Screwed Up: Can Technology Be A Substitute For Regular Maintenance

The bane of life for anyone who possesses a well-used pile of spanners is the humble nut and bolt. Durable and easy to fasten, over our lifetimes we must screw and unscrew them by the million. When they do their job they’re great, but too often they seize up solid, or more alarmingly, gradually undo themselves over time due to vibration or thermal stress. There are a host of products such as locking nuts or thread sealant to deal with this problem, but the Fraunhofer Institute have an idea which might just remove the worry surrounding important fastenings. Their work has resulted in a solar-powered bolt with an embedded sensor that phones home when the connection loosens, allowing an engineer to be dispatched with a spanner to tighten it up.

The sensor itself is a washer which reports the force placed upon it, when this reduces an alert is sent. Communication is via Fraunhofer’s own MIoTy low-power wide-area network (LPWAN) protocol, but we’d imagine that one of the many competitor technologies could also serve.

This is an interesting idea that could no doubt result in targeted maintenance catching faulty fastenings early and averting disaster in the infrastructure projects such as bridges and wind turbines that they mention. We worry slightly though, because these types of structures have lives not in the few years of most tech products but in centuries. Will an IoT bolt head sensor still be phoning home in a few decades time, or will the system rely on old bolts being replaced at regular intervals of a decade? It’s not unknown for disasters to be the result of failures in fastenings a century old, so we sincerely hope that authorities in charge of whatever bridge relies on these won’t be tempted to skimp on their replacements. Perhaps a guy with a spanner every few years might be a more dependable option.

A vape pen, broken into parts, all laid out on a cutting mat

2022 Hackaday Prize: Disposable Vape Pens Turned Project Parts

Disposable vape pens, a sub-genre of electronic cigarettes, have been a fad for a few years now – they’re small self-contained devices with a rechargeable battery and some vape liquid inside. As the battery discharges and the liquid runs out, the entire vape pen is typically thrown out. [Dimitar] wants to change that, however, and teaches us how to reuse as much of the vape pen as possible — as yet another underappreciated source for parts we can use in our projects.

In an extensive worklog, he breaks down and documents a vape pen’s inner workings, coupled with a video we’ve placed below the break showing ways to disassemble them. In these, he shows how we can reuse the casing and the plastic parts, should any of us be interested in a project that happens to fit the e-cig form factor. Attention is paid to the sensor that triggers the evaporation — it may look like a microphone, but is actually a purpose-built pressure-sensor with a high-side switch! He tears into one of these in a separate video, showing how to reuse it as a capacitive touch controller. He also aiming to assemble a small database of related resources on GitHub, currently, hosting the files for the protection circuit he developed as part of his recommendations for safely reusing vape pen Li-ion batteries.

[Dimitar]’s journey is ongoing, and we can’t wait to see some fun uses for these components that he will certainly stumble upon on his way! For instance, here’s a hacker using an e-cig battery to power a pair of RGB LED-adorned sunglasses, replacing the AAAA battery they originally came with. We’ve seen hackers make guides on reusing each and every part of microwave ovens, printers and laptops, and we ourselves have talked about reusing ATX power supplies and computer mice.

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The module on a green PCB, connected to the Pixhawk controller, powering the servo rail

Anxieties Of Hardware Bringup During Parts Shortage

[Dirksavage88] tells us a story about developing a simple BEC in times of chip shortage. He needed a small 5V/3A regulator board for a servo rail on his drone, and decided to use one of the new integrated-inductor modules from Texas Instruments. Hardly requiring any external parts, such modules are exceptionally nice to use for all your power rail needs, albeit at a slightly increased cost – the downside is that, as the parts shortage hit, most of them have been out of stock. Originally priced at about $7 USD, the asking price for these specific modules, LMZM33603, has climbed as high as $800. Somehow, he obtained a few of these modules nevertheless, and went on designing a board.

It can be daunting to test your very first PCBs when the silicon you’re putting on it is effectively irreplaceable for your purposes. TI is known for their wacky footprints, and this module is no exception – the solder paste application took a bit of time, and seeing small solder balls around the module after reflow didn’t exactly reassure him. Thankfully, when he powered it all up, the module worked wonders, and took its rightfully earned spot in his drone’s servo turret. He says we can expect the next revision of his design in 2024, or whenever it is that the reported 100 week lead time is due. In case some of us could use them, Eagle files are available on GitHub!

Quite a few of us are lucky enough to have enough crucial parts for what we need, but most of us got a good few projects shelved until better times – take this WiFi-enabled wall charger project, for instance. Even bigger projects are suffering, from SmoothieBoard to Raspberry Pi. Just a year ago, we had our readers share their chip shortage stories.

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Watch A Complete Reflector Telescope Machined From A Single Block Of Glass

If this is the easy part of making a complete reflector telescope from a single piece of glass, we can’t wait to get a load of the hard part!

A little backstory may be in order for those who don’t follow [Jeroen Vleggaar]’s Huygens Optics channel on YouTube. A few months ago, he released a video discussing monolithic telescopes, where all the reflective and refractive surfaces are ground into a single thick block of glass. Fellow optical engineer [Rik ter Horst] had built a few tiny monolithic Schmidt-Cassegrain reflectors for use in cube sats, so [Jeroen] decided to build a scaled-up version himself.

