Fail Of The Week: Taking Apart A Tesla Battery

September 7, 2019 by Bryan Cockfield 86 Comments

It takes a lot of energy to push a car-sized object a few hundred miles. Either a few gallons of gasoline or several thousand lithium batteries will get the job done. That’s certainly a lot of batteries, and a lot more potential to be unlocked for their use than hurling chunks of metal around on wheels. If you have an idea for how to better use those batteries for something else, that’s certainly an option, although it’s not always quite as easy as it seems.

In this video, [Kerry] at [EVEngineering] has acquired a Tesla Model 3 battery pack and begins to take it apart. Unlike other Tesla batteries, and even more unlike Leaf or Prius packs, the Model 3 battery is extremely difficult to work with. As a manufacturing cost savings measure, it seems that Tesla found out that gluing the individual cells together would be less expensive compared to other methods where the cells are more modular and serviceable. That means that to remove the individual cells without damaging them, several layers of glue and plastic have to be removed before you can start hammering the cells out with a PEX wedge and a hammer. This method tends to be extremely time consuming.

If you just happen to have a Model 3 battery lying around, [Kerry] notes that it is possible to reuse the cells if you have the time, but doesn’t recommend it unless you really need the energy density found in these 21700 cells. Apparently they are not easy to find outside of Model 3 packs, and either way, it seems as though using a battery from a Nissan Leaf might be a whole lot easier anyway.

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Who Needs Four Wheels When You’ve Got A Gyro?

September 6, 2019 by Lewin Day 15 Comments

Your garden variety car generally comes with four wheels, plus a spare in the boot. It’s a number landed upon after much consideration, with few vehicles deviating from the norm. That doesn’t mean there aren’t other possibilities however, and [RCLifeOn] decided to experiment in just such a manner.

The result is a gyro-stabilized two-wheeled RC car, or as we might have put it, a motorcycle of sorts. A brushless motor drives the rear wheel, while steering up front is handled by a servo controlling the front wheel. A large spinning disc acts as a gyro in the center of the vehicle, and it’s all packaged in a simple 3D printed frame.

Results are impressive, with the gyro making a demonstrable difference to the vehicle’s performance. While it can be driven without the gyro enabled, it requires continual steering corrections to stay upright. With the gyro spun up, it rides much more like a bicycle, with few stability issues.

It’s a fun project, and a great way to learn about gyroscopic stability. Of course, there are great primers on the topic, too. Video after the break. Continue reading “Who Needs Four Wheels When You’ve Got A Gyro?” →

Are Hydrogen Cars Still Happening?

September 4, 2019 by Lewin Day 318 Comments

Potentially coming to a service station near you.

In every comment section, there’s always one. No matter the electric vehicle, no matter how far the technology has come, there’s always one.

“Only 500 miles of range? Electric cars are useless! Me, and everyone I know, drives 502 miles every day at a minimum! Having to spend more than 3 minutes to recharge is completely offensive to my entire way of life. Simply not practical, and never will be.”

Yes, it’s true, electric cars do have limited range and can take a little longer to recharge than a petrol or diesel powered vehicle. Improvements continue at a rapid pace, but it’s not enough for some.

To these diehards, hydrogen fuel cell vehicles may have some attractive benefits. By passing hydrogen gas through a proton-exchange membrane, electricity can be generated cleanly with only water as a byproduct. The technology holds a lot of promise for powering vehicles, but thus far hasn’t quite entered our daily lives yet. So what is the deal with hydrogen as a transport fuel, and when can we expect to see them in numbers on the ground?

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Double 3: Your Instant Physical Presence Anywhere, No Matter Where You Are

August 31, 2019 by Maya Posch 18 Comments

Telepresence is one of those futuristic buzzwords that’s popped up a few times over the decades; promising the ability to attend a meeting in New York City and another in Tokyo an hour later, all without having to leave the comfort of your home or office. This is the premise of Double Robotics’ Double 3, its most recent entry in this market segment, as the commercial counterpoint to more DIY offerings.

More than just a glorified tablet screen.

Looking like a tablet perched on top of a Segway, the built-in dual 13 megapixel cameras allow the controller to get a good look at their surroundings, while the 6 beamforming microphones should theoretically allow one to pick up any conversation in a meeting or on the work floor.

Battery life is limited to 4 hours, and it takes 2 hours to recharge the built-in battery. Fortunately one can just hop over to another, freshly charged Double 3 if the battery runs out. Assuming the $3,999 price tag doesn’t get in the way of building up a fleet of them, anyway.

