economy and torque than comparable gasoline engines. Particularly popular in Europe, diesel established a strong consumer base in both small commuter cars as well as heavy vehicles such as trucks and buses.

Despite this, the tide is turning, and for the average motorist, diesel’s days may be numbered. Why is this the case, and what are the potential alternatives vying for diesel’s crown?

Plenty of Pros, but Plenty of Cons

Diesel remains a fuel with a varied uptake around the world. It has enjoyed great popularity in Europe in small commuter cars.

Diesel is a hydrocarbon fuel with several advantages over gasoline. Its lack of volatility makes it workable to use in a compression-ignition mode, and diesel engines can be run with lean fuel-air ratios. It also has a higher volumetric energy density than gasoline, and thanks to low volatility, diesel engines can run at significantly higher compression ratios without risking detonation. These benefits allow diesel engines to produce significantly more torque than similarly sized gasoline engines, and they can offer fuel economy gains in excess of 15%.

Unfortunately, diesel also comes with its fair share of drawbacks. Diesel engines are typically poor when it comes to power to weight ratio, as their high compression ratio and torque output demands heavier materials in their construction. The major bugbear of the diesel engine, however, is its emissions. Despite greater fuel efficiency, carbon dioxide output from a diesel engine is often far worse than that of a comparable gas motor. Additionally, their lean-burning nature leads to production of high levels of oxides of nitrogen (NOx), which have major negative environmental effects. There’s also the problem of particulate pollution, which is responsible for respiratory harm in humans. Diesel automobiles rank significantly worse than gasoline vehicles in all these areas. It’s begun to cause figurative headaches for the industry, and literal headaches for the public. Continue reading “The Future Of Diesel Is On Shaky Ground” →

100 Year Old Atomic Clock

September 25, 2019 by Gregory L. Charvat 33 Comments

Precision time is ubiquitous today thanks to GPS and WWVB. Even your Macbook or smartphone displays time which is synchronized to the NIST-F1 clock, a cesium fountain atomic clock (aka the ‘Atomic Clock’) that is part of a global consortium of atomic clocks known as Coordinated Universal Time (UTC). Without precise timing there would be train collisions, markets would tumble, schools would not start on time, and planes would fall out of the sky.

But how was precision timing achieved in the 19th century during the era of steam, brass, and solenoids? One of the first systems of precision timing kept trains running safely and on time, rang the bells at school, and kept markets trading by using a special clock designed by the Self Winding Clock Company. Through measurements of celestial objects by the US Naval Observatory, and time synchronization pulses broadcast by the Western Union telegraph network, this system synchronized time across the United States in an era where the speed of our train system was out-pacing by the precision of our clocks.

Those clocks were designed so well that many of them are still around and functioning. One of these 100-year-old self-winding clocks made its way onto my workbench. I did what any curious hacker would do, figured out how the synchronization worked and connected it to a clock source with atomic precision. Let’s take a look!

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A Virtual Tour Of The B-17

September 24, 2019 by Tom Nardi 98 Comments

The Boeing B-17 “Flying Fortress” is arguably the most recognizable aircraft of the Second World War. Made infamous by the daring daylight strategic bombing runs they carried out over Germany, more than 12,000 of these four-engined bombers were produced between 1939 and 1945. Thanks to the plane’s renowned survivability in battle, approximately 60% of them made it through the war and returned home to the United States, only to be rounded up in so-called “boneyards” where they were ultimately cut up and sold as scrap. Today there are fewer than 50 intact Boeing B-17s left in the world, and of those, only 11 remain airworthy.

One of them is Nine-O-Nine, a B-17G built in April 7, 1945. This particular aircraft was built too late to see any combat, although in the 1950s she was fitted with various instruments and exposed to three separate nuclear blasts for research purposes. It’s actually not the real Nine-O-Nine either, the original was scrapped after it completed eighteen bombing runs over Berlin. Without a combat record of its own, this bomber was painted to look like the real Nine-O-Nine in honor of its incredible service record of never losing a crewman.

Since 1986, Nine-O-Nine has been owned by the Collings Foundation, who operate her as a living history exhibit. The bomber flies around the United States with an entourage of similarly iconic WWII aircraft as part of the Wings of Freedom Tour, stopping by various airports and giving the public a chance to climb aboard and see the pinnacle of mid-1940s strategic bombing technology. History buffs with suitably deep pockets can even book a seat on one of the scheduled 30-minute flights that take place at every stop on the Tour.

