Design And Hacking Drilldown: SuperCon Badge

October 17, 2016 by Voja Antonic 18 Comments

One can imagine a political or business conference without an interactive badge — but not a hacker conference. Does this make the case for hackers being a special breed of people, always having something creative to show for their work? Yes, I think it does.

Following the Hackaday Belgrade conference in April of this year, we met at the Supplyframe offices to discuss the badge for the Hackaday SuperConference that will happen in Pasadena on 5+6th of November. The Belgrade conference badge (which was fully documented if you’re curious) was surprisingly popular, and I was asked to design the new one as well.

I was prepared to come up with something completely new, but [Mike Szczys] suggested keeping with the same basic concept for the project: “No reason to change anything, we have a badge that works”. To which I responded: “Well, the next one will also work”. But then I realized that “works” does not stand for “being functional”. The key is that it was embraced by visitors who played with it, coded on it, and solved a crypto challenge with it.

The World Doesn’t Have Enough LEDs

Fast forward six months — here are the modifications made to the basic concept. First, the existing LED matrix, which was composed of two compact 8×8 blocks, was replaced by 128 discrete SMD LEDs. It was a much needed change to help scale down the dimensions and clunkiness, but also to avoid another painful experience of trying to purchase and have the matrix displays shipped, which seriously threatened the production of the previous badge.

It’s a long story which I discussed in my Belgrade talk — it turned out we did not manage to get enough common anode (CA) displays from all distributors in the whole world. We had a plan B, which also fizzled, leaving us with the plan C which actually included two “C”s: Common Cathode. We cleaned up all the supplies at five distributors, and managed to get 122 CA red, 340 CC red and 78 CA green displays (enough for only 270 badges) — the entire world supply. After that, you couldn’t get any 38 mm Kingbright’s display for months! The only problem was that there were two different versions of PCBs, one for CA and the other for CC displays, but luckily only one version of software, as it could autodetect the display type.

Motion and Expansion

So, what else was new in the concept? In the Belgrade version, the badge supported an accelerometer module and included an unpopulated footprint in case you decided to install it, but now the badge has the MEMS chip LIS3 as an integral part. There are nine pads (with five I/O ports, driven directly from the MCU) to which you can add a 9-pin expansion connector. There will be a number of these connectors at the Design Lab, so that anyone can expand their badge for their convenience, on the spot.

The Visual Design

The biggest change was in the visual design. What we came up with ended up being a fair bit smaller, lighter, with a more convenient shape, and less than half the thickness of the previous one. After we had scrapped quite a few ideas during the development process (including stylized skull, frog, etc), we were left with a couple of options which you can see on the image below. The wireframe drawing on the left hand side is the Belgrade badge, shown here for a size comparison. At this point the locale and date of the conference weren’t yet definitive, which is why you see San Francisco written on the images.

Design number 4 prevailed, so the PCB layout could begin. I don’t like autorouted PCBs, so I was in for quite a rough time trying to solve the routing manually having only 2 layers on the board at my disposal.

Routing a Compact LED Matrix

The LED matrix is so dense that there was virtually no room on the LED layer, so most of the tracks on the component layer had to be routed as if it was a single layer PCB. To make matters worse, the LED layer is routed as a matrix, with a bunch of horizontal and vertical tracks, otherwise a good reason to use a 4-layer PCB. To stay inside the budget, everything had to be placed on 2 layers, and that’s why the final result seems so confusing at the populated area between batteries:

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Look What Showed Up For Bring-A-Hack At OSH Park

October 15, 2016 by Mike Szczys 10 Comments

Hackaday was in Portland last weekend for the Open Hardware Summit. I did a brief recap earlier this week but this post has been on my mind the entire time. The night before the summit, OSH Park (the Purveyors of Perfect Purple PCBs which we all know and love) hosted a Bring-A-Hack at their headquarters. [Laen] knows how to throw a party — with a catered spread and open bar which all enjoyed. The place was packed with awesome hackers, and everyone had something amazing to show off.

In fact, there were far too many people showing off hardware for me to capture all in one evening. But join me after the jump for six or seven examples that really stuck out.

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Li-Ion Tech Staring Into The Abyss With Note 7 Failure

October 14, 2016 by Will Sweatman 155 Comments

Unless you’ve been living under a high voltage transformer, you’ve heard about the potential for Samsung’s latest phone, the Note7, to turn into a little pocket grenade without warning. With over 2.5 million devices in existence, it’s creating quite a headache for the company and its consumers.

