Misc Hacks

4086 Articles

Sanity Check Your Engines With This Dynamometer

April 14, 2021 by 2 Comments

As you get ready to pop the hood of your RC car to drop in a motor upgrade, have you ever wondered how much torque you’re getting from these small devices? Sure, we might just look up the motor specs, but why trust the manufacturer with such matters that you could otherwise measure yourself? [JohnnyQ90] did just that, putting together an at home-rig built almost from a stockpile of off-the-shelf parts.

To dig into the details, [JohnnyQ90] has built himself a Prony Brake Dynamometer. These devices are setup with the motor shaft loosely attached to a lever arm that can push down on a force-measuring device like a scale. With our lever attached, we then power up our motor. By gradually increasing the “snugness” of the motor shaft, we introduce sliding friction that “fights” the motor, and the result is that, at equilibrium, the measured torque is the maximum amount possible for the given speed. Keep turning up that friction and we can stall the motor completely, giving us a measurement of our motor’s stall torque.

Arming yourself with a build like this one can give us a way to check the manufacturer’s ratings against our own, or even get ratings for those “mystery motors” that we pulled out the dumpster. And [JohnnyQ90’s] build is a great reminder on how we can leverage a bit of physics and and a handful of home goods to get some meaningful data.

But it turns out that Prony Brake Dynamometers aren’t the only way of measuring motor torque. For a disc-brake inspired, have a look at this final project. And if you’re looking to go bigger, put two motors head-to-head to with [Jeremy Felding’s] larger scale build.

 

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New HackadayU Classes: Antenna Basics, Raspberry Pi Pico, And Designing Complex Geometry

April 13, 2021 by 4 Comments

Get ’em while they’re hot: a new session of HackadayU just opened with classes from three fantastic instructors and seats are filling up fast.

Introduction to Antenna Basics — Instructor Karen Rucker teaches the fundamentals of antenna design as if it were your first year on-the-job. She’ll cover the common types of antenna designs and the fundamentals of radio frequency engineering that go into them. Begins Thursday, May 6th.

Raspberry Pi Pico and RP2040 – The Deep Dive — Instructor Uri Shaked guides the class through the internals of the RP2040 microcontroller, covering system architecture, hardware peripherals, and dipping into some ARM assembly language examples. Begins Wednesday, May 5th.

Designing with Complex Geometry — Instructor James McBennett helps you up your 3D modelling game with a course on using complex geometries in Grasshopper3D (part of Rhino3D). Dive into Non-uniform rational B-spline (NURBS) and go from simple shapes to incredibly complex objects with a bit of code. Begins Tuesday, May 4th.

Each course includes five weekly classes beginning in May. Being part of the live class via Zoom offers interactivity with the instructor and other attendees. All tickets are “pay-as-you-wish” with a $20 suggested donation; all proceeds go to socially conscious charities.

For the benefit of all, each class will be edited and published on Hackaday’s YouTube channel once this session has wrapped up. Check out our playlists for past HackadayU courses, or watch them all in one giant playlist.

You might also consider becoming an Engineering Liaison for HackadayU. These volunteers help keep the class humming along for the best experience for students and instructors alike. Liaison applications are now open.

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aemkei's xor patterns

Alien Art Drawn With Surprisingly Simple Math

April 13, 2021 by 20 Comments

Programmer [aemkei] Tweeted the formula (x ^ y) % 9 alongside code for more “alien art”. But how can a formula as simple as (x ^ y) % 9 result in a complex design? The combination of Bitwise XOR (^) and Modulo (%) generate a repeating pattern that’s still complex enough to satisfy the eye, and it’s ok if that doesn’t sound like an explanation. Bitwise operations are useful when working with memory and shift registers, but also worth learning if you want to drive lines or matrices of LEDs or interpret combinations of multiple switches, or in this case a great way to throw an interesting test pattern up on a new flip-dot display or low-res LED matrix. Are you into it? We are, so let’s jump in.

XOR Truth Table
0b00 0b01 0b10 0b11
0b00 0b00 0b01 0b10 0b11
0b01 0b01 0b00 0b11 0b10
0b10 0b10 0b11 0b00 0b01
0b11 0b11 0b10 0b01 0b00

Bitwise XOR compares each binary digit of the two inputs. The XOR returns a 1 when only one of the two digits is a 1, otherwise, it returns a zero for that position. Let’s say the coordinates were 3, 2. Converted to binary we have 0b11 and 0b10. From this truth table, we can see the most-significant digits are both 1, returning a 0, while only one of the least-significant digits is a 1, so the comparison returns a 1.

