Retrotechtacular: Automotive Suspension Is All About Waves

In addition to driving home the need for Steadicam or Optical Image Stabilization, this eighty-year-old video illustrates some elegant solutions the automotive industry developed in their suspension systems. Specifically, this Chevrolet video from 1938 is aimed at an audience that values science and therefore the reel boils down the problem at hand using models that will remind you of physics class.

Model of a wheel with a leaf spring records the effect of a bump on a piece of paper above

The problem is uneven ground — the “waves in the Earth’s surface” — be it the terrain in an open field, a dirt road, or even a paved parkway. Any vehicle traveling those surfaces will face the challenge of not only cushioning for rough terrain, but accounting for the way a suspension system itself reacts to avoid oscillation and other negative effects. In the video this is boiled down to a 2-dimensional waveform drawn by a model which begins with a single tire and evolves to include a four wheeled vehicle with different suspension systems in the front and the rear.

Perhaps the most illuminating part of the video is the explanation of how the car’s front suspension actually works. The wheels need to be able to steer the vehicle, while the suspension must also allow the tire to remain perpendicular to the roadway. This is shown in the image at the top of this article. Each wheel has a swing arm that allows for steering and for vertical movement of the wheel. A coil spring is used in place of the leaf springs shown in the initial model.

You probably know what’s coming next. The springs are capable of storing and releasing energy, and left to their own devices, they’ll dissipate the energy of a bump by oscillating. This is exactly what we don’t want. The solution is to add shock absorbers which limit how the springs perform. The waveforms drawn by the model encountering bumps are now tightly constrained to the baseline of flat ground.

This is the type of advertising we can wholeheartedly get behind. Product engineers of the world, please try to convince your marketing colleagues to show us the insides, tell us why the choices were made, and share the testing that helps users understand both how the thing works and why it was built that way. The last eighty years have brought myriad layers of complexity to most of the products that surround us, but human nature hasn’t changed; people are still quite curious to see the scientific principles in action all around us.

Make sure you don’t bomb out of the video before the very end. A true bit of showmanship, the desktop model of a car is recreated in a full-sized Chevy, complete with “sky-writing smoke” to draw the line. I don’t think it’s a true analog, but it’s certainly the kind of kitsch I always look for in a great Retrotechtacular subject.

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How To Get Into Cars: Handling Mods

As a budding automotive enthusiast, you finally took the plunge and scored yourself a sweet project car. After going through it from top to toe, you’ve done your basic maintenance and it’s now running like a top. Now you’re getting comfortable, you’ve set your sights on turning your humble ride into a corner carving machine. Here’s a guide to get yourself started.

It’s All About Grip

When it comes to creating a handling monster, the aim is to create a car that sticks to the road like glue, and is controllable when it does break loose. Having a car that handles predictably at the limit is a big help when you’re pushing hard on track, particularly for an inexperienced driver. And, whether you’re hitting the canyons on the weekend or trying to slash your laptimes, it’s always nice to have more grip. Through selecting the right parts and getting the set up right, it’s possible to hone your car’s cornering ability to make it a rewarding experience to drive fast and hard. Continue reading “How To Get Into Cars: Handling Mods”

Dexter Robot Arm Embraces New Manufacturing With First Micro-Factory

Haddington Dynamics, the company behind the Dexter robot arm that won the 2018 Hackaday Prize, has opened its first microfactory to build robot arms for Australia and Southeast Asia.

You may remember that the combination of Dexter’s makeup and capabilities are what let it stand out among robotics projects. The fully-articulated robot arm can be motion trained; it records how you move the arm and can play back with high precision rather than needing to be taught with code. The high-precision is thanks to a clever encoder makeup that leverages the power of FPGAs to amplify the granularity of its optical encodes. And it embraces advanced manufacturing to combine 3D printed and glue-up parts with mass produced gears, belts,  bearings, and motors.

It’s a versatile robot arm, for a fraction of the cost of what came before it, with immense potential for customization. And did I mention that it’s open source? Continue reading “Dexter Robot Arm Embraces New Manufacturing With First Micro-Factory”

PCB Finishes Hack Chat

Join us on Wednesday, March 11 at noon Pacific for the PCB Finishes Hack Chat with Mark Hughes and Elijah Gracia!

There’s no way to overestimate the degree to which the invention of the printed circuit board revolutionized electronics. What was once the work of craftspeople weaving circuits together with discrete components, terminal strips, and wiring harnesses could now be accomplished with dedicated machines, making circuit construction an almost human-free process. And it was all made possible by figuring out how to make copper foil stick to a flat board, and how to remove some of it while leaving the rest behind.

​Once those traces are formed, however, there’s more work to be done. Bare copper is famously reactive stuff, and oxides soon form that will make the traces difficult to solder later. There are hundreds of different ways to prevent this, and PCB surface finishing has become almost an art form itself. Depending on the requirements for the circuit, traces can be coated with tin, lead, gold, nickel, or any combination of the above, using processes ranging from electroplating to immersion in chemical baths. And the traces aren’t the only finishes; solder resist and silkscreening are both important to the usability and durability of the finished board.

