Ammo Can Holds A 14,000 Lumen LED Flashlight

March 28, 2019 by Tom Nardi 10 Comments

For most people, a flashlight is just something you keep in a drawer in the kitchen in case the power goes out. There’s even a good chance your “flashlight” is just an application on your phone at this point. But as we’ve seen many times before from mechanical keyboards to Power Wheels, hardcore niche communities can develop around the most innocuous pieces of hardware; and the lowly flashlight is no different.

Case in point, this 14,000 lumen LED flashlight built by [Bryson Hicks]. Designed around a 100 watt module from Stratus LED, the flashlight uses a number of 3D printed components to make itself at home in a suitably hardcore enclosure: a metal ammo can. With the addition of some modular electronics and a rather slick little control panel, his light is ready to deliver an unreasonable level of brightness anywhere he wishes.

The Stratus LED module includes its own driver, and just needs to be hooked up to a suitably beefy power source to do its thing. [Bryson] went with a 4500 mAh LiPo battery that he says gets him about a one hour runtime at full brightness. For somewhat less intense operation, he’s added a potentiometer which interfaces with the module’s driver board to control the LED output. Considering how fast the light sucks down the juice, adding a small LCD battery charge indicator to the top of the device seems like it was a prudent decision.

To prevent you from cooking anyone’s eyes at close range, the light requires you to first “arm” it by flipping the military style protected switch. Once the switch is in the on position, an illuminated push button is used to actually turn the LED module on and off. You can also snap the toggle switch back into the closed and covered position if you needed to kill the light in a hurry.

This isn’t the first preposterously bright LED flashlight we’ve seen around these parts. There’s something of an arms-race between hackers and makers to develop increasingly bright lights they can carry around, on the off chance they need to illuminate an entire neighborhood.

Arduino Converts Serial To Parallel: The Paralleloslam

March 28, 2019 by Lewin Day 34 Comments

After a youth spent playing with Amigas and getting into all sorts of trouble on the school computer network, I’ve always had a soft spot in my heart for hardware from the 80s and 90s. This extends beyond computers themselves, and goes so far as to include modems, photocopiers, and even the much-maligned dot matrix printer.

My partner in hacking [Cosmos2000] recently found himself with a wonderful Commodore MPS 1230 printer. Its parallel interface was very appropriate in its day, however parallel ports are as scarce as SID chips. Thankfully, these two interfaces are easy to work with and simple in function. Work on a device to marry these two disparate worlds began.

Enter: The Paralleloslam

While I was gallivanting around the Eastern coast of Australia, [Cosmos2000] was hard at work. After some research, it was determined that it would be relatively simple to have an Arduino convert incoming serial data into a parallel output to the printer. After some testing was performed on an Arduino Uno, a bespoke device was built – in a gloriously plastic project box, no less.

An ATMEGA328 acts as the brains of the operation, with a MAX232 attached for level conversion from TTL to RS232 voltage levels. Serial data are received on the hardware TX/RX lines. Eight digital outputs act as the parallel interface. When a byte is received over serial, the individual bits are set on the individual digital lines connected to the printer’s parallel port. At this point, the strobe line is pulled low, indicating to the attached device that it may read the port. After two microseconds, it returns high, ready for the next byte to be set on the output lines. This is how parallel interfaces operate without a clock signal, using the strobe to indicate when data may be read.

At this point, [Cosmos2000] reached out – asking if I had a name for the new build.

“Hm. Paralleloslam?”

“Done. Cheers!”

Continue reading “Arduino Converts Serial To Parallel: The Paralleloslam” →

Stuck Designing Two-Layer PCBs? Give Four Layers A Try!

March 27, 2019 by Ted Yapo 44 Comments

Many readers are certainly familiar with the process for home-etching of PCBs: it’s considered very straightforward, if a little involved, today. This was not the case in my youth, when I first acquired an interest in electronics. At that time, etching even single-sided boards was for “advanced” hobbyists. By the time I started etching my own PCBs, the advanced hobbyists were on to double-sided home-etched boards — the only type not pictured above, because I couldn’t find the one successful example I ever created. I later saw the rise of “bare bones” fabricated PCBs: professionally made fixed size boards with plated-through holes, but no soldermask or silkscreen. Eventually, this gave way to the aggregating PCB services we have now with full two-layer boards, complete with soldermask and silkscreen.

Today, the “advanced” hobbyist may be using four-layer boards, although the four-layer adoption rate is still relatively low – OSH Park produces around 90% two-layer and 10% four-layer, for instance. I think this will inevitably increase, as has been the case with all the previous technologies: the advanced eventually becomes the mainstream. Each of the previous shifts has brought easier design and construction as well as improved performance, and the same will be true as four layers becomes more commonplace.

So, let’s take a look at designing four-layer PCBs. If you’ve never considered one for any of your designs, you may be pleasantly surprised at what little extra cost is involved for all the benefits you gain. Continue reading “Stuck Designing Two-Layer PCBs? Give Four Layers A Try!” →

A Keyboard For Your Thumb

March 26, 2019 by Brian Benchoff 11 Comments

Here’s an interesting problem that no one has cracked. There are no small keyboards that are completely configurable. Yes, you have some Blackberry keyboards connected to an Arduino, but you’re stuck with the key layout. You could get one of those Xbox controller chat pads, but again, you’re stuck with the keyboard layout they gave you. No, the right solution to building small and cheap keyboards is to make your own, and [David Boucher] has the best one yet.

The Thumb Keyboard uses standard through-hole 4mm tact switches on a 10×4 grid, wired up in a row/column matrix. Yes, this is a mechanical keyboard, which is important: no one wants those terrible rubber dome keyswitches, and you need only look at the RGB gaming keyboard market for evidence of that. These tact switches fit into a standard perfboard, allowing anyone to build this at home with a soldering iron. After wiring up the keyboard and connecting it to an Arduino, [David] had a working keyboard.