Moving onto the %, which is the Modulo operator has nothing to do with percentages. This operator divides two numbers and returns the remainder if any. Take 9 % 5. When dividing 9 by 5, 5 goes in once with a remainder of 4 so 9 % 5 = 4. Now our original formula from the top will draw a black box for every ninth number except that the bitwise XOR throws a wrench into that count, varying how often a number divisible by 9 appears and supplying the complexity necessary for these awesome patterns.

detail of aemkei's xor patterns

What are the most interesting designs can you create in a simple formula?

The Dynamotor Simplified

April 11, 2021 by 28 Comments

[Robert Murray-Smith] doesn’t like the price of inverters to convert DC to AC. That led him to build a dynamotor, or what is sometimes called a motor-generator set. These devices are just DC motors driving a generator. Of course, motors can also be used as generators and [Robert] had a stack of brushless motors in the form of PC fans. A two-fan dynamotor was born.

The brushless motors are attractive because, traditionally, the brushes are what usually fail on a dynamotor. The fan that will act as a generator needs some surgery, but it is simple. He scraped off all the control electronics and connected wires to the coils to form a three-phase generator. There’s no need for the fan blades in that configuration, either. If you were using ordinary motors and a generator, getting shafts concentric would be an important task. With the fans, it is simple to just line up the mounting holes and you get perfect alignment for free.

How does it work? [Robert] has a second video showing the output on a scope. You can see both videos below. The dynamotor makes a good-looking sine wave, probably much better than most reasonable-priced solid state inverters. He didn’t mention how much current he could successfully draw, but it probably isn’t much. You’d also need a transformer to replace a commercial inverter that would put out line voltage, so that would be some more loos in the system. On the other hand, if you wanted AC at a lower voltage, you might just replace all the transformers, if you were building a piece of gear yourself.

We’ve looked at how these things work in some detail. There were common in old tube radios, particularly military ones.

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Shoot Above The Waves On This E-Foil Made From A Rifle Case

April 7, 2021 by 17 Comments

So you say you want to fly above the waves on an electric hydrofoil, but you don’t have the means to buy a commercial board. Or, you don’t have the time and skills needed to carve a board and outfit it with the motor and wing that let it glide above the water. Are you out of luck? Not if you follow this hackworthy e-foil build that uses a waterproof rifle case as the… hull? Board? Whatever, the floaty bit.

If you haven’t run across an e-foil before, prepare to suddenly need something you never knew existed. An e-foil is basically a surfboard with a powerful brushless motor mounted on a keel of sorts, fairly far below the waterline. Along with the motor is a hydrofoil to provide lift, enough to raise the board well out of the water as the board gains speed. They look like a lot of fun.

Most e-foils are built around what amounts to a surfboard, with compartments to house the battery, motor controller, and other electronics. [Frank] and [Julian] worked around the difficult surfboard build by just buying a waterproof rifle case. It may not be very hydrodynamic, but it’s about the right form factor, it already floats, and it has plenty of space for electronics. The link above has a lot of details on the build, which started with reinforcing the case with an aluminum endoskeleton, but at the end of the day, they only spent about 2,000€ on mostly off-the-shelf parts. The video below shows the rifle case’s maiden voyage; we were astonished to see how far and how quickly the power used by the motor drops when the rifle case leaves the water.

Compared to some e-foil builds we’ve seen, this one looks like a snap. Hats off to [Frank] and [Julian] for finding a way to make this yet another hobby we could afford but never find time for.

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Harmonic Drive Uses Compliant Mechanism To Slim Down

April 7, 2021 by 15 Comments

[Levi Janssen] has a secret: he doesn’t like harmonic drives. But rather than abandon the torque-amplifying transmission completely, he decided to see about improving them using 3D-printed compliant mechanisms.

For the uninitiated, harmonic drives, also known as strain-wave gears, are a compact, high-torque gearbox that has become popular with “robotic dog” makers and other roboticists. The idea is to have a rigid, internally-toothed outer ring nested around an externally-toothed, flexible cup. A wave generator rotates within the inside cup, stretching it so that it meshes with the outer ring. The two gears differ by only a couple of teeth, meaning that very high gear ratios can be achieved, which makes them great for the joints of robot legs.

[Levi]’s problem with the harmonic drive is that due to the depth of the flexible spline cup, compactness is not among its virtues. His idea is to couple the flex spline to the output of the drive through a flat spring, one that allows flexion as the wave generator rotates but transmits torque efficiently. The entire prototype is 3D-printed, except for the wave generator bearings and stepper motor, and put to the test.

As the video below shows after the excellent introduction to harmonic drives, the concept works, but it’s not without its limitations. Even lightly loaded, the drive made some unpleasant crunching sounds as the PLA springs gave out. We could easily see that being replaced with, say, a steel spring, either machined or cut on a water-jet machine. That might solve the most obvious problem and make [Levi]’s dream of a compact harmonic drive a reality. Of course, we have seen pretty compact strain-wave gears before.

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