I was lucky enough to have the The Wings of Freedom Tour pass through my area recently, and couldn’t pass up the opportunity to experience this incredible aircraft first hand. The fact that I’m equal parts a coward and miser kept me from taking a ride aboard the 74 year old Nine-O-Nine, at least for now, but I made sure to take plenty of pictures from inside this lovingly restored B-17G while it was safely on the ground.

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FIDO2: The Dream Of Password-Free Authentication On The WWW

September 23, 2019 by Maya Posch 29 Comments

Of all the things which are annoying about the modern World Wide Web, the need to create and remember countless passwords is on the top of most people’s lists. From dozens of passwords for everything from social media sites to shopping, company, and productivity-related platforms like Github, a large part of our day is spent dealing with passwords.

While one can totally use a password manager to streamline the process, this does not absolve you from having to maintain this list and ensure you never lose access to it, while simultaneously making sure credentials for the password manager are never compromised. The promise of password-less methods of authentication is that of a world where one’s identity is proven without hassle, and cannot ever be stolen, because it relies on biometrics and hardware tokens instead of an easily copied password.

The FIDO2 project promises Web Authentication that means never entering a password into a website again. But like everything, it comes with some strings attached. In this article, we’ll take a look at how FIDO2 plans to work and how that contrasts with the state of security in general.

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Solar System Wars: Walmart Versus Tesla

September 19, 2019 by Dan Maloney 61 Comments

It seems like hardly a day goes by that doesn’t see some news story splashed across our feeds that has something to do with Elon Musk and one or another of his myriad companies. The news is often spectacular and the coverage deservedly laudatory, as when Space X nails another double landing of its boosters after a successful trip to space. But all too often, it’s Elon’s baby Tesla that makes headlines, and usually of the kind that gives media relations people ulcers.

The PR team on the automotive side of Tesla can take a bit of a breather now, though. This time it’s Elon’s solar power venture, Tesla Energy Operations, that’s taking the heat. Literally — they’ve been sued by Walmart for rooftop solar installations that have burst into flames atop several of the retail giant’s stores. While thankfully no lives have been lost and no major injuries were reported, Walmart is understandably miffed at the turn of events, leading to the litigation.

Walmart isn’t alone in their exposure to potential Tesla solar problems, so it’s worth a look to see what exactly happened with these installations, why they failed, and what we as hackers can learn from the situation. As we’ll see, it all boils down to taking electrical work very seriously and adhering to standards designed to keep everyone safe, even when they just seem like a nuisance.

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Tool Rolls, The Fabric Design Challenge That Can Tidy Up Any Workshop

September 18, 2019 by Kristina Panos 31 Comments

You’ve designed PCBs. You’ve cut, drilled, Dremeled, and blow-torched various objects into project enclosurehood. You’ve dreamed up some object in three dimensions and marveled as the machine stacked up strings of hot plastic, making that object come to life one line of g-code at a time. But have you ever felt the near-limitless freedom of designing in fabric?

I don’t have to tell you how satisfying it is to make something with your hands, especially something that will get a lot of use. When it comes to that sweet cross between satisfaction and utility, fabric is as rewarding as any other medium. You might think that designing in fabric is difficult, but let’s just say that it is not intuitive. Fabric is just like anything else — mysterious until you start learning about it. The ability to design and implement in fabric won’t solve all your problems, but it sure is a useful tool for the box.

WoF? Fat quarter? How much is a yard of fabric, anyway?

To prove it, I’m going to take you through the process of designing something in fabric. More specifically, a tool roll. These two words may conjure images of worn, oily leather or canvas, rolled out under the open hood of a car. But the tool roll is a broad, useful concept that easily and efficiently bundles up anything from socket wrenches to BBQ utensils and from soldering irons to knitting needles. Tool rolls are the best in flexible, space-saving storage — especially when custom-designed for your need.

In this case, the tools will be pens, notebooks, and index cards. You know, writer stuff. But the same can just as easily organize your oscilloscope probes. It’s usefully and a great first foray into building things with fabric if this is your first time.

Continue reading “Tool Rolls, The Fabric Design Challenge That Can Tidy Up Any Workshop” →