Low-Power Motor Can Run For Years On A Coin Cell

December 25, 2017 by Dan Maloney 29 Comments

Can you run an electric motor for two years on a single lithium coin cell? [IamWe] figured out how to do it, and even though his donut motor doesn’t look like any motor we’ve ever seen before, it’s a pretty solid lesson in low-current design.

The donut motor is really just a brushless DC motor with a sign-pole stator and a multi-pole rotor. The frame of the motor is built from a styrofoam donut, hence the motor’s name. The rotor is a styrofoam sphere with neodymium magnets embedded around its equator. A sharpened bicycle spoke serves as an axle, and clever magnetic bearings provide near-zero friction rotation. The stator coil comes from an old solenoid and is driven by a very simple two-transistor oscillator. [IamWe]’s calculations show that the single CR2032 coin cell should power this motor for over two years. This one looks easy enough to whip up that it might make a nice project for a long winter’s night. Watch it spin in the video below.

This one seems like a perfect entry for the Coin Cell Challenge contest. Sure, it may not be a coin cell jump starter for your car, but our guess is this motor will still be spinning in 2020, and that’s no mean feat.

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Powder Coating With A Fluidized Bed

December 25, 2017 by Dan Maloney 16 Comments

There’s no beating the beauty and durability of a high-quality powder-coated part. There’s just something about the look and feel of the finish that goes far beyond mere painting and makes it worth the effort and expense. The typical electrostatic spray powder-coating setup can be expensive, though, and not necessarily suitable for every workpiece.

Enter the fluidized-bed powder coating chamber, perfect for limited runs of small parts, and the brainchild of [Andrew Mayhall]. With a business providing furniture kits based on iron pipe, [Andrew] needed a way to finish flanges and fittings, and powder coating provided the best look. The fluidizer he built is a great alternative to spray coating; it blows air through a bed of fine thermoplastic granules, which causes them to act like a fluid. It’s similar to the fluidized-bed hot tub we recently featured, but on a much smaller scale and with different requirements based on the ultrafine particle size and aggregation properties of the powder. [Andrew] had to add mechanical agitation to achieve a homogeneous fluid bed, and after much experimentation he’s now able to dip preheated parts into the bed and achieve one-step powder coating. The video after the break shows some of the operational details.

Does electrostatic powder-coating sound like more of your thing? No problem – DIY solutions abound, and a homebrew oven to bake your parts may be as close as the nearest file cabinet.

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Floating Death Star Is Just In Time

December 23, 2017 by Will Sweatman 8 Comments

Unless you’ve been living under a high voltage transformer, you’re aware of the latest release in the Star Wars Saga. [John] has a relative that is clearly a big Star Wars fan, so he set about to build them the perfect Christmas present – a levitating Death Star! Instead of reinventing the wheel, [John] decided to start off with a magnetically levitating model of the Earth – a globe. He then took a Death Star mood lamp and gracefully cut it half with his trusty Dremel.

A nice twist for the mood lamp is that it was powered by a hacker’s best friend – five volts from a USB power supply. This made it easy to wire in a LiPo battery along with a charger and some fiber optic lighting. A pile of cat litter to represent a smoldering planet blown to bits ties the whole build together as only cat litter can.

Be sure to visit [John’s] Instructable page for full details along with a video, which you can also see below.

Read Home Power Meters With RTL-SDR

December 21, 2017 by Will Sweatman 62 Comments

[k-roy] hates electricity. Especially the kind that can be lethal if you’re not careful. Annoyed by the constant advertisements for the popular Sense Home Energy monitors (which must be installed in the main breaker box by an electrician), [k-roy] set out to find a cheaper and easier way. He wondered how the power company monitored his meter, and guessed correctly that it must be transmitting the information wirelessly. Maybe he could just listen in?

Using a cheap RTL-SDR, it didn’t take long for [k-roy] to tap into this transmission and stumbled across the power readings for his entire neighborhood using a simple command:

~/gocode/bin/rtlamr -msgtype=idm --format=json -msgtype=scm+

Ironically, the hardest part wasn’t snooping on everyone’s power and water usage patterns in the neighborhood, it was trying to figure out which meter was his. In the end, he was able to make some nice graphical layouts of the data with PHP.

We’ve seen some righteous power meter hacks in our time, but this one stands out for its simplicity and elegance. Be sure to check out [k-roy’s] blog for more details, and [rtlamr’s] github for the program used to read the meters.