The build starts with a 45 mm thick block of crown glass, from which a 50 mm cylinder is bored with a diamond hole saw. The faces of the blank are then ground into complex curves to reflect incoming light, first off the parabolic rear surface and then onto the hyperbolic secondary mirror ground into the center of the front face. A final passage through a refracting surface in the center of the rear face completes the photons’ journey through the block of glass, squeezing a 275 mm focal length into a compact package.

All this, of course, vastly understates the work required to pull it off. Between the calculations needed to figure out the surface shapes in the first place to the steps taken to machine a famously unforgiving material like glass, every step is fraught with peril. And because the design is monolithic, any mistakes mean starting all over again. Check out the video below and marvel at the skills needed to get results like this.

What strikes us most about [Jeroen]’s videos is the mix of high-tech and age-old methods and materials used in making optics, which we’ve seen him put to use to make everything from tiny Tesla valves to variable-surface mirrors.

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Copper: Rectifying AC A Century Ago

[Robert Murray-Smith] presents for us an interesting electronic device from years gone by, before the advent of Silicon semiconductors, the humble metal oxide rectifier. After the electronic dust had settled following the brutal AC/DC current wars of the late 19th century — involving Edison, Tesla and Westinghouse to name a few of the ringleaders — AC was the eventual winner. But there was a problem. It’s straightforward to step down the high voltage AC from the distribution network to a more manageable level with a transformer, and feed that straight into devices which can consume alternating current such as light bulbs and electrical heaters. But other devices really want DC, and to get that, you need a rectifier.

It turns out, that even in those early days, we had semiconductor devices which could perform this operation, based not upon silicon or germanium, but copper. Copper (I) Oxide is a naturally occurring P-type semiconductor, which can be easily constructed by heating a copper sheet in a flame, and scraping off the outer layer of Copper (II) Oxide leaving the active layer below. Simply making contact to a piece of steel is sufficient to complete the device.

Obviously a practical rectifier is a bit harder to make, with a degree of control required, but you get the idea. A CuO metal rectifier can rectify as well as operate as a thermopile, and even as a solar cell, it’s just been forgotten about once we got all excited about silicon.

Other similar metallic rectifiers also saw some action, such as the Selenium rectifier, based on the properties of a Cadmium Selenide – Selenium interface, which forms an NP junction, albeit one that can’t handle as much power as good old copper. One final device, which was a bit of an improvement upon the original CuO rectifiers, was based upon a stack of Copper Sulphide/Magnesium metal plates, but they came along too late. Once we discovered the wonders of germanium and silicon, it was consigned to the history books before it really saw wide adoption.

We’ve covered CuO rectifiers before, but the Copper Sulphide/Magnesium rectifier is new to us. And if you’re interested in yet more ways to steer electrons in one direction, checkout our coverage of the history of the diode.

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Gaskets, Can They Be 3D Printed?

Anyone who’s owned an older engine, whether it be in a car, motorcycle, or garden machine, will at some time have been faced with the need for a gasket. Even when the gasket is readily available there may be an imperative to fix the engine rather than wait for the part to arrive, so it’s common to make your own replacements. Simple ones are easy to cut from thin card, but if you’ve ever tried to do this with a really complex one you’ll know the pain of getting it right. This is the problem tackled in a video from [the_eddies], who has explored the manufacture of replacement gaskets by 3D printing.

The advantages of CAD and easy manufacture are obvious, but perhaps many common plastics might not perform well in hot or oily environments. For that reason he settles on TPU filament, and gives it a test in a bath of 2-stroke fuel mix to see how well it resists degradation. It passes, as it does also when used with a carburetor, though we’d be curious to see the results of a long-term test. We’ve placed the video below the break, so reach your own conclusions.

Gaskets have featured here before, and if you’re interested then there are other machines which can be used to make them.

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Taking A Close Look At Parallel Plate Capacitors

Of course, we all know that capacitors are conceptually two conductors separated by a dielectric of some sort. But outside of air-variable capacitors you normally don’t see them looking like that. For example, a film capacitor has its plates rolled up in a coil with an insulating film in between. You can’t really see that unless you take them apart. But [Electronoobs] makes some giant capacitors using large plates and does a few experiments to demonstrate their characteristics. You can see his work in the video below.

The arrangement reminded us of a Leyden jar except there’s no physical motion. He also had some entertaining footage of electrolytic capacitors exploding when connected backwards. The reason, by the way, is that electrolytic capacitors have conductive goo in them. By putting a controlled current through them during manufacturing, a very thin insulating layer forms on one electrode. The thinner the layer, the higher the potential capacitance is. The downside is that putting current in the opposite way of the formation current causes catastrophic results, as you can see.

The value of a capacitor depends on the area, the spacing, and the type of dielectric between the plates. The video covers how each of those alters the capacitor value. Real capacitors also have undesirable characteristics like leakage and parasitic resistance or inductance.

It used to be that capacitance meters were exotic gear, but these days many meters have that capability. This would be a great set of experiments for a classroom or as the basis for a kid’s science project. For example, measuring different dielectric materials to determine which is the best for different purposes.

Granted, capacitors are pretty basic physics, but it is easy to get wrapped up in using them and not think about what’s going on inside. This video is a good introduction or a refresher, if you need one. It is easy enough to make your own variable capacitors or even special capacitors for high voltages.

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