Designing A 360 Degree All Metal Hinge

Looking for a 360 degree hinge that had no slop was harder than [Mr. LeMieux] thought it would be. Add to the fact it had to be made completely out of metal with no plastic components — and basically fireproof. He was coming up blank.

You see, [Mr. LeMieux] is casting metal components, and needed a hinge to close two halves of a mold. When he couldn’t find anything commercially available, he decided to design his own. Using aluminum, he machined the two halves with an interlocking mechanism between the two. Essentially, it’s a 3-bar linkage, but if he stopped there, it would have too much slop. So he actually designed in two fixed gears that roll over each other — this ensures the hinge stays perfectly smooth throughout its entire range of movement — it’s actually quite ingenious.

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Teslaphoresis: Tesla Coil Causes Self-Assembly In Carbon Nanotubes

teslaphoresis_strings_1

This significant discovery in nanotechnology could also be the first practical use of a Tesla coil in modern times that goes beyond fun and education. A self-funded research team at Rice University has found that unordered heaps of carbon nanotubes will self-assemble into conductive wires when exposed to the electric field of a strong Tesla coil. The related paper by lead author and graduate student [Lindsey R. Bornhoeft], introduces the phenomenon as “Teslaphoresis”. Continue reading “Teslaphoresis: Tesla Coil Causes Self-Assembly In Carbon Nanotubes”

128 LEDs, 5 Buttons, IR Comm, And A Few Hours: What Could You Create?

When the second band had played its last encore, before the legendary DJ took the stage, a cadre of hardware hackers climbed three steps with a twinkle in their eyes and glowing electronics in their hands. I’m surprised and relieved that the nugget of excitement that first led me to twiddle a byte in a microcontroller is still alive, and this moment — this crossroads of hacker family — stirred that molten hot center of adventure in everyone.

The badge hacking demoscene is a welcoming one. No blinking pixel is too simple, and no half-implemented idea falls short of impressing everyone because they prove the creativity, effort, and courage of each who got up to share their creation. How could we ever get together as a community and not do this?

It was after midnight before we began the demoparty. I somehow managed to come to the Hackaday | Belgrade conference without a USB webcam to use as a top-down camera. I also didn’t line up someone to record with a camera until minutes before. Please forgive our technical difficulties — we first tried to use a laptop webcam to project to the bigscreen. When that failed, focusing on the badges because tough for our ad-hoc camera operator. This video is a hack, but I think it’s worth looking past its tech problems.

The crowd gathered as close to the stage as possible and there was electricity in the audience as the wiles of the day were explained. Join me after the break for a brief rundown of each demo, along with a timestamp to find it in the video.

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Measuring Parts Badly For Accurate Reverse Engineering

Previous headquarters of Useful Thing Inc.
Previous headquarters of Useful Thing Inc. They made the best widget you could buy in the 80s.

Like most hackers, I’ve run into a part that looks like it might do what I want, but the only documentation came from a company so thoroughly defunct their corporate office is now a nail salon and a Subway.

So, as any hacker who’s wandered through a discount store with a spare twenty, at one point I bought a Chinese caliper. Sure it measures wrong when the battery is low, the temperature has changed, if I’ve held it in my hand too long, the moon is out, etc. but it was only twenty dollars. Either way, how do I get accurate measurements out of it? Well, half-wizardry and telling yourself educated lies.

There are two golden rules to getting accurate measurements by telling lies. It may be obvious to some, but it took me quite a bit of suffering to arrive at them.

  1. Engineers are lazy. So lazy. Most things are going to be even numbers, common fractions, and if possible standard sizes. If sheets and screws come in 2 and 3mm then you bet you’re going to see a lot of 2mm and 3mm features. Also, even though the metric world is supposedly pure, you’re still going to see more 0.25 (1/4) mm measurements than you are .333333 (1/3) mm measurements. Because some small fractions are easier to think about than decimals.
  2. Your eyes lie. If it matters, measure it to be sure.

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Most Of What You Wish You Knew About Coils Of Wire But Were Afraid To Ask

If you are a novice electronic constructor, you will become familiar with common electronic components. Resistors, capacitors, transistors, diodes, LEDs, integrated circuits. These are the fodder for countless learning projects, and will light up the breadboards of many a Raspberry Pi or Arduino owner.

There is a glaring omission in that list, the inductor. True, it’s not a component with much application in simple analogue or logic circuits, and it’s also a bit more expensive than other passive components. But this omission creates a knowledge gap with respect to inductors, a tendency for their use to be thought of as something of a black art, and a trepidation surrounding their use in kits and projects.

