Fail Of The Week: Color Meter For Adjusting LEDs

January 16, 2014 by Mike Szczys 29 Comments

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[John Peterson] answered our call to document your hacks by discussing what he learned while building this color meter. He conceived the project as a way to precisely match the color output of LEDs driven with a PWM signal. The thought was that it could sample an LED’s output, then use that data to calculate values necessary to match the color of other LEDs. This is a good idea when using LEDs of different types, but even diodes from the same production line can show variations in color output.

Of course this project wouldn’t be featured as a Fail of the Week if it worked as he had expected. It turns out the sensor that he used, an Avago ADJD-S371-QR999 on a SparkFun breakout board, takes very quick color readings. This is great for solid objects, but not great for a light source being switched on and off like the PWM LEDs.

We like it that [John] posted a list of lesson learned on the project. The real fail is in trying to use this particular sensor, but we figure there must be some way to get meaningful data through sampling. Check out the page for the retired sensor which also includes a link to the datasheet. Can you think of a firmware hack which would allow this hardware to sample so that the PWM value could be extrapolated through averaging or other calculations? Let us know in the comments.

Fail of the Week is a Hackaday column which runs every Wednesday. Help keep the fun rolling by writing about your past failures and sending us a link to the story — or sending in links to fail write ups you find in your Internet travels.

Fail Of The Week: Frying FETs With 500mA

January 9, 2014 by Mike Szczys 31 Comments

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When [Simon] fried his 3A rated FET with just 500mA of current he wrote it off to an inability of the SOT23 package to dissipate the heat without a heatsink. For the next iteration of the project he upgraded to a 12A rated part. Luckily he decided to test the circuit one more time before sending his board off for fab. He threw together this constant current load test which led him to discover his failure.

The switching circuit, which was for his home security system project that we’ve seen at least twice, worked just fine up to 500mA. But when he drove it above that threshold the package quickly warmed up. It got so hot that it actually reflowed its solder joints! The problem has to do with oscillation, but even with further testing he couldn’t get the FET to reliably shut off all the way. Take a look at his fail write-up linked at the top and then let us know some possible remedies for the situation.

Fail Of The Week: AFSK Build Doomed By Rail Noise

January 2, 2014 by Mike Szczys 19 Comments

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[Scott] and his buddies were having some fun with their handheld transmitters one day when they decided it was time to build some add-on hardware that could transmit and receive location data. They set their sights on a set of Audio Frequency Shift Keying units that could each encoded and decipher location from the counterpart.

The build got off to an easy start, centering around an Arduino board with a GPS module for capturing precise location data. Next it was time to implement AFSK. On the transmitting side this was done by bit banging the output pins. After a look at the resulting signals on an oscilloscope the team was able to tune the firmware for a pretty tight 1200 and 2200 Hz output. But trouble was brewing on the decoding side of the equation.

The first decoding attempt used the FreqMeasure library written by [Paul Stoffregen]. After no success they moved to a hardware solution in the form of the XR-2211 FSK Demodulator chip. It should have been simple, feed it the signals and read the digital output pins to capture the desired data. This is the point at which you need to click the project link at the top to soak in all of the gory details. Long story short, a noisy power rail was causing sporadic performance of this chip. By the time this issue was discovered interest had waned and the project was ditched as a failure. Was there a quick fix that could have salvaged it such as adding a filtering circuit for that chip? Let us know how you would get this back on track by leaving a comment below.

[Thanks Lewin]

Fail Of The Week: Physical Pixel Display

December 12, 2013 by Mike Szczys 51 Comments

This physical pixel display reminds us of a couple of different hacks that we’ve seen over the years. It looks impressive, but [Matt] couldn’t quite get it to work. It wasn’t the Kinect sensor and image interpretation that was the problem. It was a failure to get the hardware components seen above to perform reliably.

If you can’t figure out what this is supposed to do, take at look at the inFORM morphing table or the pixel wall installed at the Hyundai expo last year. [Matt’s] attempt is much more modest with a grid of just 10×6. The pixels themselves are ballpoint pens (he gets bonus points for cheap and easy materials). The pens move in and out thanks to some Bowden cables connected to hobby servos. The mechanical engineers have probably already figured out the fail… the pixels seem to get hung up and despite several revisions in the materials used , it couldn’t be fixed.

The hobby servos were chosen because they are much less expensive than proper linear actuators. We thought maybe [Matt] should build his own solenoids but that’s not a great idea because you can’t have variable depth that way (can you?). Perhaps the pens should be vertical and the servos could pull on a string attached to the pen via a pulley with gravity to return them to the starting position? There’s got to be an inexpensive and relatively simple way get this thing working. Let us know how you’d get the project back on track by leaving a comment below.

Fail Of The Week: Hackaday Writer’s First CNC Adventure

December 5, 2013 by Mike Szczys 41 Comments

This Fail of the Week post focuses on a project from [Limkpin] aka [Mathieu Stephan], one of the Hackaday contributors. He wanted a CNC mill of his very own and decided to go with a kit that you assemble yourself. If it had been clear sailing we wouldn’t be talking about it here. Unfortunately he was met with a multitude of fails during his adventure. We’ll cover the highlights below.

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Fail Of The Week: How A Cheap USB AC Adapter Might Indirectly Burn Your House Down

November 28, 2013 by Mathieu Stephan 41 Comments

This Fail of the Week will remind our readers that every project they make, no matter how small they might be, may have big consequences if something goes wrong. Shown in the picture above is an oven that [Kevin] tweaked to perform reflow soldering. The story is he had just moved into a new place a few weeks ago and needed to make a new batch of boards. As he had cycled this oven many times, he was confident enough to leave the room to answer a few emails. A few minutes later, he had the unfortunate experience of smelling something burning as well as discovering white smoke invading his place.

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Fail Of The Week: Commute-Shortening Electric Scooter

November 21, 2013 by Mike Szczys 38 Comments

Please don’t judge [Alan] on his choice of vests. This project is from 1999 when it was common to see people rockin’ these threads. Anyone who has ever spent time on the University of Minnesota campus in Minneapolis, Minnesota will know that parking is at a premium. [Alan] had a 12-15 minute walk from his parking garage to his office and was considering a cheaper parking location that would balloon that to 20-25 minutes. But engineers don’t see problems, they see project ideas. He started work on a tiny electric scooter that could slim down his commute. Obviously he did find some success, but it was interspersed with failures that make his scooter the Fail of the Week.

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