hardware

1808 Articles

Toddler EV Gets Big Boy Battery Upgrade

July 29, 2022 by 13 Comments

No matter the type of vehicle we drive, it has a battery. Those batteries wear out over time. Even high end EV’s have batteries with a finite life. But when your EV uses Lead Acid batteries, that life is measured on a much shorter scale. This is especially true when the EV is driven by a driver that takes up scarcely more space in their EV than a stuffed tiger toy! Thankfully, the little girl in question has a mechanic:

A 3d printed adapter sends go-juice to the DC-DC converter

Her daddy, [Brian Lough], who documented the swift conversion of his daughter’s toy truck from Lead Acid to Li-Ion in the video which you can see below the break.

Facing challenges similar to that of actual road worthy passenger vehicles, [Brian] teamed up with [bitluni] to solve them. The 12 V SLA battery was being replaced with a 20 V Li-Ion pack from a power tool. A 3d printed adapter was enlisted to break out the power pins on the pack. The excessive voltage was handled with a DC-to-DC converter that, after a bit of tweaking, was putting out a solid 12 V.

What we love about the hack is that it’s one anybody can do, and it gives an inkling of what type of engineering goes into even larger projects. And be sure to watch the video to the end for the adorable and giggly results!

Speaking of larger projects, check out the reverse engineering required in this Lead Acid to Li-Ion conversion we covered in 2016.

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The charging station on the table, with twelve powerbanks plugged into it, charging. A small meter on the front panel shows 4.73 volts and 4.38 amps.

A Simple Charging Station For Twelve Powerbanks

July 25, 2022 by 13 Comments

[jasonwinfieldnz] uses twelve small powerbanks day to day – powering LED strips around his trampoline, presumably, to avoid the mess of wires and make the assembly easily portable. However, if you have twelve powerbanks, you’ll find yourself hogging all the household’s microUSB cables every so often, as they eventually discharge. This was not good enough for our hacker, and he decided to build a charging station to refill them all at once.

If you need 5 volts and many amps, an ATX PSU isn’t your worst bet. From there, he only had to add twelve microUSB connectors to – and condensed the entire contraption into a beautiful charging station. For the microUSB part, he hacked some microUSB cable ends off and embedded them into the case. An embedded voltage and current module is of big help – letting you see at a glance when charging has really finished. Using copper tape as bus bars and banana plugs for charging input, this project is easy to build and solves the problem well.

The 3D printing files and cutting templates are right there on the project page, so if any of us hackers has a problem that twelve powerbanks could help with, [Jason]’s project is quite repeatable. If your devices are more diverse, you could use a pegboard to build a stylish charging station for them! If, on the other hand, you have a single device you need to plug multiple cords into, moldable plastic is there to help.

A Simple Web-Based Wiring Harness Tool

July 15, 2022 by 33 Comments

When building electronic assemblies there is quite often the need to construct custom cables to hook things up. It’s all very well if you’re prototyping by hand, or just building one or two of a thing, but if you’re cranking them out using outside help, then you’re going to want to ensure that cable is described very accurately. [Christian Nimako-Boateng Jr.] presents for us the first version of wirely, a wiring harness tool. This is a web-based tool that allows one to describe the cable ends and connectivity between them, producing a handy graphic and exports to excel in a format that should be easy to follow.

Based around the wireviz Python library running on a flask-based backend, image data are sent to the web assembly front-end and rendered with OpenGL. Configuration files can be imported and exported as JSON, making it easily linkable to other tools if required. Helpfully, the tool also seems to support some kind of revision control, although we didn’t try that yet. The process is straightforward enough, one simply defines a few groups (these relate to individual PCBs or other floating items in the assembly) which each contain one or more connectors. First, the connectors are described with part numbers, and wire gauge data, before defining the list of connections (wires) showing which signal and physical pins are connected together. Nothing more complex than that yet. We think there is still some more functionality that the tool could manage, such as shielding and guarding details, twisted pair definitions and a few others, but for a first pass, wirely looks pretty handy.

If you want a more heavyweight option using IEC 60617 symbols for describing wiring harnesses, then look no farther than QElectroTech, and yes, we have covered wireviz before, just for those that want to cut out the middleman and describe their cables in Python directly.

GCore: Make Portable Devices With Less Frustration

July 9, 2022 by 9 Comments

[Dan Julio]’s gCore (short for Gadget Core) is aimed at making GUI-based portable and rechargeable gadgets much easier to develop. gCore is the result of [Dan]’s own need for a less tiresome way to develop such hardware.