For this Hack Chat, we’ll be talking to Elijah Gracia and Mark Hughes from Royal Circuit Solutions. They’re both intimately familiar with the full range of PCB coatings and treatments, and they’ll help us make sense of the alphabet soup​: HASL, OSP, ENIG, IAg, LPI, and the rest. We’ll learn what the different finishes do, which to choose under what circumstances, and perhaps even learn a bit about how to make our homebrew boards look a little more professional and perform a bit better.

join-hack-chatOur Hack Chats are live community events in the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Wednesday, March 11 at 12:00 PM Pacific time. If time zones have got you down, we have a handy time zone converter.

Click that speech bubble to the right, and you’ll be taken directly to the Hack Chat group on Hackaday.io. You don’t have to wait until Wednesday; join whenever you want and you can see what the community is talking about.

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Hackaday Links: March 8, 2020

A lot of annoying little hacks are needed to keep our integer-based calendar in sync with a floating-point universe, and the big one, leap day, passed us by this week. Aside from the ignominy of adding a day to what’s already the worst month of the year, leap day has a tendency to call out programmers who take shortcuts with their code. Matt Johnson-Pint has compiled a list of 2020 leap day bugs that cropped up, ranging from cell phones showing the wrong date on February 29 to an automated streetlight system in Denmark going wonky for the day. The highest-profile issue may have been system crashes of Robinhood, the online stock trading platform. Robinhood disagrees that the issues were caused by leap day code issues, saying that it was a simple case of too many users and not enough servers. That seems likely given last week’s coronavirus-fueled trading frenzy, but let’s see what happens in 2024.

Speaking of annoying time hacks, by the time US readers see this, we will have switched to Daylight Saving Time. Aside from costing everyone a precious hour of sleep, the semiannual clock switch always seems to set off debates about the need for Daylight Saving Time. Psychologists think it’s bad for us, and it has elicited a few bugs over the years. What will this year’s switch hold? Given the way 2020 has been going so far, you’d better buckle up.
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From Hacker Hotel 2020: Badges, Sharks, Tentacles, Old-School Hacking, And Much More

The North Sea in a winter storm is a spectacular sight, one of foam-crested waves and squalls driven on the gale. It’s not a place to spend a lot of time if you are a land-lubber, so to cross it twice in a few weeks must mean there is something very much worth seeing on its other side.

More of that exotic cruise ship lifestyle.
More of that exotic cruise ship lifestyle.

But one of the best antidotes to February weather in the European hacker community was Hacker Hotel 2020. Around 350 people came from all the countries of the northwest of the continent to the comfort and hospitality of the Westcord Hotel de Veluwe in the eastern Netherlands, to experience a hacker camp with all the convenience and luxury of a resort hotel rather than a muddy field.

Three days in this environment results in a camp that’s just a bit special, and one that’s very much worth a visit if your range extends this far.

An Upscale Hotel Gets The Hacker Treatment

The Hacker Hotel badge 2020 has many hidden depths
The Hacker Hotel badge 2020 has many hidden depths

Our small party of Brits arrived a day early, on a damp Thursday morning ready to lend a hand with the set-up. Slowly an upscale business conference centre was transformed into a hacker camp venue, with conference rooms turned into lecture halls, lighting and video equipment in place and 3-phase power cables snaking along the skirting boards. A large hardware hacking area was set up in one wing of the building, then the EventInfra people came in and laid out a hacker-camp-grade wireless and wired network that delivered connectivity everywhere. The contrast between the two worlds is significant, but together they make for a unique experience.

One by one, hackers arrived from all points of the compass, bearing crates of the usual cool stuff. An amateur TV satellite earth station, a brace of oversized delta 3D printers, a coin-pushing game that’s familiar from other camps. And smaller projects; little roving robots, indoor-sized multirotors, and several crates of outdated Chinese photo-frames that it’s said can be hacked to run a Linux distro.

This is the lifeblood of a hacker camp, but of course the signature piece of hardware for any hacker camp is its badge. In this Hacker Hotel 2020 didn’t disappoint, with a beautifully designed Ancient Egyptian-themed badge that concealed an array of puzzles across multiple levels. We’ll cover the badge in detail in a separate piece, but suffice to say that it is something of a tour de force. For now let’s jump into all of people and activities on offer at the con.

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Hackaday Podcast 057: Dismantled LCD Panels, Unexpected Dynamometer, A Flappy POV, And Dastardly Encryption

Hackaday editors Mike Szczys and Elliot Williams are onto an LCD and motors kick this week. Two different LCD screen teardowns caught our eye as one lets you stare into the void while using your iMac and the other tries to convince us to be not afraid of de-laminating the LCD stackup. On the motors front, it’s all about using magnets and coils in slightly different ways; there’s a bike generator that uses a planar alternator design, a dynamometer for testing motor power that itself is built from a motor, and a flex-PCB persistence of vision display that’s a motor/display hybrid. We round out the episode with talk of the newly revealed espionage saga that was Crypto AG, and riveting discussion of calculators, both real and virtual.

Take a look at the links below if you want to follow along, and as always tell us what you think about this episode in the comments!

Take a look at the links below if you want to follow along, and as always, tell us what you think about this episode in the comments!

Direct download (60 MB or so.)

Continue reading “Hackaday Podcast 057: Dismantled LCD Panels, Unexpected Dynamometer, A Flappy POV, And Dastardly Encryption”