hardware

1647 Articles

Solving Ultra High Vacuum Leaks Has An Elementary Solution

August 16, 2021 by 34 Comments

When we think of a vacuum leak we generally think of a car that just doesn’t want to run quite right. Most normally aspirated internal combustion engines rely on the vacuum created by the pistons to draw in the air fuel mixture that’s produced by the carburetor or fuel injection system. Identifying the leak usually involves spraying something combustible around common trouble areas while the engine is running. Changes to the engine speed indicate when the combustible gas enters the intake manifold and the leak can be found.

What if your vacuum leak is in a highly specialized piece of scientific equipment where the pressures are about 12 times orders of magnitude lower than atmospheric pressure, and the leak is so small it’s only letting a few atoms into the vacuum chamber at a time? [AlphaPhoenix] takes dives deep into this very subject in his video “Air-tight vs. Vacuum-tight.” which you can watch below the break.

Not only does [AlphaPhoenix] discuss how a perfect pressure vessel is sealed, he also explains the specialized troubleshooting methods used which turn out not to be all that different from troubleshooting an automotive vacuum leak- only in this case, several magnitudes more complex and elemental in nature.

We also enjoyed the comments section, where [AlphaPhoenix] addresses some of the most common questions surrounding the video: Torque patterns, the scarcity of the gasses used, and leaving well enough alone.

Does talking about vacuums get you pumped? Perhaps you’d enjoy such vacuum hacks as putting the toothpaste back in the tube in your homemade vacuum chamber.

Thank you [Morgan] for sending this one in. Be sure to send in your own hacks, projects, and fantastic finds through the Tip Line!

Continue reading “Solving Ultra High Vacuum Leaks Has An Elementary Solution” →

The Zeloof Z2 Intergrated Circuit Has 100 Transistors

August 14, 2021 by 30 Comments

Back in 2018 we reported on the first silicon integrated circuit to be produced in a homemade chip fab. It was the work of [Sam Zeloof], and his Z1 chip was a modest six-transistor amplifier. Not one to rest on his laurels, he’s back with another chip, this time the Z2 is a hundred-transistor array. The Z2 occupies about a quarter of the area of the previous chip and uses a 10µm polysilicon gate process as opposed to the Z1’s metal gates. It won’t solve the global chip shortage, but this is a major step forward for anyone interested in building their own semiconductors.

The transistors themselves are FETs, and [Sam] is pleased with their consistency and characteristics. He’s not measured his yield on all samples, but of the twelve chips made he says he has one fully functional chip and a few others with at least 80% functionality. The surprise is that his process is less complex than one might expect, which he attributes to careful selection of a wafer pre-treated with the appropriate oxide layer.

You can see more about the Z2 in the video below the break. Meanwhile, should you wish to learn more about the Z1 you can see [Sam’s] Hackaday Superconference talk on the subject. We’re looking forward to the Z3 when it eventually arrives, with bated breath!

Continue reading “The Zeloof Z2 Intergrated Circuit Has 100 Transistors” →

Hacked IKEA Air Quality Sensor Gets Custom PCB

August 13, 2021 by 19 Comments

Last month we brought word of the IKEA VINDRIKTNING, a $12 USD air quality sensor that could easily be upgraded to log data over the network with the addition of an ESP8266. It only took a couple of wires soldered to the original PCB, and since there was so much free space inside the enclosure, you didn’t even have to worry about fitting the parasitic microcontroller; just tape it to the inside of the case and button it back up.

Now we’ve got nothing against the quick and dirty method around these parts, but if you’re looking for a slightly more tidy VINDRIKTNING modification, then check out this custom PCB designed by [lond]. This ESP-12F board features a AP2202 voltage regulator, Molex PicoBlade connectors, and a clever design that lets it slip right into a free area inside the sensor’s case. The project description says the finished product looks like it was installed from the factory, and we’re inclined to agree.

Nothing has changed on the software side, in fact, the ESP-12F gets flashed with the same firmware [Sören Beye] wrote for the Wemos D1 Mini used in his original modification. That said [lond] designed the circuit so the MCU can be easily reprogrammed with an FTDI cable, so just because you’re leaving the development board behind doesn’t mean you can’t continue to experiment with different firmware builds.

It’s always gratifying to see this kind of community development, whether or not it was intentionally organized. [lond] saw an interesting idea, found a way to improve its execution, and released the result out into the wild for others to benefit from. It wouldn’t be much of a stretch to say that this is exactly the kind of thing Hackaday is here to promote and facilitate, so if you ever find yourself inspired to take on a project by something you saw on these pages, be sure to drop us a line.

Who Needs Pin Headers?

August 12, 2021 by 31 Comments

[Martin] sent this query, along with the lead photo, into the tip line, and he makes a good point. Most development and evaluation boards have multiple rows of pin headers, often arriving loose in the package — soldering is left to the user. In an abundance of caution, we usually design our prototype boards with many pin headers for debugging and testing. But as [Martin] reminds us, there are other alternatives to solder.

