Tesla Model 3 Battery Pack Teardown

June 4, 2018 by Tom Nardi 53 Comments

The Tesla Model 3 has been available for almost a year now, and hackers and tinkerers all over the world are eager to dig into Elon’s latest ride to see what makes it tick. But while it’s considerably cheaper than the Model S that came before it, the $35,000+ USD price tag on the new Tesla is still a bit too high to buy one just to take it apart. So for budget conscious grease monkeys, the only thing to do is wait until somebody with more money than you crashes one and then buy the wreckage cheaply.

Which is exactly what electric vehicle connoisseur [Jack Rickard] did. He bought the first wrecked Model 3 he could get his hands on, and proceeded to do a lengthy teardown on what’s arguably the heart and soul of the machine: its 75 kWh battery pack. Along the way he made some interesting discoveries, and gained some insight on to how Tesla has been able to drop the cost of the Model 3 so low compared to their previous vehicles.

On a Tesla, the battery pack is a large flat panel which takes up effectively the entire underside of the vehicle. To remove it, [Jack] and his assistant raise the wreck of the Model 3 up on a standard lift and then drop the battery down with a small lift table. Here the first differences are observed: while the Model S battery was made for rapid swapping (a feature apparently rarely utilized in practice), the battery in the Model 3 battery is obviously intended to be a permanent piece of the car; removing it required taking out a good portion of the interior.

With the battery out of the car and opened up, the biggest change for the Model 3 becomes apparent. The battery pack actually contains the charger, DC-DC converter, and battery management system in one integrated unit. Whereas on the Model S these components were installed in the vehicle itself, on the Model 3, most of the primary electronics are stored in this single module.

That greatly reduces the wiring and complexity of the car, and [Jack] mentions the only significant hardware left inside the Model 3 (beyond the motors) would be the user interface computer in the dashboard. When the communication protocol for this electronics module is reverse engineered, it may end up being exceptionally useful for not only electric vehicle conversions but things like off-grid energy storage.

A little over a year ago we featured a similar teardown for the battery back in the Tesla Model S, as well as the incredible project that built a working car from multiple wrecks.

[Thanks to DarksideDave for the tip.]

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Counting Bees With A Raspberry Pi

May 30, 2018 by Tom Nardi 34 Comments

Even if keeping bees sounds about as wise to you as keeping velociraptors (we all know how that movie went), we have to acknowledge that they are a worthwhile thing to have around. We don’t personally want them around us of course, but we respect those who are willing to keep a hive on their property for the good of the environment. But as it turns out, there are more challenges to keeping bees than not getting stung: you’ve got to keep track of the things too.

Keeping an accurate record of how many bees are coming and going, and when, is a rather tricky problem. Apparently bees don’t like electromagnetic fields, and will flee if they detect them. So putting electronic measuring devices inside of the hive can be an issue. [Mat Kelcey] decided to try counting his bees with computer vision, and so far the results are very promising.

After some training, a Raspberry Pi with a camera can count how many bees are in a given image to within a few percent of the actual number. Getting an accurate count of his bees allows [Mat] to generate fascinating visualizations about his hive’s activity and health. With real-world threats such as colony collapse disorder, this type of hard data can be crucial.

This is a perfect example of a hack which might not pertain to many of us as-is, but still contains a wealth of information which could be applicable to other projects. [Mat] goes into a fantastic amount of detail about the different approaches he tried, what worked, what didn’t, and where he goes from here. So far the only problem he’s having is with the Raspberry Pi: it’s only able to run at one frame per second due to the computational requirements of identifying the bees. But he’s got some ideas to improve the situation.

As it so happens, we’ve covered a few other methods of counting bees in the past, though this is the first one to be entirely vision based. Interestingly, this method is similar to the project to track squirrels in the garden. Albeit without the automatic gun turret part.

Smart Plugs Don’t Save You Energy, But Don’t Consume Much Either

May 29, 2018 by Bob Baddeley 60 Comments

Amazon Alexa, Google Home, and just about every electronic device manufacturer are jumping on the bandwagon of connected devices. They promise us the ability to turn on our toaster from another room, unlock our doors just by shouting at them from outside, and change the channel on our TV through perfectly enunciating a sentence instead of mashing the buttons on our remotes like chumps. And yet, despite all this new-fangled finger-less control, there is an unanswered question: does this technology save us energy in the long run?

For years we’ve been hearing about vampire power and all the devices in our home that sit in standby, waiting for their masters to turn them on, quietly burning power to listen for that signal to wake. Fortunately the One Watt Initiative and general awareness and design for energy savings has cut out a lot of this phantom load. So how does the smart home, which essentially adds a bunch of connected vampires to our base load, end up saving money in the long run? And is it better than other alternatives or just good habits? I put these questions to the test with today’s smart power strips and controllable outlets.

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Open Source Underwater Distributed Sensor Network

May 23, 2018 by Steven Dufresne 32 Comments

One way to design an underwater monitoring device is to take inspiration from nature and emulate an underwater creature. [Michael Barton-Sweeney] is making devices in the shape of, and functioning somewhat like, clams for his open source underwater distributed sensor network.

