Hacklet 44 – Teardowns

April 25, 2015 by Adam Fabio 14 Comments

Just about every hacker, maker and tinkerer out there received their early education the same way: A screwdriver in one and a discarded bit of electronics in the other. There is no better way to find out how something works than cracking it open and examining each piece. In recent years, teardown videos have become popular on YouTube, with some of the great examples coming from users like [EEVblog], [mikeselectricstuff], and [The Geek Group]. This week’s Hacklet is all about the best teardown projects on Hackaday.io!

We start with [zakqwy] and his Savin C2020 Teardown. Photocopiers (and multifunction machines) are the workhorses of the modern office. This means there are plenty of used, abused, and outdated photocopiers available to hackers. [Zakqwy] got this monster when it started misbehaving at his office. Copiers are a venerable cornucopia of motors, gears, sensors (lots and lots of breakbeam sensors) and optics. The downside is toner: it’s messy, really bad to breathe, and if you don’t wear gloves it gets down into the pores of your skin, which takes forever to get out. [Zakqwy] persevered and found some awesome parts in his copier – like an Archimedes’ screw used to transport black toner.

Next up is [Bob Blake] with Belkin WeMo Insight Teardown. [Bob] wanted a WiFi outlet, but wasn’t about to plug something in to both his power grid and his network without taking it apart first. [Bob] did an awesome job of documenting his teardown with lots of great high resolution photos – we love this stuff! He found a rather well thought out hardware design. The Insight has 3 interconnected PCBs inside. The power switching and supply circuits are all on one board. It includes slots and the proper creep distances one would expect in a design that will be carrying 120V AC mains power. A small daughter board holds an unknown chip – [Bob] is guessing it is the power sensing circuitry. A third board a tucked in at the top of the module holds the main CPU, a Ralink/MediaTek RT5350F SoC, RAM, and the all important WiFi antenna.

[Drhatch] took things into the danger zone with an X-ray Head Teardown. We’re not sure if [Drhatch] is a real doctor, but he does have a Heliodent MD dental X-ray head. Modern X-ray machines are generally radiation safe if they’re not powered up. Radiation isn’t the only dangers to worry about though – there are latent charged capacitors and cooling oils which may contain nasty chemicals like PCBs, among other things. [Drhatch] found some pretty interesting design decisions in his X-ray head. The tube actually fires through the cylindrical high voltage transformer. This means the transformer acts as a beam collimator, focusing the X-ray beam down like a lens. He also found plenty of lead shielding. Interestingly there are two thickness of lead in the housing. Shielding close to the tube is 1 mm thick, while shielding a bit further away is only 0.7 mm thick.

Finally, we have [danielmiester] with Inside a 3ph AC Motor Controller(VFD). [Daniel] tore down a Hitachi Variable-Frequency Drive (VFD) with the hopes of creating a frequency converter for a project. These high voltage, high power devices have quite a bit going on inside, so the conversion became a teardown project all its own. VFDs such as this one are used in industry to drive high power AC motors at varying speeds efficiently. As [Daniel] says, the cheaper ones are ” just really fancy PWM modules”. Handling 1.5 kW is no joke though. This VFD had a large brick of power transistors potted into its heat sink. The controller board was directly soldered to the transistors, as well as the rectifier diodes for the DC power supply. [Daniel] was doing some testing with the unit powered up, so he built a custom capacitor discharge unit from 3 C7 Christmas lights. Not only did they keep the capacitors discharged, they provided an indication that the unit was safe. No light means no charge.

Not satisfied? Want more teardown goodness? Check out our freshly minted Teardown List!

That’s about all the time we have for this week’s Hacklet. As always, see you next week. Same hack time, same hack channel, bringing you the best of Hackaday.io!

$50k In Play: Thirty Projects Will Win Custom PCBs This Week

April 24, 2015 by Mike Szczys 30 Comments

This week we’re giving away $1500 in OSH Park codes to thirty different projects. Submit your project to the 2015 Hackaday Prize now!

$50,000 over the next 17 weeks!

For each of the last four weeks we’ve awarded prize packages to three projects just for submitting ideas. Now it’s time to crank up the rewards. Over the next 17 weeks we will give away $50,000 in prizes. We’re kicking off the week by giving $50 OSH Park codes to 30 different projects.

Of course this is just the tip of the iceberg. This year’s prizes total half a million dollars, with a trip into space for the Grand Prize winner and $100,000 for the Best Product prize. Sitting this one out would be a huge mistake!

You need to post your project on Hackaday.io and officially submit it to the 2015 Hackaday Prize, which means clicking the “Submit-To” button on the left sidebar of your entry (shown below). You can confirm that you’re in the running by looking for the 2015 Hackaday Prize logo on your project gallery picture. Here you can see [castvee8] has submitted the Binary fuel tank, do you think it’s ready for a custom PCB?