There’s a lot going on with this build, not the least of which is the custom, 3D printed bezel for those tiny, tiny tact switches. This is a much simpler solution than building an entirely new PCB, which we’ve seen before. Since this is a 3D printed bezel, it’s easy to put labels or whatnot above the keys, or potentially print buttons. It’s great work, and one of the best small keyboards we could imagine.

Making The World’s Fastest 555 Timer, Or Using A Modern IC Version

March 25, 2019 by Ted Yapo 24 Comments

If you’re not familiar with the 555 timer, suffice it to say that this versatile integrated circuit is probably the most successful ever designed, and has been used in countless designs, many of which fall very far afield from the original intent. From its introduction, the legendary 555 has found favor both with professional designers and hobbyists, and continues to be used in designs from both camps. New versions of the IC are still being cranked out, and discrete versions are built for fun, a temptation I just couldn’t resist after starting this article.

If you think all 555s are the same, think again. Today, a number of manufacturers continue to produce the 555 in the original bipolar formulation as well as lower-power CMOS. While the metal can version is no longer available, the DIP-8 is still around, as are new surface-mount packages all the way down to the chip-scale. Some vendors have also started making simplified variants to reduce the pinout. Finally, you can assemble your own version from a few parts if you need something the commercial offerings won’t do, or just want a fun weekend project. In my case, I came up with what is probably the fastest 555-alike around, although I spared little expense in doing so.

Follow along for a tour of the current state of the 555, and maybe get inspired to design something entirely new with this most versatile of parts.

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A Ruined Saw Blade Becomes A Bowl

March 24, 2019 by Jenny List 19 Comments

Every workshop generates waste, whether it be wood shavings, scrap metal, or fabric scraps, and sometimes that waste seems too good to throw away. [Igor Nikolic]’s hackerspace had a ruined circular saw blade in the trash, and rather than let it go to waste he took it to the forge and fashioned a bowl from it. Then because another blade came his way and he wasn’t quite happy with the first one, he made another.

The second of the two bowls, in its finished state.

Saw blades are not promising material for forge work, being made of a very high-quality hardened steel they do not take well to hammering even when hot. So his first task was to anneal his blade in a kiln, heating it up and then letting it cool slowly to soften it.

Working the blade into a bowl shape was done on a home-made ball anvil. The blade was marked to provide guide rings as an aid to forming, and the bowl shape was progressively built out from the center. The first bowl was a little irregular, in his second try he’d got into his stride. Both bowls were mounted, one on a cut acrylic base, the other on a set of feet.

A project such as this can only be done with a huge amount of work, for which owners of larger forges will typically use a power hammer. [Igor] admits that a swage block (a specialized anvil for forming such curved shapes) would have made his life easier, but we think he’s done a pretty good job.

If you’ve been paying attention to recent Hackaday articles you may have noticed the start of our series on blacksmithing. We’re indebted to [Igor] for the genesis of that piece, for he was operating the portable forge that features in it.

Faster Computers Lead To Slower Experiences?

March 22, 2019 by Kerry Scharfglass 110 Comments

Ever get that funny feeling that things aren’t quite what they used to be? Not in the way that a new washing machine has more plastic parts than one 40 years its senior. More like “my laptop can churn through hundreds of gigaflops, but when I scroll it doesn’t feel great.” That perception of smoothness might be based on a couple factors, including system latency. A couple years ago [danluu] had that feeling too and measured the latency of “devices I’ve run into in the past few months” (based on this list, he lives a more interesting life than we do). It turns out his hunch was objectively correct. What he wrote was a wonderful deep dive into how and why a wide variety of devices work and the hardware and software contributors to latency.

Let’s be clear about what “latency” means in this context. [danluu] was checking the time between a user input and some response on screen. For desktop systems he measured a keystroke, for mobile devices scrolling a browser. If you’re here on Hackaday (or maybe at a Vintage Computer Festival) the cause of the apparent contradiction at the top of the charts might be obvious.

Q: Why are some older systems faster than devices built decades later? A: The older systems just didn’t do much! Instead of complex multi-tasking operating systems doing hundreds of things at once, the CPU’s entire attention was bent on whatever user process was running. There are obvious practical drawbacks here but it certainly reduces context switching!

In some sense this complexity that [danluu] describes is at the core of how we solve problems with programming. Writing code is all about abstraction. While it’s true that any program could be written directly in machine code and customized to an individual machine’s hardware configuration, it would be pretty inconvenient for both developer and user. So over time layers of sugar have been added on top to hide raw hardware behind nicer interfaces written in higher-level programming languages.

And instead of writing every program to target exact hardware configurations there is a kernel to handle the lowest layers, then layers adding hotplug systems, power management, pluggable module and driver infrastructure, and more. When considering solutions to a programming problem the approach is always recursive: you can solve the problem, or add a layer of abstraction and reframe it. Enough layers of the latter makes the former trivial. But it’s abstractions all the way down.

[danluu]’s observation is that we’re just now starting to curve back around and hit low latency again, but this time by brute force! Modern solutions to latency largely look like increasingly exotic display technologies and complex optimizations which reach from UI draw functions all the way down to the silicon, not removing software and system infrastructure. It turns out the benefits of software complexity in terms of user experience and ease of development are worth it most of the time.

For a very tangible illustration of latency as applied to touchscreen devices, check out the Microsoft Research video after the break (linked to in [danluu]’s piece).

Continue reading “Faster Computers Lead To Slower Experiences?” →