Project Egress: The Hinges

July 18, 2019 by Dan Maloney 34 Comments

A door’s hinges are arguably its most important pieces. After all, a door without hinges is just, well, a wall. Or a bulkhead, if we’re talking about a hingeless hatch on a spacecraft.

And so the assignment for creating hinges for Progress Egress, the celebration of the 50th anniversary of the Apollo 11 landing by creating a replica of the command module hatch, went to [Jimmy DiResta]. The hinges were complex linkages that were designed to not only handle the 225 pound (102 kg) hatch on the launch pad, but to allow extended extravehicular activity (EVA) while en route to the Moon. [Jimmy], a multimedia maker, is just as likely to turn metal as he is to work in wood, and his hinges are a study of 1960s aerospace engineering rendered in ipe, and extremely hard and dense tropical hardwood, and brass.

[Jimmy]’s build started with a full-size 3D-printed model of the hinge, a move that paid off as the prints acted both as templates for machining the wood components and as test jigs to make sure everything would articulate properly. Sheet brass was bent and soldered into the hinge brackets, while brass rod stock was turned on the lathe to simulate the hydraulic cylinder hinge stays of the original. The dark ipe and the brass work really well together, and should go nicely with [Fran Blanche]’s walnut and brass latch on the assembled hatch.

With [Adam Savage]’s final assembly of all the parts scheduled for Thursday the 18th, we’re down to the wire on this celebration of both Apollo and the maker movement that was at least in part born from it.

Note: the assembly started at 11:00 Eastern time, and there’s a live stream at https://airandspace.si.edu/events/project-egress-build.

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Hardware Notifications For ISS Flybys

July 16, 2019 by Bryan Cockfield 3 Comments

Since Sputnik launched in the 1950s, its been possible to look outside at night and spot artificial satellites orbiting with the naked eye. While Sputnik isn’t up there anymore, a larger, more modern satellite is readily located: the International Space Station. In fact, NASA has a program which will alert anyone who signs up when the ISS is about to fly overhead. A better alert, though, is this ISS notifier which is a dedicated piece of hardware that guarantees you won’t miss the next flyby.

This notifier is built around the Tokymaker, a platform aimed at making electronics projects almost painfully easy to learn. Connections to various modules can be made without soldering, and programming is done via a graphical interface reminiscent of Scratch. Using these tools, [jaime_lc98] designed a tool which flips up a tiny paper astronaut whenever the ISS is nearby. The software side takes advantage of IFTTT to easily and reliably control the servo on the Tokymaker.

The project pages goes into detail about how to set up IFTTT and also how to use the block-style language to program the Tokymaker. It’s pretty straightforward to get it up and running, relatively inexpensive, and looks like a great way to get the miniature hackers in your life excited about space. If they happen to learn a little something in the proces, well, we won’t tell them if you won’t. It might also be a good stepping stone on the way to other ISS-related hacks.

Project Egress: A Bracket And A Bell Crank For The Latches

July 15, 2019 by Dan Maloney 29 Comments

Put yourself in [This Old Tony]’s shoes: you get an email out of the blue asking you to take part in making a replica of a 50-year-old spacecraft. Would you believe it? He didn’t, at least not at first, but in the end it proved to be true enough that he made these two assemblies for Project Egress in his own unique style.

If you haven’t heard of Project Egress, check out our coverage of the initial announcement. The idea is to build a replica of the crew hatch from the Apollo 11 Command Module Columbia, as part of the 50th anniversary of the Apollo 11 landing next week. [Adam Savage] at Tested has enlisted 44 hackers and makers to help, spreading the work out among the group and letting everyone work in whatever materials and with whatever methods they feel like. [Old Tony], perhaps unsurprisingly, chose mainly Apollo-era dehydrated space-grade aluminum, machined using a combination of manual and CNC machining. We really like the finish he chose – a combination of sandblasting and manual distressing to give it a mission-worn look.

As for exactly what the parts themselves are, the best [Old Tony] could come up with to call them is a bracket and a bell crank. From the original hatch drawings, it looks like there were two bell cranks, which will transmit force around the hatch to the latches that [Fran Blanche], [Joel] and [Bob], and no doubt others have contributed to the build.

We’re eagerly anticipating the final assembly, to be executed by [Adam] live at the Smithsonian’s National Air and Space Museum on July 18. Project Egress is as much a celebration of the maker movement as it is a commemoration of Apollo, and we’re pleased that people will get a chance to see the fruits of the labors of all these hackers in so public a forum.

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New Space Abort Systems Go Back To The Future

July 15, 2019 by Tom Nardi 26 Comments

Throughout the history of America’s human spaceflight program, there’s been an alternating pattern in regards to abort systems. From Alan Shepard’s first flight in 1961 on, every Mercury capsule was equipped with a Launch Escape System (LES) tower that could pull the spacecraft away from a malfunctioning rocket. But by the first operational flight of the Gemini program in 1965, the LES tower had been deleted in favor of ejection seats. Just three years later, the LES tower returned for the first manned flight of the Apollo program.

With the Space Shuttle, things got more complicated. There was no safe way to separate the Orbiter from the rest of the stack, so when Columbia made its first test flight in 1981, NASA returned again to ejection seats, this time pulled from an SR-71 Blackbird. But once flight tests were complete, the ejector seats were removed; leaving Columbia and all subsequent Orbiters without any form of LES. At the time, NASA believed the Space Shuttle was so reliable that there was no need for an emergency escape system.