To give yourself the best chance at winning, publish a new project log this week that outlines the PCB work your want to do for the entry. We’ll be looking for those as we judge the prizes that are most ready to begin (or advance) their hardware build.

OSH Park offers double-layer boards for $5 per square-inch and you get 3 copies of the board with shipping included. This $50 prize will land you quite a bit of board space. Get started now, you need to have your projects submitted by the morning of Wednesday, April 29th.

The 2015 Hackaday Prize is sponsored by:

Crowdfunding Follies: $100 To Disprove Isaac Newton

April 23, 2015 by Brian Benchoff 170 Comments

Are satellites fake? Nobody knows, because no one has done an experiment to determine if rocket engines will produce thrust in a vacuum. At least that’s what this Kickstarter says, and it’s asking for $100 to test multiple types of rocket engines in an enclosed, evacuated chamber.

Anyone who has thought about this problem for half a second will tell you yes, rocket engines will work in a vacuum. It’s an application of Newton’s Third Law of Motion; if you explode fuel and dump it out the back of a rocket, the rocket will go forward. Rocket engines don’t push against air.

Strap in, because this one gets better. In a video linked to from the Kickstarter Campaign, satellites do not exist. This is because gas molecules in the thermosphere can reach 2,500 °C, hot enough to melt the metal satellites are made of. Never mind that the 2,500 °C figure is only for individual gas molecules; the atmosphere at these altitudes is so rarefied, there isn’t much contact with matter. Oh, second point: have you ever realized that a Google image search of the word ‘satellite’ mostly shows illustrations and renders? It’s not because to take a picture of a satellite in orbit would require two satellites flying in formation; no, it must be because satellites don’t exist. It gets better from there.

Retrotechtacular: Stateside Assembly And Launch Of V-2 Rockets

April 21, 2015 by Kristina Panos 28 Comments

At the end of World War II, the United States engaged in Operation Paperclip to round up German V-2 rockets and their engineers. The destination for these rockets? White Sands Proving Grounds in the New Mexico desert, where they would be launched 100 miles above the Earth for the purpose of high altitude research.

This 1947 War Department Film Bulletin takes a look inside the activities at White Sands. Here, V-2 rockets are assembled from 98% German-made parts constructed before V-E day. The hull of each rocket is lined with glass wool insulation by men without masks. The alcohol and liquid oxygen tanks are connected together, and skins are fitted around them to keep fuel from leaking out. Once the hull is in place around the fuel tanks, the ends are packed with more glass wool. Now the rocket is ready for its propulsion unit.

In the course of operation, alcohol and liquid oxygen are pumped through a series of eighteen jets to the combustion chamber. The centrifugal fuel pump is powered by steam, which is generated separately by the reaction between hydrogen peroxide and sodium permanganate.

A series of antennas are affixed to the rocket’s fins. Instead of explosives, the warhead is packed with instruments to report on high altitude conditions. Prior to launch, the rocket’s tare weight is roughly five tons. It will be filled with nine tons of fuel once it is erected and unclamped.

At the launch site, a gantry crane is used to add the alcohol, the liquid oxygen, and the steam turbine fuels after the controls are wired up. The launch crew assembles in a blockhouse with a 27-foot-thick roof of reinforced concrete and runs through the protocol. Once the rocket has returned to Earth, they track down the pieces using radar, scouting planes, and jeeps to recover the instruments.

Thanks for the tip, [Thomas].

Retrotechtacular is a weekly column featuring hacks, technology, and kitsch from ages of yore. Help keep it fresh by sending in your ideas for future installments.

Your Arduino Packaging Could Sway A Court Case

April 19, 2015 by Mike Szczys 115 Comments

Our friends over at Adafruit just made an interesting suggestion regarding the Arduino vs. Arduino saga. They noticed that the packaging for the Arduino UNO includes a pamphlet that states:

Manufactured under license
from Arduino by
SMART PROJECTS S.r.l.

Wow. That’s pretty interesting. Smart Projects is the former name of Arduino SRL. If you missed it, go back and read some of our previous coverage. Specifically, Arduino SRL is claiming to be the real trademark holder and has gone as far as forking the Arduino IDE and upping the version number in what appears to be an attempt to direct users toward their newly founded Arduino.org website/ecosystem/quagmire. If they feel they own the trademark why would they include this statement in their packaging?

Finding this in the a unit from a September 2014 is interesting. But Adafruit’s post is a call to action. We share their curiosity of discovering how far back official Arduino hardware has included such license notices. So, head on down to your work bench… start peeling back years worth of discarded hacks, clipped leads, fried servos, and other detritus. Find the packaging and take a picture. Bonus points if you have an invoice that associates a date with it. Either way, post the pictures on your social media hub of choice with #TeamArduinoCC. You can also embed it in the comments using HTML IMG tags if you wish.