They quickly tied the problem to faulty Li-ion batteries and started replacing them, while issuing a firmware update to stop charging at 60 percent capacity. But after 5 of the replacement phones caught fire, Samsung killed the Note7 completely. There is now a Total Recall on all Note7 phones and they are no longer for sale. If you have one, you are to turn it off immediately. And don’t even think about strapping it into a VR headset — Oculus no longer supports it. If needed, Samsung will even send you a fireproof box and safety gloves to return it.

note_01 — Every airline has been broadcasting warnings not to power on or charge a Note 7 on a plane. Image Source: CNET

It should be noted that the problem only affects 0.01% of the phones out there, so they’re not exactly going to set the world on fire. However, it has generated yet another discussion about the safety of Li-ion battery technology.

It was just a few months ago we all heard about those hoverboards that would catch fire. Those questionably-engineered (and poorly-named) toys used Li-ion batteries as well, and they were the source of the fire problem. In the wake of this you would think all companies manufacturing products with Li-ion batteries in them would be extra careful. And Samsung is no upstart in the electronics industry — this should be a solved problem for them.

Why has this happened? What is the deal with Li-ion batteries? Join me after the break to answer these questions.

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Too Good To Throw Away: Dealing With An Out-Of-Control Junk Hoard

October 13, 2016 by Jenny List 193 Comments

There it was, after twenty minutes of turning the place over, looking through assorted storage boxes. A Thinwire Ethernet network. About the smallest possible Thinwire Ethernet network as it happens, a crimped BNC lead about 100mm long and capped at each end by a T-piece and a 50 ohm terminator. I’d been looking for a BNC T-piece on which to hook up another terminator to a piece of test equipment, and I’d found two of them.

As I hooked up the test I wanted to run I found myself considering the absurdity of the situation. I last worked somewhere with a Thinwire network in the mid 1990s, and fortunately I am likely to never see another one in my life. If you’ve never encountered Thinwire, be thankful. A single piece of co-ax connecting all computers on the network, on which the tiniest fault causes all to fail.

So why had I held on to all the parts to make one, albeit the smallest possible variant? Some kind of memento, to remind me of the Good Old Days of running round an office with a cable tester perhaps? Or was I just returning to my past as a hoarder, like a Tolkienic dragon perched atop a mountain of electronic junk, and not the good kind of junk?

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Measuring capacitance with wax dielectric

How To Measure The Dielectric Constant For DIY Capacitors

October 12, 2016 by Steven Dufresne 7 Comments

Every now and then you need to make your own capacitor. That includes choosing a dielectric for it, the insulating material that goes between the plates. One dielectric material that I use a lot is paraffin wax which can be found in art stores and is normally used for making candles. Another is resin, the easiest to find being automotive resin used for automotive body repairs.

The problem is that you sometimes need to do the calculations for the capacitor dimensions ahead of time, rather than just throwing something together. And that means you need to know the dielectric constant of the dielectric material. That’s something that the manufacturer of the paraffin wax that makes it for art stores won’t know, nor will the manufacturers of automotive body repair resin. The intended customers just don’t care.

It’s therefore left up to you to measure the dielectric constant yourself, and here I’ll talk about the method I use for doing that.

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What We Are Doing Wrong. The Robot That’s Not In Our Pocket

October 11, 2016 by Gerrit Coetzee 109 Comments

I’m not saying that the magic pocket oracle we all carry around isn’t great, but I think there is a philosophical disconnect between what it is and what it could be for us. Right now our technology is still trying to improve every tool except the one we use the most, our brain.

At first this seems like a preposterous claim. Doesn’t Google Maps let me navigate in completely foreign locations with ease? Doesn’t Evernote let me off-load complicated knowledge into a magic box somewhere and recall it with photo precision whenever I need to? Well, yes, they do, but they do it wrong. What about ordering food apps? Siri? What about all of these. Don’t they dramatically extend my ability? They do, but they do it inefficiently, and they will always do it inefficiently unless there is a philosophical change in how we design our tools.

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The People, Talks, And Swag Of Open Hardware Summit

October 10, 2016 by Mike Szczys 6 Comments

Friday was the 2016 Open Hardware Summit, a yearly gathering of people who believe in the power of open design. The use of the term “summit” rather than “conference” is telling. This gathering brings together a critical mass of people running hardware companies that adhere to the ideal of “open”, but this isn’t at the exclusion of anyone — all are welcome to attend. Hackaday has built the world’s largest repository of Open Hardware projects. We didn’t just want to be there — We sponsored, sent a team of people, and thoroughly enjoyed ourselves in the process.

Join me after the break for a look at the talks, a walk through the swag bags, and a feel for what this wonderful day held.

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