Making An Espresso Pot In The Machine Shop

September 30, 2016 by Gerrit Coetzee 18 Comments

[This Old Tony] was cleaning up his metal shop after his yearly flirtation with woodworking when he found himself hankering for a nice coffee. He was, however, completely without a coffee making apparatus. We imagine there was a hasty round of consulting with his inanimate friends [Optimus Prime] and [Stefan Gotteswinter Brush] before he decided the only logical option was to make his own.

So, he brought out two chunks of aluminum from somewhere in his shop, modeled up his plan in SolidWorks, and got to work. It was designed to be a moka style espresso pot sized around both the size of stock he had, and three purchased parts: the gasket, funnel, and filter. The base and top were cut on a combination of lathe and mill. He had some good tips on working with deep thin walled parts. He also used his CNC to cut out some parts, like the lid and handle. The spout was interesting, as it was made by building up a glob of metal using a welder and then shaped afterward.

As usual the video is of [This Old Tony]’s exceptional quality. After quite a lot of work he rinsed out most of the metal chips and WD40, packed it with coffee, and put it on the stove. Success! It wasn’t long before the black stuff was bubbling into the top chamber ready for consumption.

Homebrew Powerwall Sitting At 20kWh

September 29, 2016 by Gerrit Coetzee 128 Comments

Every now and then a hacker gets started on a project and forgets to stop. That’s the impression we get from [HBPowerwall]’s channel anyway. He’s working on adding a huge number of 18650 Lithium cells to his home’s power grid and posting about his adventures along the way. This week he gave us a look at the balancing process he uses to get all of these cells to work well together. Last month he gave a great overview of the installed system.

His channel starts off innocently enough. It’s all riding small motor bikes around and having a regular good time. Then he experiments a bit with the light stuff, like a few solar panels on the roof. However, it seems like one day he was watching a news brief about the Powerwall (Tesla’s whole-home battery storage system) and was like, “hey, I can do that.”

After some initial work with the new substance it wasn’t long before he was begging, borrowing, and haggling for every used 18650 lithium battery cell the local universe in Brisbane, Australia could sell him. There are a ton of videos documenting his madness, but he’s all the way up to a partly off-grid house with a 20kWh battery bank, for which he has expansion plans.

There’s a lot of marketing flim flam and general technical pitfalls in the process of generating your own non-grid electricity. But for hackers in sunny areas who want to dump those rays into local storage this is an interesting blueprint to start with.

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Hackaday Prize Entry: Theia IoT Light-switch

September 24, 2016 by Jenny List 17 Comments

There are it seems no wireless-enabled light switches available in the standard form factor of a UK light switch. At least, that was the experience of [loldavid6], when he decided he needed one. Also, none of the switches he could find were open-source, or easy to integrate with. So he set out to design his own, and the Theia IoT light switch is the result.

In adapting a standard light switch, he was anxious that his device would not depend on the position of the switch for its operation. Therefore he had to ensure that the switch became merely an input to whichever board he designed, rather than controlling the mains power. He settled upon the ESP8266 wireless-enabled microcontroller as the brains of the unit, with a relay doing the mains switching. He first considered using an LNK304 off-line switching PSU chip to derive his low voltages, but later moved to an off-the-shelf switch-mode board.

So far two prototype designs have been completed, one for each power supply option. Boards have been ordered, and he’s now in the interminable waiting period for international postage. All the KiCad and other files are available for download o the project’s hackaday.io page, so you can have a look for yourselves if you are so inclined.

You might ask why another IoT light switch might be needed. But even though they are now available and inexpensive, there is still a gap for a board that is open, and more importantly does not rely on someone else’s cloud backend. Plus, of course, this board can be used for more than lighting.

Light bulb image: Осадчая Екатерина (Own work) [CC BY-SA 4.0], via Wikimedia Commons.

