Prepping For Power Outages

December 19, 2017 by Jenny List 268 Comments

When the mains power goes, we are abruptly brought face-to-face with how many of the devices and services we take for granted rely upon it. Telephones for instance, where once they were attached to the wall by a cable, now they are a cordless device with a mains-powered base station. Your cellphone can fill that gap, but a modern smartphone with a battery life of under a day is hardly a reliable long-term solution. Meanwhile modern heating systems may still burn gas or fuel oil, but rely on an electric pump for circulation. Your kitchen is full of electrically-powered white goods, your food is preserved by an electric refrigerator, even your gas cooker if you have one will probably expect a mains supply.

When the power goes out we might say that we instantaneously travel back a couple of centuries, but the reality is that our ancestors in 1817 wouldn’t have been in the same mess we are, they had appropriate solutions to surviving a wickedly cold winter when electricity was still something of a gleam in [Michael Faraday]’s eye. In short, they were prepared in a way most of us are not. That’s a shame, so let’s take a closer look sensible modern preparedness.

Continue reading “Prepping For Power Outages” →

3D Printing The Final Frontier

December 18, 2017 by Tom Nardi 29 Comments

While down here there’s room for debate about the suitability of 3D printing for anything more serious than rapid prototyping, few would say the same once you’ve slipped the surly bonds of Earth. With 3D printing, astronauts would have the ability to produce objects and tools on-demand from a supply of inert raw building materials. Instead of trying to pack every conceivable spare part for a mission to Mars, replacements (assuming a little forward thinking on the part of the spacecraft designers) can be made to order out of the stock of raw plastic or metal kept on-board. The implications of such technology for deep space travel or off-world settlement simply cannot be overstated.

In the more immediate future, 3D printing can be used to rapidly develop and deploy unmanned spacecraft. Tiny satellites (referred to as CubeSats) could be printed, assembled, and deployed by astronauts already in orbit. Innovations such as these could allow science missions to be planned and executed in months instead of years, and at a vastly reduced cost.

Continue reading “3D Printing The Final Frontier” →

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.

Continue reading “Machined Lightsaber Pen For A More Civilized Age” →

DIY Cable Chain Looks Great, Stays Cheap

December 17, 2017 by Tom Nardi 50 Comments

If you’ve built a 3D printer, CNC, laser cutter, or basically any piece of electrical equipment that moves around, then you’ve run into the problem of securing the bundle of wires that such machines always require. The easy way out is to zip tie them all up into a tight harness or put them in commercially available wraps or sleeves, but these don’t really impart any mechanical strength on the wires. With repetitive motion it’s not unheard of to break a conductor or two, causing intermittent failures and generally leading to a painful diagnostic session trying to isolate the broken wire.

An alternative are what are generally referred to as “cable chains”. These are rigid enclosures for your wiring that not only keep things tidy, but give the wires the mechanical support necessary to prevent fatigue. Unfortunately, they are often many times more expensive than a simple wire wrap or pack of zip ties. But [Brad Parcels] has written into our tip line to share with us a sort of hybrid approach to wire management that has many of the same advantages as a traditional cable chain, but at a greatly reduced cost.

The key to the design is using the metallic tape from a cheap tape measure to give the bundle of wires some mechanical strength. As anyone who’s ever played around with a tape measure knows, if you bend the tape over into a U shape it will hold the bend even if you extend and retract it. Thanks to this principle, [Brad] realized that all he need to do was add some wire sleeves and he would have a cheap and effective way to keep his wiring neat and sag-free.

[Brad] punches holes in the tape to secure it to his 3D printed mounting arms, but really any method of securing the tape to the frame of your machine will work just as well. He then slides a cable sleeve over the tape itself to protect from any possibility of the edge of the tape nicking a wire, and then finally a larger wire sleeve over the entire assembly.

After running the wires between the two sleeves, heatshrink can be used on the ends to neatly close everything up. Just make sure you remember all your wires before you seal it, [Brad] learned that one the hard way. But overall, he reports this DIY cable chain arrangement has been working wonderfully in his machine, providing smooth and silent movement for only a few bucks.

Cable management for projects that move is one of those things that doesn’t always get the attention it deserves. Not only can it keep your project looking professional, but it just might save you some time down the road by preventing failures.

Hardware Heroes: Isambard Kingdom Brunel

December 15, 2017 by Jenny List 45 Comments

There are some notable figures in history that you know of for just one single thing. They may have achieved much in their lifetimes or they may have only been famous for Andy Warhol’s fifteen minutes, but through the lens of time we only know them for that single achievement. Then on the other hand there are those historic figures for whom there is such a choice of their achievements that have stood the test of time, that it is difficult to characterize them by a single one.