The clams contain the electronics, sensors, and means of descending and ascending within their shells. A bunch of them are dropped overboard on the surface. Their shells open, allowing the gas within to escape and they sink. As they descend they sample the water. When they reach the bottom, gas fills a bladder and they ascend back to the surface with their data where they’re collected in a net.

Thus far he’s made a few clams using acrylic for the shells which he’s blown himself. He soldered the electronics together free-form and gave them a conformal coating of epoxy. He’s also used a thermistor as a stand-in for other sensors and is already working on a saturometer, used for measuring the total dissolved gas (TDG) in the water. Knowing the TDG is useful for understanding and mitigating supersaturation of water which can lead to fish kills.

He’s also given a lot of thought into the materials used since some clams may not make it back up and would have to degrade or be benign where they rest. For example, he’s been using a lithium battery for now but would like to use copper on one shell and zinc on another to make a salt water battery, if he can make it produce enough power. He’s also considering using 3D printing since PLA is biodegradable. However, straight PLA could be subject to fouling by underwater organisms and would require cleaning, which would be time-consuming. PLA becomes soft when heated in a dishwasher and so he’s been looking into a PLA and calcium carbonate filament instead.

Check out his hackaday.io page where he talks about all these and more issues and feel free to make any suggestions.

MoAgriS: A Modular Agriculture System

May 14, 2018 by James Hobson 19 Comments

Hackaday.io user [Prof. Fartsparkle] aims to impress us again with MoAgriS, a stripped-down rig for bringing crops indoors and providing them with all they need.

This project is an evolution of their submission to last year’s Hackaday Prize, MoRaLiS — a modular lighting system on rails — integrating modules for light, water, airflow, fertilizer and their appropriate sensors. With an emphasis on low-cost, a trio of metal bars serve as the structure, power and data transmission medium with SAM D11 chips shepherding each plant.

Reinforced, angled PCBs extend rails horizontally allowing the modules to be mounted at separate heights. Light module? Up top. Water sensor? Low on the rails above the pot’s rim. You get the idea. 3D printed clamps attach the rails to the plant’s pot with a touch of paint to keep it from sticking out like a sore thumb among the leaves.

Airflow modules replicate wind currents — the lack of which results in thin, fragile stems — and light modules include a soft white LED to accompany and mitigate the full-spectrum LEDs’ pink neon-like glow. To manage watering the plants, [Prof. Fartsparkle] initially wanted to use one pump to distribute water to every plant, but found some smaller pumps at a low enough price-point to make one per plant viable — and simpler to integrate as a module as well!

If you prefer your gardening to take place outdoors, consider a robot assistant to tackle your weeding.

Battery-Powered Watering Timer Converted To Solar On The Cheap

May 12, 2018 by Dan Maloney 13 Comments

Watering the garden or the lawn is one of those springtime chores that is way more appealing early in the season than later. As the growing season grinds along, a chore that seemed life-giving and satisfying becomes, well, just another chore, and plants often suffer for it.

Automating the watering task can be as simple as buying a little electronic timer valve that turns on the flow at the appointed times. [A1ronzo] converted his water hose timer to solar power. Most such timers are very similar, with a solenoid-operated pilot valve in line with the water supply and an electronic timer of some sort. The whole thing is quite capable of running on a pair of AA batteries, but rather than wasting money on new batteries several times a season, he slipped a LiPo pack and a charge controller into the battery case slot and connected a small solar panel to the top of the controller.

The LiPo is a nominal 3.7-volt pack, so he did a little testing to make sure the timer would be OK with the higher voltage. The solar panel sits on top of the case, and the whole thing should last for years. And bonus points for never having to replace a timer that you put away at the end of the season with batteries still in it, only to have them leak. Ask us how we know.

Like the best of hacks, this one is quick, easy and cheap — $15 in parts, aside from the timer. There are more complicated irrigation solutions, of course, one of which even won the Hackaday Prize once upon a time. But this one has us ordering parts to build our own right now.

The Metabolizer Turns Trash Into Treasure

May 9, 2018 by Kristina Panos 35 Comments

The amount of stuff we humans throw away is too damn high, and a bunch of it harms the ecosystem. But what are you gonna do? [Sam Smith] thinks we can do better than shoving most of it in a landfill and waiting for it to break down. That’s why he’s building The Metabolizer. It’s a series of systems designed to turn household trash (including plastic!) into useful things like fuel, building materials, and 3D prints.

The idea is to mimic the metabolism of a living organism and design something that can break down garbage into both useful stuff and fuel for itself. [Sam] is confident that since humans figured out how to make plastic, we can figure out a system to metabolize it. His proof-of-concept plan is to break down waste into combustible, gaseous fuel and use that fuel to power a small engine. The engine will power an open-source plastic shredder and turn a generator that powers an open-source plastic pellet printer like the SeeMeCNC Part Daddy.

Shredding plastic for use as a biomass requires condensing out the tar and hydrocarbons. This process leaves carbon monoxide and hydrogen syngas, which is perfect for running a Briggs & Stratton from Craigslist that’s been modified to run on gaseous fuel. Condensation is a nasty process that we don’t advise trying unless you know what you’re doing. Be careful, [Sam], because we’re excited to watch this one progress. You can watch it chew up some plastic after the break.

If [Sam] ever runs out of garbage to feed The Metabolizer, maybe he could build a fleet of trash-collecting robots.

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