Thanks to [Jasper J] for the tip!

Reusing Motors From Washing Machines

December 20, 2017 by Lewin Day 57 Comments

Big ol’ motors are great when you need to get a big job done, but they can be expensive or hard to source new. However, there’s a source of big, fat, juicy motors right at home for most people – the garden variety washing machine. These motors would usually require a special controller, however [Jerry] is here to show us how to hack the controller that comes with the machine.

The hack begins as [Jerry] decides to gut a Maytag MAH7500 Neptune front loader. Many projects exist that borrow the motor but rely on a seperately sourced variable frequency drive, so the goal was to see if the machine’s original controller was usable. The machine was first troubleshooted using a factory service mode, which spins the drum at a set speed if everything is working correctly.

From there, it was a relatively simple job to source the machine schematics to identify the pinouts of the various connectors. After some experimentation with a scope and a function generator, [Jerry] was able to get the motor spinning with the original controller doing the hard work.

It’s a simple hack, and one that relies on the availability of documentation to get the job done, but it’s a great inspiration for anyone else looking to drive similar motors in their own projects. The benefit is that by using the original motor controller, you can be confident that it’s properly rated for the motor on hand.

Perhaps instead of an induction motor, you’d rather drive a high powered brushless DC motor? This project can help.

How Provably Loaded Dice Lead To Unprovable Cheating

December 18, 2017 by Donald Papp 16 Comments

Here’s a really interesting writeup by [Mike] that has two parts. He shows that not only is it possible to load wooden dice by placing them in a dish of water, but that when using these dice to get an unfair advantage in Settlers of Catan, observation of dice rolls within the game is insufficient to prove that the cheating is taking place.

[Mike] first proves that his pair of loaded dice do indeed result in a higher chance of totals above seven being rolled. He then shows how this knowledge can be exploited by a Settlers of Catan player to gain an average 5-15 additional resource cards in a typical game by taking actions that target the skewed distribution of the loaded dice.

The second part highlights shortcomings and common misunderstandings in current statistical analysis. While it’s possible to prove that the loaded dice do have a skewed distribution by rolling them an arbitrary number of times, as [Mike] and his wife do, it is not possible to detect this cheating in a game. How’s that? There are simply not enough die rolls in a game of Settlers to provide enough significant data to prove that dice distribution is skewed.

Our staff of statistics Ph.D.s would claim that [Mike] overstates his claims about shorcomings in the classical hypothesis testing framework, but the point remains that it’s possible to pass through any given statistical testing process by making the effect just small enough. And we still think it’s neat that he can cheat at Settlers by soaking wooden dice in water overnight.

This isn’t the first time we’ve seen Settlers of Catan at the center of some creative work. There’s this deluxe, hand-crafted reboot, and don’t forget the electroshock-enabled version.

[via Reddit; images from official Catan site]

Machined Lightsaber Pen For A More Civilized Age

December 18, 2017 by Tom Nardi 13 Comments

In an increasingly paperless society, writing implements are becoming an obsolete technology for many of us. Certainly not the kind of thing the average person would think to spend more than a couple bucks on, to say nothing of machining one out of a solid piece of aluminum bar stock. But clearly [Bob] is not most people. He recently dropped us a line about a video he uploaded to his aptly-named YouTube channel “Making Stuff”, where he goes through the steps required to turn raw materials into a writing instrument worthy of a Jedi.

Starting with a piece of aluminum chucked up in the lathe, [Bob] cuts out the iconic ribbed profile of Luke’s saber and fills in the gaps with nothing more exotic than a black Sharpie. He then moves on to the more complex shape of the emitter, and then flips the handle over in the lathe and hollows it out so a brass tube can be inserted.

Somewhat surprisingly, it seems more effort ends up being put into the acrylic “blade” than the aluminum handle itself. A chunk of acrylic is drilled and tapped so that it can be mounted in the chuck, and then turned down into a long cylinder. A tip is then cut in the end, the length of the blade is hollowed out, and finally it gets polished up to a nice shine.

The build is completed by inserting a standard ink pen cartridge down the center of the now completed saber. Surely the pen aficionados will lament that he didn’t attempt to build his own ink cartridge as well, but we think he gets a pass considering the rest of it was made from scratch.

If even a glorious writing instrument such as this isn’t enough to get you to re-learn how to write your name, fear not. Whether you’re making music or capturing flags, we’ve played home to numerous other saber projects; eye-safe or otherwise.

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