We think this is a shame, so here follows an introduction to inductors for the inductor novice, an attempt to demystify them and encourage you to look at them afresh if you have always steered clear of them.

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Hoverboards Are Here – If You’re Crazy Enough To Try

A new video has been stirring questions on the internet this week. It shows a test of the Flyboard Air, a device that is somewhere between a Back to the Future Hoverboard and Green Goblin’s glider. The video depicts pilot [Frank Zapata] taking off, flying around, and landing an a platform not much larger than a milk crate. Plenty of folks are calling the video a fake. After a few back of the napkin calculations though, we’re coming out to say we think it’s real. Details are few and far between, so much of the information in this article is educated guessing based upon the video.

Here’s our hypothesis: Flyboard Air is a jet powered platform with little or no built-in intelligence. Balance, stability and control are all handled by the pilot. A hand controller simply provides throttle to adjust altitude, take off, and land.

jetfeetLet’s start with the jet powered part. During the video, [Frank] looks down at his board and the water below. Between his sneakers we can see two round openings – which look a lot like jet intakes. At the end of the video, [Frank] flies over the camera. stopping the action shows a split second where four exhaust holes are visible on the bottom of the board. These jets look quite a bit like model aircraft jet engines.

We don’t know exactly which engines [Frank] is using, but as an example, the Jet-Cat P 400 RX-G packs 88 lbs of thrust into a shell less than 6 inches in diameter, weighing less than 8 lbs. Four of those engines would provide 352 lbs of thrust. That’s plenty to lift [Frank], the board, and a few gallons of Jet-A strapped to his back.

Why no built-in intelligence? Even the smallest quadcopters have gyros, accellerometers, and PID loops keeping them upright. The problem boils down to the physics of jet engines. Active stability in a fixed pitch rotary blade system requires very fast throttle response. Quadcopters have this with their brushless motors. Turbines however, have throttle lag on the order of seconds. You can’t beat physics. Accelerating 3 or 4 pounds metal from 78,000 RPM (~70% throttle) to 98,000 RPM (~100 % throttle) takes time.

flyboard1Standing on a column of uncontrolled thrust would take quite a bit of skill on the part of the pilot. As it turns out, [Frank] is one of the world’s most experienced thrust riders. His previous invention, the Flyboard uses a personal watercraft to create a column of thrust which the rider stands on. These boards have become tremendously popular at vacation spots in the last few years. There are plenty of videos on [Frank’s] YouTube channel showing the amount of control a skilled ride has over the board. Loops, spins, and other aerobatics look easy.

With that much skill under his belt, [Frank] would have no problem keeping balanced on four jet engines.

Such a skilled rider means that control wouldn’t really be needed on the board. We’re betting that the only electronics are the remote throttle control and the Engine Control Computers (ECU) needed to keep the jets running and synchronized. The two electric ducted fans on the sides of the Flyboard Air appear to be running all the time, only shutting down when [Frank] lands the board.

One final thought – taking off and landing a jet vertically is difficult. Ground effects destabilize the craft. Engines can suck in their own exhaust, stalling them. These are problems faced by the harrier jump jet and the joint strike fighter. [Frank’s ] solution is not never get too close to the ground. If you watch closely, he takes off and lands from a perforated metal platform mounted off the back of a van. The metal doesn’t reflect enough thrust to cause the Flyboard to become unstable or stall.

So is the video real? We think so. This is an amazing achievement for [Frank Zapata]. Is it practical or safe? Heck no! Nor is it cheap – those engines cost €8,845.00 each.  That said, we’d love a chance to ride the Flyboard Air – after a few hours of training on the original Flyboard of course.

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All Quiet On The West Virginia Border: The National Radio Quiet Zone

Ask a hundred people why they like to escape to the forest and you’ll probably get a hundred reasons, but chances are good that more than a few will say they seek the peace and quiet of the woods. And while the woods can be a raucous place between the wildlife and the human visitors, it is indeed a world apart from a busy city street, at least in the audio frequencies. But on the EM spectrum, most forests are nearly as noisy as your average cube farm, and that turns out to be a huge problem if you happen to run exquisitely sensitive radio receivers.  That’s the reason for the National Radio Quiet Zone, a 13,000 square mile electromagnetic safe-zone in the woods west of Washington DC. Who’s listening to what and why are a fascinating part of this story, as are the steps that are taken to keep this area as electromagnetically quiet as possible.

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