  • Yours truly once worked with a prolific designer of PIC microprocessor boards. Long before the advent of solutions like the Tag Connect family, [Ralph] would program his boards by just inserting a pin header into the PCB and applying gentle pressure with his thumb until the code finished flashing.
  • You may have seen the staggered offset PCB patterns that hold your pin header securely while you solder. You could tweak this a little bit to put more pressure on the pins, making a solder-less connection that is sufficient for temporary testing.
  • Taking the opposite approach, you can get solderless connectors with press-fit pins, a method we tested a few years ago on a Raspberry Pi Zero. Anyone who has worked on Eurocard-based systems like VME can appreciate the time-savings and improved reliability of 96-pin DIN-41612 press-fit connectors.
  • Or, as [Martin] proposes, you could use one of these inexpensive pogo-pin clamps. These are available for less than $10 from your favorite Asian electronics distributor. They are about the size of a large clothespin, and are available in several different pin configurations.
Tag-Connect Style of Connector
Uncle Pete’s Footprint Experiments, Sparkfun
Press-FIt 96-Pin DIN
Pogo-Pin Clamp Fixture

These techniques won’t help you if you need to plug your board into another card, such as a hat onto a Raspberry Pi. But when you just want to grab a few signals for a serial port or probing some digital I/O signals, having a few of these clips in your tool box can save you the time and headache of soldering down a header. Do you have any tips for making soldering pin headers easier, or even avoiding them altogether? Let us know in the comments below.

Relay Logic Nixie Tube Clock Checks All The Boxes

August 9, 2021 by 5 Comments

There are a few words in the electrical engineering lexicon that will perk any hardware hacker’s ears. The first of course is “Nixie tubes” with their warm cold war era ambiance and nostalgia inducing aura. A close second is “relay logic”. Between their place in computing and telecom history and the way a symphony of click and clatter can make a geek’s heart go pitter patter, most of us just love a good relay hack. And then there’s the classic hacker project: A unique timepiece to adorn our lair and remind us when we’ve been working on our project just a little too long, if such a thing even exists.

With those things in mind, you can forgive us if we swooned ever so slightly when [Jon Stanley]’s Relay Logic Nixie Tube Clock came to us via the Tip Line. Adorned with its plethora of clicking relays and set aglow by four Nixie tubes, the Relay Logic Nixie Tube Clock checks all our boxes. 

[Jon] started the build with relay modules that mimic CD4000 series CMOS logic chips. When the prototype stage was complete, the circuit was recreated on a new board that mounts all 55 Omron relays on the same PCB. The result? A glorious Nixie tube clock that will strike envy into even the purest hacker’s heart. Make sure to watch the video after the break!

[Jon] has graciously documented the entire build and even makes various relay logic boards available for purchase if you’d like to embark on your own relay logic exploits . His site overflows with unique clock projects as well, so you can be sure we’ll be checking those out. 

If you feel inspired to build your own relay logic project, make sure you source genuine Omron relays, especially if your Relay Computer Masterpiece takes six years to build.

Thanks to [Daniel] for sending this our way. Got a cool project you’d like to share? Be sure to send it in via the Tip Line. 

Continue reading “Relay Logic Nixie Tube Clock Checks All The Boxes” →

Hands On: DEF CON 29 Badge Embraces The New Normal

August 5, 2021 by 13 Comments

To say that 2020 was a transformative year would be something of an understatement. The COVID-19 pandemic completely changed the way we worked, learned, and lived. Despite all those jokes about how much time people spend on their devices rather than interacting face-to-face with other humans, it turns out that when you can’t get more than a few people together in the same room, it throws our entire society into disarray.

Our community had to rethink how we congregated, and major events like HOPE, DEF CON, and even our own Hackaday Supercon, had to be quickly converted into virtual events that tried with varying degrees of success to capture the experience of hundreds or thousands of hackers meeting up in real life. While few would argue that a virtual hacker convention can ever truly replace a physical one, we learned there are undeniable benefits to embracing the advantages offered by cyberspace. If nothing else, the virtual hacker meetups of 2020 saw a far larger and more diverse array of attendees and presenters than ever before.

As we begin seeing the first rays of light at the end of the long, dark, tunnel we’ve been stuck in, it’s clear that some of the changes that COVID-19 forced on our community are here to stay. As eager as we all are to get back to the epic hackfests of old, nobody wants to close the door on all those who would be unable to attend physically now that they’ve gotten to peek behind the curtain.

With this in mind, this year’s DEF CON is being presented in both physical and virtual forms simultaneously. If you made to Las Vegas, great. If not, you can follow along through chat rooms and video streams from the comfort of your own home. Following the theme, the DC29 badge is not only a practical tool for virtual attendees, but an electronic puzzle for those who are able to bring a few of them together physically. Let’s take a closer look at this socially distanced badge and the tech that went into it.

Continue reading “Hands On: DEF CON 29 Badge Embraces The New Normal” →

Stereo Recording Made Easy With A 3D-Printed Mount

August 1, 2021 by 15 Comments

When making a recording it can be surprisingly difficult to capture a good stereo image. A well-known technique is the ORTF microphone arrangement in which two cardoid microphones sit at 110 degrees to each other and 17cm apart, and thus pick up a readily reproducible stereo separation. It’s something that we’ve been known to do in our student days with a pair of Shure SM58s and a stack of Post Office elastic bands, but [marsairforce] has done a much nicer job with a very neat 3D-printed microphone clip.

Designed in OpenSCAD, the first iteration printed on a resin printer proved to be too brittle for the task, so a second version was printed on an FDM machine. This incorporated significant strengthening, as well as a screw mount for a microphone stand. The result is an extremely useful and cheap addition to any recording set-up, and anyone who has wrestled with achieving a good stereo image will appreciate it. You can see some of what went into it in the video below the break.

If this is your field of interest, you might also wish to look at a binaural microphone.

Continue reading “Stereo Recording Made Easy With A 3D-Printed Mount” →