3D Printed Turbo Pump Hopes To Propel Rockets To The Sky

April 25, 2022 by Lewin Day 22 Comments

There are plenty of rocket experimenters toying with various liquid-fueled contraptions at the moment, and [Sciencish] is one of them. He grew tired of using air-pressurized fuel delivery systems in his experiments due to safety reasons, and decided to create something approximating more grown up rocket designs. The result was a 3D-printed turbopump for fuel delivery.

The design is not dissimilar from a turbocharger in a car. On one side, a turbine wheel is turned by compressed air supplied from a tank or compressor. This turbine wheel is affixed to the same axle as an impeller which draws up fuel and pumps it out, ideally into a rocket’s combustion chamber. It’s all made out of resin-printed parts, which made creating the fine geometry of the turbine and impeller a cinch.

Running on compressed air at 80 psi, the turbopump is able to deliver 1.36L of water or rubbing alcohol fuel a minute. However, unfortunately, this first pass design can only deliver 20 psi of fuel pressure, which [Sciencish] suspects will not be enough to counteract combustion chamber pressures in his rocket design. More work is required to up this figure. Paired with a nozzle and ignition source, though, and it does make for some great flames.

Overall though, the safety benefit of this turbopump comes from the fact that the fuel is kept separate from the oxidizer until it reaches the combustion chamber. This comes with far less chance of fire or explosion versus a system that stores fuel pressurized by air.

While the design isn’t yet up to scratch for rocket use, it nonetheless works, and we suspect with some improvement to tolerances and fin design that the project should move along at a quick pace.

If solid rockets are more your thing though, we’ve featured plenty of those too. Video after the break.

Continue reading “3D Printed Turbo Pump Hopes To Propel Rockets To The Sky” →

Calculating Pi On The 4004 CPU, Intel’s First Microprocessor

April 15, 2022 by Lewin Day 26 Comments

These days we are blessed with multicore 64-bit monster CPUs that can calculate an entire moon mission’s worth of instructions in the blink of an eye. Once upon a time, though, the state of the art was much less capable; Intel’s first microprocessor, the 4004, was built on a humble 4-bit architecture with limited instructions. [Mark] decided calculating pi on this platform would be a good challenge.

It’s not the easiest thing to do; a 4-bit processor can’t easily store long numbers, and the 4004 doesn’t have any native floating point capability either. AND and XOR aren’t available, either, and there’s only 10,240 bits of RAM to play with. These limitations guided [Mark’s] choice of algorithm for calculating the only truly round number. Continue reading “Calculating Pi On The 4004 CPU, Intel’s First Microprocessor” →

Lego Fourteen-Segment Display Needs Plenty Of Motors

April 12, 2022 by Lewin Day 1 Comment

Hackers love 7-segment displays, and will gladly wax lyrical about the silly words you can almost spell on them and so on. Less appreciated are their bigger cousins, the fourteen and sixteen segment displays, which get all alphanumeric about things and are thus much easier for humans to read. You can even build the former out of Lego, as [ord] demonstrates.

A look at the mechanism driving the display.

The “segments” are made up of Lego shafts that are pushed up through a yellow matrix of holes when they are switched “on.” A full seven motors are used to make the single-character display work, each one driving two segments. Two Lego Powered Up controller bricks are required to drive everything going on here, making the final design not just mechanically complicated, but electronically complicated as well.

Amusingly, those don’t come cheap, either; the parts total cost of this build is likely somewhere between $50-100 US. You probably don’t want to build an entire scrolling message board using this design, even if it does look resplendent in black and taxi yellow.

We’ve seen [ord]’s work before, too, in the form of these mechanically magnificent 7-segment Lego displays. Video after the break.

Continue reading “Lego Fourteen-Segment Display Needs Plenty Of Motors” →

The end result - motorized window in a silver stainless steel frame, with the linear actuators and gas struts, shown from the outside half-open.

Swing Gate Motors Come To Help For Opening A Giant Servery Window

April 11, 2022 by Arya Voronova 34 Comments

[Martin Roberts] wrote to us, telling us about a build that his company, [Ocean View Workshop], was tasked with. Creating a four meter wide window able to open vertically is no small feat, and it had to be custom-built because the local company building such windows wasn’t comfortable working with anything other than aluminum — insufficient for the window’s scale. With massive weight of the glass alone, structural requirements for supporting it, and the mechanical loads to be applied, some careful planning was in order.