It took the loss of Challenger and her crew in 1986 to prove NASA had made a grave error in judgment, but by then, it was too late. Changes were made to the Shuttle in the wake of the accident investigation, but escape during powered flight was still impossible. While a LES would not have saved the crew of Columbia in 2003, another seven lives lost aboard the fundamentally flawed Orbiter played a large part in President George W. Bush’s decision to begin winding down the Shuttle program.

In the post-Shuttle era, NASA has made it clear that maintaining abort capability from liftoff to orbital insertion is a critical requirement. Their own Orion spacecraft has this ability, and they demand the same from commercial partners such as SpaceX and Boeing. But while all three vehicles are absolutely bristling with high-tech wizardry, their abort systems are not far removed from what we were using in the 1960’s.

Let’s take a look at the Launch Escape Systems for America’s next three capsules, and see where historical experience helped guide the design of these state-of-the-art spacecraft.

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Project Egress: Two Ways To Latch The Hatch

July 13, 2019 by Dan Maloney 11 Comments

With July slipping away and the deadline approaching, the Project Egress builds are pouring in now. And we’re starting to see more diversity in the choice of materials and methods for the parts being made, like these two latches made with very different methods by two different makers.

For the uninitiated, Project Egress is a celebration of both the 50th anniversary of Apollo 11 and the rise of the maker movement. Spearheaded by [Adam Savage], the idea is to engage 44 prominent makers to build individual parts from the Unified Crew Hatch (UCH) from the Apollo Command Module. The parts will be used to create a replica of this incredibly complex artifact, which will be assembled by [Adam] before a live audience at the National Air and Space Museum next week.

Both [Joel] from the “3D Printing Nerd” channel and [Bill Doran] from “Punished Props Academy” got the nod for one of the 15 latches needed, and both played to their respective strengths. [Joel]’s latch was executed in PLA on a Prusa I3 printer. [Bill] went a different route for his latch. He used a Form 2 SLA printer to print the parts, but used them only to make silicone molds. He then cast the parts from urethane resin, which should prove much stronger than the original SLA prints. We suspect the ability to quickly cast more latches could prove handy if any of the other latch makers should fail to deliver.

The latches [Joel] and [Bill] made joins the other parts, like the wooden latch being made by [Fran Blanche] and the hatch handle [Paul] cast in aluminum. We’re looking forward to more part builds, as well as the final assembly.

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Ask Hackaday: What Are Your Apollo Memories?

July 10, 2019 by Dan Maloney 62 Comments

This month will mark the 50th anniversary of the Apollo 11 mission that brought to a successful conclusion the challenge laid down by President Kennedy only eight years earlier. Three men went to the Moon, two walked on it, and they all came back safely, in a dramatic eight-day display of engineering and scientific prowess that was televised live to the world.

If you’ve made more than 50 trips around the sun, chances are good that you have some kind of memories of the first Moon landing. An anniversary like this is a good time to take stock of those memories, especially for something like Apollo, which very likely struck a chord in many of those that witnessed it and launched them on careers in science and engineering. We suspect that a fair number of Hackaday readers are in that group, and so we want to ask you: What are your memories of Apollo?

A Real American Hero

My memory of the Moon landing is admittedly vague. I had just turned five the month before, hadn’t even started kindergarten yet, but I had already caught the space bug in a big way. I lived and breathed the space program, and I knew everything about the Mercury missions that were over by the time I was born, and the Gemini missions that had just wrapped up. Apollo was incredibly exciting to me, and I was pumped to witness the landing in the way that only a five-year-old can be.
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Space Age Bitcoin Mining On An Apollo AGC

July 9, 2019 by Dan Maloney 6 Comments

Imagine you’ve got an Apollo Guidance Computer, the machine that took men to the Moon 50 years ago. You’ve spent ages restoring it, and now it’s the only working AGC on the planet. It’s not as though you’re going to fly to the Moon with it, so what do you do with it? Easy – turn it into a perfectly awful Bitcoin mining rig.

The AGC that [Ken Shirriff] and others have been restoring barely resembles a modern computer. The AGC could only do about 40,000 operations per second, but raw speed was far less important than overall reliability and the abundant IO needed to run a crewed spacecraft. It was a spectacular success on the Apollo missions, but [Ken] wanted to know if turning it into a Bitcoin mining rig was possible.

[Ken] gives a great overview of how Bitcoin mining works, with one of the best explanations of the hashing algorithm we’ve seen. Getting that to run on the AGC was no mean feat, especially with limits imposed by the memory addressing scheme and the lack of machine instructions for manipulating words. He eventually got it working, though, clocking in at a screaming 10.3 seconds per Bitcoin hash. [Ken] estimates that the first coin will be successfully mined in a mere 400 zettaseconds, which is about a billion times older than the universe. With about 13 quadrillion years to the first ka-ching, you have plenty of time to watch a block mined in the video below; alas, it was an old block, so no coins were awarded to compensate the team for their efforts.

This isn’t the first time [Ken] has implemented a useless Bitcoin mine. The Xerox Alto mine was actually fast compared to the AGC, but it sure beats the IBM mainframe and punchcards.

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