Artificial Skylight Brings Sunlight To Any Room

September 24, 2016 by James Hobson 90 Comments

Humans aren’t supposed to be cooped up indoors all day, but who wants to be bothered by UV rays, insects, allergens, traffic, physical activity, and other people? On the other hand, a gloomy living space generally inhibits productivity — if not making it difficult to find what you’re looking for. So, if you’re looking to illuminate any room in your place, and you have the cash and the patience to wait for its widespread release, CoeLux is a skylight that needs no sky or sun — not that you’ll be able to tell the difference.

The Italian developers [CoeLux Srl] are perhaps wisely remaining tight-lipped on how the effect is achieved, but confirm that nanoparticles in the skylight mimic the effect of atmospheric fluctuations, compressing that vast deep blue into a few milimetres while maintaining the perception of infinite depth.

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Finding ESP8266 Inside Big-Box Store IoT Plugs

September 23, 2016 by Elliot Williams 44 Comments

When we buy new shiny toys, we usually open them up to at least have a look. [Scott Gibson] does the same, apparently. He found an ESP8266 module inside the EcoPlug brand WiFi-controlled wall switches.

The original device was intended to be controlled by a (crappy) app. He sniffed the UDP packets enough to send the on-off signals to an unmodified device, but where’s the fun in that? [Scott] gave it an upgrade by replacing the ESP8266’s firmware with his own and now he’s got a much more capable remote switch, one that speaks MQTT like the rest of his home automation system.

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How To Drill A Curved Hole

September 22, 2016 by James Hobson 34 Comments

Next time you’re renovating and need to run some cables around corners in you walls, save yourself some frustration by building [izzy swan]’s corner drilling rig. It’s something akin to a custom tunnel boring machine but on a small scale.

Starting with a piece of steel, [izzy] traced and cut out a 90 degree curve with an attached arm that will allow it to rotate from a central block. He then grabs a random drill bit and attaches it to a flex shaft which is secured to the leading point of the steel curve. To complete the handy setup the entire rig is bolted to a block that will clamp over the corner stock.

As it stands, it takes some elbow grease to get the drill through, but it’s not a purpose built setup. On a second demonstration, the flex shaft breaks, but the idea is there. Now, [izzy] advises that this is most easily accomplished when re-framing walls with no drywall obstructing your drill, but the concept for this rig could nonetheless prove handy for welding, grinding, and so forth along any angled curve.

If instead you want to push your carpentry skills to their limits, build a wooden Vespa.

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An ESP8266 In Every Light Switch And Outlet

September 20, 2016 by Gerrit Coetzee 91 Comments

[Hristo Borisov] shows us his clever home automation project, a nicely packaged WiFi switchable wall socket. The ESP8266 has continuously proven itself to be a home automation panacea. Since the ESP8266 is practically a given at this point, the bragging rights have switched over to the skill with which the solution is implemented. By that metric, [Hristo]’s solution is pretty dang nice.

It’s all based around a simple board. An encapsulated power supply converts the 220V offered by the Bulgarian power authorities into two rails of 3.3V and 5V respectively. The 3.3V is used for an ESP8266 whose primary concern is the control of a triac and an RGB LED. The 5V is optional if the user decides to add a shield that needs it. That’s right, your light switches will now have their own shields that decide the complexity of the device.

The core module seen to the right contains the actual board. All it needs is AC on one side and something to switch or control on the other The enclosure is not shown (only the lid with the shield connectors is seen) but can be printed in a form factor that includes a cord to plug into an outlet, or with a metal flange to attach to an electrical box in the wall. The modules that mate with the core are also nicely packaged in a 3D printed shield. For example, to convert a lamp to wireless control, you use a shield with a power socket on it. To convert a light switch, use the control module that has a box flange and then any number of custom switch and display shields can be hot swapped on it.

It’s all controllable from command line, webpage, and even an iOS app; all of it is available on his GitHub. We’d love to hear your take on safety, modularity, and overall system design. We think [Hristo] has built a better light switch!