Standard “I am not a lawyer” disclaimer applies here. We know you aren’t either so let’s all share what we think this means to pending lawsuits in the comments. Does this matter and why?

Hackaday Links: April 19, 2015

April 19, 2015 by Mike Szczys 48 Comments

Bang & Olufsen have made some pretty amazing equipment for a long, long time. That last part can become a problem. [Oliver] found the electrolytic caps on his Beomaster 2400 were causing problems. He completely recapped the unit, all the electrolytics anyway, and the pictures of the process are nothing short of eye-candy.

The closure of the Bacman forums marks the end of an era. For years this has been among the top (okay, it’s definitely been the top one but we don’t want to start a flamewar) sites for handheld and console modding. Here’s just one random example of the many projects we covered from that community (note that main link is now sadly 404). The closure message cites the near-absolute death of modding. We haven’t thought about it much, but these mods were futuristic. Then smartphones.

Fans of How It’s Made and 3D printing will want to tune in on April 30th at 9pm EST. The show does a fantastic job of showing off the amazing story behind how all the stuff in our lives comes to be visited LulzBot in Loveland, Colorado for a segment on the manufacturing process of a 3D printer.

We’re not sure why we didn’t lead with this: All celebrate, for humanity is saved! The secret behind getting something out of nothing has been discovered. This reactionless generator has been tested at efficiencies as high as 250%. We’re working on a way to bottle all that extra juice and sell it at outrageous prices.

The thing about free energy is that you become dependent on it. What if the laws of physics return from vacation and the thing stops working? Then you have a robot apocalypse with all kinds of hidden messages and puzzles in it.

Hacklet 43 – Flashlight Projects

April 17, 2015 by Adam Fabio 10 Comments

Mankind has always looked for ways to light up the night as they walk around. Fires are great for this, but they aren’t very safe or portable. Even kept safe in a lantern, an open flame is still dangerous – especially around cows. Enter the flashlight, or torch if you’re from the other side of the pond. Since its invention in 1899, the flashlight has become a vital tool in modern society. From patrolling the dark corners of the city, to reading a book under the covers, flashlights enable us to beat back the night. The last decade or so has seen the everyday flashlight change from incandescent bulbs to LEDs as a light source. Hackers and makers were some of the first people to try out LED flashlights, and they’re still tinkering and improving them today. This weeks Hacklet focuses on some of the best flashlight projects on Hackaday.io!

We start with [Norman], and the LED Flashlight V2. Norman built a flashlight around a 100 Watt LED. These LEDs used to be quite expensive, but thanks to mass production, they’ve gotten down to around $6 USD or so. Norman mounted his LED a custom aluminum case. At this power level, even LEDs get hot. An extruded aluminum heatsink and fan keeps things cool. Power is from a 6 cell LiPo battery, which powers the LED through a boost converter. It goes without saying that this flashing is incredibly bright. Even if the low-cost LEDs aren’t quite 100 Watts, they still put many automotive headlights to shame! Nice work, [Norman].

A tip of the fedora to [Terrence Kayne] and his Grain-Of-Light LED LIGHT. [Terrence] loves LED flashlights, be he wanted one that had a bit of old school elegance. Anyone familiar with LEDs knows CREE is one of the biggest names in the industry. [Terrence] used a CREE XM-L2 emitter for his flashlight. He coupled the LED to a reflector package from Carlco Optics. The power source is an 18650 Lithium cell, which powers a multi-mode LED driver. [Terrence] spent much of his time turning down the wooden shell and aluminum tube frame of the flashlight. His workmanship shows! Our only suggestion would be to go with a lower profile switch. The toggle [Terrence] used would have us constantly checking our pockets to make sure the flashlight hadn’t accidentally been activated.

Harbor Freight’s flashlights are a lot like their multimeters: They generally work, but you wouldn’t want to trust your life to them. That wasn’t a problem for [Steel_9] since he needed a strobe/party light. [Steel_9] hacked a $5 “27 LED” light into a stylish strobe light. He started by cutting the power traces running to the LED array. He then added in an adjustable oscillator circuit: two BJTs and a handful of discrete components make up an astable multivibrator. A third transistor switches the LEDs. Switching a load like this with a 2N3906 probably isn’t the most efficient way to do things, but it works, and the magic smoke is still safely inside the semiconductors. [Steel_9] built the circuit dead bug style, and was able to fit everything inside the original plastic case. Rave on, [Steel_9]!

If you want to see more flashlight projects, check out our new list on Hackaday.io! That’s about all the time we have for this week’s Hacklet. As always, see you next week. Same hack time, same hack channel, bringing you the best of Hackaday.io!