Probably the most interesting aspect of the product is its self-driving feature, which has resulted in a whole range of sensors and cameras (Intel RealSense D430 stereo vision depth sensors) being installed. To handle the processing of this sensor data, the system is equipped with an NVidia Jetson TX2 ARM board, running Ubuntu Linux, which also renders the mixed-reality UI for the user with way points and other information.

Currently Double Robotics accepts sign-ups for the private beta of the Double 3 API, which would give developers access to the sensor data and various autonomous features of Double 3’s hardware. Co-founder of Double Robotics, [Marc DeVidts] stated to Hackaday that he is looking forward to seeing what people can build with it. Hopefully this time people will not simply take the thing for a joyride, like what happened with a predecessor of the Double 3.

Building A Robot Rover For Those Tough Indoor Missions

August 30, 2019 by Maya Posch 4 Comments

Making an outdoor rover is easy stuff, with lots of folk having them doing their roving activities on beaches and alien worlds. Clearly the new frontier is indoor environments, a frontier which is helpfully being conquered by [Andreas Hoelldorfer]’s Mantis Rover.

OK, we’re kidding. This project started out life as a base for [Andreas]’s exquisite 3D printable robotic arm, but it’s even capable of carrying people around, as the embedded video after the break makes abundantly clear. The most eye-catching feature of the Mantis Rover are its Mecanum wheels, which allow it to move in any direction, and is perfect for those tight spots where getting stuck would be really awkward.

The Mecanum wheels are 3D printed, making the motors and the associated controllers the more complicated part of this package. Plans for the wheels involve casting some kind of rubber, to make the wheels more gentle on the floors it has to drive on. The electronics include TMC 5160 motor drivers and an STM32F407VET6 MCU, as well as a W5500-equipped custom ‘Robot Shield’.

It seems that there are still a lot of tweaks underway to make the project even more interesting. Maybe it’s the perfect foundation for your next indoor roving sessions at the office or local hackerspace?

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The Trials And Tribulations Of E-Bike Drivetrain Design

August 26, 2019 by Lewin Day 32 Comments

[Tom Stanton] is well-regarded in the maker community, and has put much effort in over the years on a variety of electric vehicle builds. In the process of upgrading his e-bike last year, he ran into some issues with the main drive pulley. Rather than rely on guesswork, he threw engineering at the problem.

Static weight tests were carried out in combination with FEA to determine the root cause of the problem.

The problem concerned the mounting bolts on the pulley’s hub, which would pull out under high torque. [Tom’s] initial finite element simulations had suggested the design was sound, but reality was proving otherwise. After further analysis and testing, [Tom] determined that his analysis hadn’t properly simulated the bolt pull-out condition. With this corrected in the software, it was readily apparent that there simply wasn’t enough material around the bolt holes to hold the torque load.

With the simulation now more closely agreeing with reality, [Tom] was able to correct the design. New parts were created with a strengthened mounting section, and the pulley was successfully able to deal with the loads in service.

It’s a great example of using engineering simulation tools to solve a problem quickly, rather than simply guessing and hoping things will hold up. We’ve seen [Tom]’s work before, too — like this fun backyard trebuchet build. Video after the break.

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Electric Dump Truck Produces More Energy Than It Uses

August 22, 2019 by Bryan Cockfield 77 Comments

Electric vehicles are everywhere now. It’s more than just Leafs, Teslas, and a wide variety of electric bikes. It’s also trains, busses, and in this case, gigantic dump trucks. This truck in particular is being put to work at a mine in Switzerland, and as a consequence of having an electric drivetrain is actually able to produce more power than it consumes. (Google Translate from Portugese)

This isn’t some impossible perpetual motion machine, either. The dump truck drives up a mountain with no load, and carries double the weight back down the mountain after getting loaded up with lime and marl to deliver to a cement plant. Since electric vehicles can recover energy through regenerative braking, rather than wasting that energy as heat in a traditional braking system, the extra weight on the way down actually delivers more energy to the batteries than the truck used on the way up the mountain.

The article claims that this is the largest electric vehicle in the world at 110 tons, and although we were not able to find anything larger except the occasional electric train, this is still an impressive feat of engineering that shows that electric vehicles have a lot more utility than novelties or simple passenger vehicles.

Thanks to [Frisco] for the tip!