A touchscreen is great, but high-quality power control and charging features are what really make a portable device sing.

[Dan] found that he seemed to always be hacking a lot of extra circuitry into development boards just to get decent power management and charge control. To solve this, he designed his own common hardware platform for portable gadgets and the gCore was born.

While the color touchscreen is an eye-catching and useful addition, the real star of his design is the power management and charging features. Unlike most development hardware, the gCore intelligently shares load power with charging power. Power on and power off are also all under software control.

Sound intriguing? That’s not all the gCore has to offer, and you can learn more from the project page at hackaday.io (which has a more in-depth discussion of the design decisions and concept.) There are also some additional photos and details on [Dan]’s website.

[Dan] is no stranger to developing hardware. The tcam-mini thermal imager (and much more) is his work, and we have no doubt the gCore’s design and features are informed directly by [Dan]’s actual, practical development needs.

Dual Power Supply In A Pinch

July 2, 2022 by 14 Comments

Recently I needed a dual voltage power supply to test a newly-arrived PCB, but my usual beast of a lab power supply was temporarily at a client’s site. I had a FNIRSI programmable power supply which would have been perfect, but alas, I had only one. While digging around in my junk box I found several USB-C power-delivery “trigger” boards which I bought for an upcoming project. These seemed almost too small for the task at hand, but after a little research I realized they would work quite well.

The ones I had used the Injoinic IP2721 USB-C power delivery chip, commonly used in many of these boards. Mine had been sold pre-configured for certain output voltages, but they were easy to re-jumper to the voltages I needed, +5 VDC  and +20 VDC. The most challenging aspect was physically using them — they are the size of a fingernail. This version had through-hole output pads on 0.1″ centers, so I decided to solder them to the base of a standard MTA pin header. A few crimps later and I was up and running, along with the requisite pair of USB-C cables and power adapters.

For just a few dollars each, these trigger boards are useful to have in your toolbox, both for individual projects and for use in a pinch. We reviewed these modules a couple of years ago, and check out the far more flexible PD Micro that we covered last year.

render of the MNT Pocket Reform on a desk

MNT Reform Goodness, Now Even Smaller With Pocket Reform

July 1, 2022 by 12 Comments

You might have already seen the pretty pictures in pastel colors online — a small netbook-like computer with a full-size keyboard. This, while a render, is what the MNT Pocket Reform is going to look like. Reminiscent of the netbook aesthetic in all the right ways, it’s a small device with a mechanical keyboard taking as much space as possible, trackball for navigation, and we assume, exactly the kind of screen that’d be comfortable to use.

We’ve reviewed the MNT Reform a year ago, and this device inherits a lot of its good parts. The motherboard’s connectivity is likely subject to change, but on the motherboard renders, we can spot three USB-C ports, a Micro HDMI port, a microSD card slot, ix Industrial Ethernet, and M.2 B-key and M-key slots for WWAN and SSD cards respectively.

If you expected computational specs, there isn’t really a specific CPU+RAM configuration announced – for a good reason. The Pocket Reform takes advantage of the CPU card concept designed into the MNT Reform – able to take a card with an NXP i.MX8M CPU, Raspberry Pi CM4, Pine SOQuartz, a Kintex-7 FPGA, or any of the cards yet to be developed. The design files are open-source, the prototype motherboards have been ordered, mechanical usability aspects have been worked through. This is a very compelling project, and we can’t wait to see it bear fruit!

This Custom Workbench Will Make You Flip

June 26, 2022 by 26 Comments

In a recent video, [SomeSkillStudio] created a tidy tool storage system for their slim garage workbench. We have seen the “five knuckle” 270 degree hinges used here before and knew they’d enable some cool hacks. Here you’ll see how he puts this unique type of hardware to work building a densely packed work surface. For anyone who’s set up shop in a garage that’s somehow also supposed to still regularly host vehicles, you’ll know how important it is to have a place to put everything away and make it easy to do so.

The video has several great tips on making sure everything fits together, something key for anyone reproducing this with their own tool collection. If you have even less space, we have some great past workshop builds from portable, to tiny, to elaborate. Even if you’ve already established a place to work, we have tips on organizing your shop, giving each tool a home in a shadow board or across an infinite grid. Clearly, making a work space is one of our favorite kinds of projects.

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