To start with, this window had to be motorized, as an average person wouldn’t be capable of pulling it upwards. Not satisfied with the linear actuator choice available, they went to a hardware store and found some swing gate actuators that, in workshop tests, proved themselves to be more than capable of handling way over the weight required. In fact, they were capable of lifting [Martin] himself off the ground without much hassle.

Continue reading “Swing Gate Motors Come To Help For Opening A Giant Servery Window” →

Two pairs of boards described in the article, with toggle switches and RCA jacks, shown interconnected, LEDs on all four boards lit up.

Boards For Playful Exploration Of Digital Protocols

April 10, 2022 by Arya Voronova 1 Comment

Teaching people efficiently isn’t limited to transmitting material from one head to another — it’s also about conveying the principles that got us there. [Mara Bos] shows us a toolkit (Twitter,
nitter link) that you can arm your students with, creating a small playground where, given a set of constraints, they can invent and figure communication protocols out on their own.

This tool is aimed to teach digital communication protocols from a different direction. We all know that UART, I2C, SPI and such have different use cases, but why? Why are baud rates important? When are clock or chip select lines useful? What’s the deal with the start bit? We kinda sorta figure out the answers to these on our own by mental reverse-engineering, but these things can be taught better, and [Mara] shows us how.

Gently guided by your observations and insights, your students will go through defining new and old communication standards from the ground up, rediscovering concepts like acknowledge bits, bus contention, or even DDR. And, as you point out that the tricks they just discovered have real-world counterparts, you will see the light bulb go on in their head — realizing that they, too, could be part of the next generation of engineers that design the technologies of tomorrow.

Continue reading “Boards For Playful Exploration Of Digital Protocols” →

The Bose headphone plug in question, with reverse-engineered schematic of the filter overlaid.

This 3.5mm Cable Distorts Signals, Hides Audio-Filtering Circuit

April 10, 2022 by Arya Voronova 57 Comments

[Avian]’s dad got a new ham radio transceiver with a 3.5 mm jack, and his pile-of-cables got him a headphone cable from Bose headphones. He built a DB9 to 3.5 mm adapter with that one – and it failed to let data through, outputting distorted garbage of a waveform instead. With a function generator and an oscilloscope, [Avian] plotted the frequency response of the cable, which turned out to be quite far from a straight line. What was up?

Taking the connector apart was a tricky job. A combination of blunt force and a nail polish remover soak didn’t quite get them all the way, so [Avian] continued to apply blunt force and took the jack apart with minimal casualties. Turned out that there was more to the 3.5 mm plug indeed — a whole PCB with a few resistors and capacitors, reverse-engineered into the schematic seen above.

Looks like Bose decided to tweak the audio characteristics of a specific pair of headphones, and an in-plug filter was, somehow, the most efficient solution. We probably shouldn’t expect to see this often, but it bears keeping in mind: next time your repurposed 3.5 mm cable doesn’t behave as expected, it would be prudent to do a capacitance test with your trusty meter or oscilloscope.

With how small MCUs have gotten, you can easily hide more than just a few capacitors! We don’t often see circuits built into cables, but when we do, it’s for malicious purposes.

Raspberry Pi Test Stand Tells You Which Glues To Use

April 7, 2022 by Dan Maloney 6 Comments

Not all glues are created equal; or rather, not every glue is good for every application. But how is one to know which glue to use in which kinds of joints? The answer to that is not always clear, but solid numbers on the comparative strength of different glues are a great place to start.

To quantify what can ordinarily be a somewhat subjective process, there’s probably no one better than woodworker and hacker [Matthias Wandel], equipped as he is with his DIY strength-tester. Using its stepper-driven power to blast apart glued lap joints, [Matthias] measured the yield point of the various adhesives using a strain gauge connected to a Raspberry Pi.

His first round of tests had some interesting results, including the usually vaunted construction adhesive ending up in a distant last place. Also performing poorly, at least relative to its reputation and the mess it can cause, was the polyurethane-based Gorilla Glue. A surprise standout in overall strength was hot glue, although that seemed to have a sort of plastic yield mode. Ever the careful empiricist, [Matthias] repeated his tests using hardwoods, with remarkably different results; it seems that glues really perform better with denser wood. He also repeated a few tests to make sure every adhesive got a fair shake. Check out the video below for the final results.

It’s always good to see experiments like this that put what we often take for granted to the test. [John] over at the Project Farm channel on YouTube does this kind of stuff too, and even did a head-to-head test of epoxy adhesives.

Continue reading “Raspberry Pi Test Stand Tells You Which Glues To Use” →