[Isambard Kingdom Brunel], in front of the launching chains for the Great Eastern. [Public domain] — Isambard Kingdom Brunel, in front of the launching chains for the *Great Eastern*. [Public domain]

Such is the case of Isambard Kingdom Brunel, the subject of today’s Hardware Heroes piece. Do we remember him for his involvement in the first successful tunnel to pass beneath a river, as a builder of some of the most impressive bridges on the 19th century, the innovator in all aspects of rail engineering, the man behind the first screw-driven ocean-going iron ship, or do we remember him as all of those and more?

It is possible that if you are not British, or in particular you are not from the West of England, this is the first you’ve heard of Brunel. In which case he is best described as a towering figure of many aspects of engineering over the middle years of the 19th century. His influence extended from civil engineering through the then-emerging rail industry, to shipbuilding and more, and his legacy lives on today in that many of his works are still with us.

Engineering: The Family Trade

Brunel’s father, Marc Brunel, was an engineer and refugee from the French Revolution who found success in providing the British Navy with a mass-production system for wooden pulley blocks as used in the rigging of sailing ships. He enters this story for his grand project, the world’s first tunnel to be dug under a navigable river, beneath London’s River Thames from Rotherhithe to Wapping, and for his patented tunneling shield which made it possible to be dug.

Continue reading “Hardware Heroes: Isambard Kingdom Brunel” →

The Zombie Rises Again: Drone Registration Is Back

December 14, 2017 by Jenny List 69 Comments

It’s a trope of horror movies that demonic foes always return. No sooner has the bad guy been dissolved in a withering hail of holy water in the denoeument of the first movie, than some foolish child in a white dress at the start of the next is queuing up to re-animate it with a careless drop of blood or something. If parents in later installments of popular movie franchises would only keep an eye on their darn kids, it would save everybody a whole lot of time!

The relevant passage can be found in section 1092(d) of the National Defense Authorization Act, on page 329 of the mammoth PDF containing the full text, and reads as follows:

(d) RESTORATION OF RULES FOR REGISTRATION AND MARKING OF UNMANNED AIRCRAFT
.—The rules adopted by the Administrator
of the Federal Aviation Administration in the matter of registration
and marking requirements for small unmanned aircraft (FAA-2015-
7396; published on December 16, 2015) that were vacated by the
United States Court of Appeals for the District of Columbia Circuit
in Taylor v. Huerta (No. 15-1495; decided on May 19, 2017) shall
be restored to effect on the date of enactment of this Act.

This appears to reverse the earlier decision of the court, but does not specify whether there has been any modification to the requirements to prevent their being struck down once more by the same angle of attack. In particular, it doesn’t change any of the language in the FAA Modernization Act of 2012, which specifically prevents the Agency from regulating hobby model aircraft, and was the basis of Taylor v. Huerta. Maybe they are just hoping that hobby flyers get fatigued?

We took a look at the registration system before it was struck down, and found its rules to be unusually simple to understand when compared to other aviation rulings, even if it seemed to have little basis in empirical evidence. It bears a resemblance to similar measures in other parts of the world, with its 250 g weight limit for unregistered machines. It will be interesting both from a legal standpoint to see whether any fresh challenges to this zombie law emerge in the courts, and from a technical standpoint to see what advances emerge from Shenzhen as the manufacturers pour all their expertise into a 250 g class of aircraft.

Thanks [ArduinoEnigma] for the tip.

Truly Terrible Dimensioned Drawings

December 14, 2017 by Brian Benchoff 147 Comments

I’m in the planning stages of a side project for Hackaday right now. It’s nothing too impressive, but this is a project that will involve a lot of electromechanical parts. This project is going to need a lot of panel mount 1/8″ jacks and sockets, vertical mount DIN 5 connectors, pots, switches, and other carefully crafted bits of metal. Mouser and Digikey are great for nearly every other type of electrical component, but when it comes to these sorts of electromechanical components, your best move is usually to look at AliExpress or DealExtreme, finding something close to what you need, and buying a few hundred. Is this the best move for a manufacturable product? No, but we’re only building a few hundred of these things.

I have been browsing my usual Internet haunts in the search for the right bits of stamped brass and injection molded plastic for this project, and have come to a remarkable conclusion. Engineers, apparently, have no idea how to dimension drawings. Drafting has been a core competency for engineers from the dawn of time until AutoCAD was invented, and now we’re finally reaping the reward: It’s now rare to find a usable dimensioned drawing on the Internet.

This post is going to be half rant, half explanation of what is wrong with a few of the dimensioned drawings I’ve found recently. Consider this an example of what not to do. There is no reason for the state of engineering drawing to be this bad.

Continue reading “Truly Terrible Dimensioned Drawings” →