Fail Of The Week: Flaming Brushless Motor Controller

October 24, 2013 by Mike Szczys 41 Comments

Yep, smoke and flames are usually a sign that your electronics aren’t functioning as expected. This is actually the second failure encountered while learning about brushless motor controllers.

[Michael Kohn] purchase the motor while working on a different project and it went unused for quite some time. When he came across it again he decided he should learn the not-so-dark art of BLDC control.

The first hurdle was to figure out how to drive the three-wire motor when he had been expecting only two. The answer required him to come up with switching mechanism that allows three states for each wire: positive, negative, and not connected. His solution was to use MOSFETs. It’s a good idea, but unfortunately during the first iteration they were under-spec’d and he scared the crap out of himself when one of them blew up during testing (clip #1 below). After sourcing a more robust set of MOSFETs [Micheal] went back to testing which is when this little fire broke out. The 22 gauge wires connecting the Lithium battery to the driver just couldn’t cut it. See for yourself in the second clip.

It’s been awhile since we’ve said it: Please remember the Fail of the Week is not about ridiculing the hacker who was gracious enough to document his or her failure. It’s about learning from the mistake and discussing alternatives that can help others in the future. For instance, in this case some advice in determining MOSFET specs and wire gauge for any type of motor would be quite helpful. Have at it in the comments.

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3D Printering: A Call For An Open Source Automated Build Platform

October 23, 2013 by Brian Benchoff 79 Comments

I’ve said this before, and I’ll say it again: if you’re using a 3D printer to make a few hundred identical plastic parts, you’re doing it wrong. That’s the place for traditional manufacturing methods such as injection molding or resin casting. If, however, you’re looking at printing a few dozen identical plastic parts, or even running a script to optimize your machine time, the current open source 3D printer world leaves one thing to be desired.

An Automated Build Platform

An Automated Build Platform is a fairly simple idea: put a conveyor belt on your heated bed, and when the print is done, send a command to drive a motor, dumping the newly printed part into a bin, The printer then begins the next part with a clean bed, and the days of doting over a 3D printer soon fade into the past.

For such a simple and useful idea, it’s surprising there hasn’t been much done with this idea in open source circles. There are, of course, problems both technical and legal, but hopefully nothing that should indefinitely derail anyone who would want to create the first open source automated build platform.

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Retrotechtacular: Steam Locomotive Construction In The 1930’s

October 22, 2013 by Mike Szczys 52 Comments

Here’s a fascinating look at high-tech manufacturing in the 1930’s. This week’s Retrotechtacular features the building of a steam-powered locomotive. The quality of the black and white footage, and the audio accompanying it are almost as impressive as the subject material — which is nothing short of a machinist’s wet-dream but also includes much forging and smithing. Digging through the video for a suitable still image was a tough task, as every step in the process was interesting to us. But this image showing some of the 2700 feet of tubing used in the locomotive seems most appropriate.

The build covers all aspects of the build. Huge sheets of steel make up two side plates between which the cast engine block is mounted. The mold for casting was huge, required twelve hours dry time before the pour, and took a day or two to cool before breaking the mold. That yielded a rough block which then headed off for machining.

We were delighted by the crane used to transport steel sheets from the oven to a stamping machine. The counterweight is workers (and lots of them) on the other side of the fulcrum. After a glimpse of the ancillary part fabrication you begin to get a look at the complexity of the machine as it is assembled.

Does anyone feel a deep appreciation for the pedagogy that went into making something like this? What we mean is that the teams building No. 6207 don’t seem to be using skills learned in a book or from a class, but rather those passed down from the masters that have been on the job most of their lives. Watching them all work is nothing short of astounding!

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Adventures In Hackerspacing: Freeside Atlanta, Part II

October 21, 2013 by Marsh 7 Comments

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This week on Adventures in Hackerspacing, Freeside Atlanta Part II: Hacking the Hackerspace!

After learning about the culture behind the space, I was eager to ask hackerspace veterans [Alan] and [Steven] about nuts and bolts, about behind-the-scenes crucial decisions, and one question in particular: What’s the most important requirement for a hackerspace? [Alan] jumped in with this response:

Number one by and far is a willing landlord. I think if you have a willing landlord everything else is incidental. You make it hard on yourself if you are on the second story, but take the second story if you have a willing landlord.

That wasn’t the answer I was expecting, but when you look around Freeside, it starts to make sense…

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Hackaday Links: October 20, 2013

October 20, 2013 by Mike Szczys 15 Comments

Winter is coming. We’ve see those gloves in stores made specifically to work with your smartphone. [hardsoftlucid] isn’t buying it. He made his own version using… well, you just have to see it.

Here’s an eBookmark for a real book. What? Well, you know how an eReader does a great job of keeping your place between reading sessions? This is an electronic bookmark for paper books which uses LEDs to show you where you last left off reading. [via Adafruit]

[Thomas Brittain] wrote in to share his BLE Module and Pulse sensor updates. Both were featured in a recent Fail of the Week column and the latest iteration takes them from fail to functioning!

You may be able to get a free XMOS xCORE starter kit. The company is giving away 2500 of them. [Thanks Tony]

After learning about custom labels for microcontroller pinouts from [John Meachum] we’re happy to get one more helpful tip: a breadboard trench is a great place to hide axial decoupling capacitors.

A bit of cutting, solder, and configuring lets you turn a simple gamepad into a 4-controller interface for MAME.

Many of the Hackaday Staff are into Minecraft (between Let’s Play videos, running servers, and building computers in-game it’s a wonder we get anything done around here). We restrained ourselves by not making this video of a Restone circuit Blender animation on your desktop into a full front page feature. [via Reddit]

Fail Of The Week: [Caleb’s] Phosphorescent CD Player

October 17, 2013 by Mike Szczys 35 Comments

When [Caleb Kraft] was in full production for Hackaday he pumped a pile of awesome videos. But not every project worked out. He’s been a fan of the Fail of the Week posts, and sent in his own recollection of a project gone wrong. Above you can see his phosphorescent CD player. He prototyped the project in May of last year but technical issues and looming deadlines meant it never saw the light of day. We’ll fill you in on his fail after the jump.

Editor’s note: We need more tips about your own failure! There are a handful of submissions left in our reserves, but to keep this topic as a weekly column we need help tracking down more failed projects. Please document your past failures and send us a link to the write-up. If you don’t have a blog to post it on you may do what [Caleb] has done and email us directly. Remember to include any images and links to video which you may have.

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3D Printering: Pastestruders

October 16, 2013 by Brian Benchoff 41 Comments

While bits of plastic are the usual material for 3D printers, there are hundreds of other materials that are equally well suited for 3D printing. One of the most famous is chocolate, a material so popular and easy to manipulate inside an extruder there are even Kickstarters for 3D printed chocolate bars.

There are many more materials deserving of being 3D printed, though: wax for lost wax castings, other foodstuffs for improbably shaped edibles, and ceramics so I can finally print a life-sized, functional version of the Utah Teapot.

Unfortunately, for all the progress of plastic extrusion, little has been done about extruding pastes, foods, and clay with a 3D printer. The RepRap paste extrusion working group is fairly close to being dead, so let this volume of 3D Printering explore what has been done in the world of paste printing.

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