The Electric Vehicles Of EMF Camp

June 25, 2018 by Jenny List 3 Comments

There is joy in the hearts of British and European hardware and software hackers and makers, for this is an EMF Camp year. Every couple of years, our community comes together for three summer days in a field somewhere, and thanks to a huge amount of work from its organizers and a ton of volunteers, enjoys an entertaining, stimulating, and engrossing hacker camp.

One of the features of a really good hacker camp are the electric vehicles. Not full-on electric cars, but personal camp transport. Because only the technically inept walk, right? From Hitchin’s Big Hak to TOG’s duck, with an assortment of motorized armchairs and beer crates thrown in, these allow the full creativity of the hardware community free rein through the medium of overdriven motors and cheap Chinese motor controllers.

This year at EMF Camp there will be an added dimension that should bring out a new wave of vehicles, there will be a Hacky Racers event. Novelty electric vehicles will compete for on-track glory, will parade around the camp, and will no doubt also sometimes release magic smoke. There is still plenty of time to enter, so if you’re going to EMF, get building!

We have an interest in these little electric vehicles, not least because there may well be a Hackaday-branded machine on the tarmac. We’d like to feature some of them over the weeks running up to the event, so if you are building one and have a write-up handy, please tell us about it in the comments. Charge your batteries, and we’ll see you there!

Header image: [Mark Mellors], with permission.

An Arduino Powered Tank Built To Pull Planes

June 19, 2018 by Tom Nardi 39 Comments

Surely our readers are well aware of all the downsides of owning an airplane. Certainly the cost of fuel is a big one. Birds are a problem, probably. That bill from the traveling propeller sharpener is a killer too…right? Alright fine, we admit it, nobody here at Hackaday owns an airplane. But probably neither do most of you; so don’t look so smug, pal.

But if you did own a plane, or at least work at a small airport, you’d know that moving the things around on the ground is kind of a hassle. Smaller planes can be pulled by hand, but once they get up to a certain size you’ll want some kind of vehicle to help out. [Anthony DiPilato] wanted a way to move around a roughly 5,200 pound Cessna 310, and decided that all the commercial options were too expensive. So he built his own Arduino powered tank to muscle the airplane around the tarmac (if site is down try Google cache), and his journey from idea to finished product is absolutely fascinating to see.

So the idea here is pretty simple. A little metal cart equipped with two beefy motors, an Arduino Mega, a pair of motor controllers, and a HC-08 Bluetooth module so you can control it from your phone. How hard could it be, right? Well, it turns out combining all those raw components into a little machine that’s strong enough to tow a full-scale aircraft takes some trial and error.

It took [Anthony] five iterations before he fine tuned the design to the point it was able to successfully drag the Cessna without crippling under the pressure. The early versions featured wheels, but eventually it was decided that a tracked vehicle would be required to get enough grip on the blacktop. Luckily for us, each failed design is shown along with a brief explanation about what went wrong. Admittedly it’s unlikely any of us will be recreating this particular project, but we always love to see when somebody goes through the trouble of explaining what went wrong. When you include that kind of information, somewhere, somehow, you’re saving another maker a bit of time and aggravation.

Hackers absolutely love machines with tank treads. From massive 3D printed designs to vaguely disturbing humanoid robots, there’s perhaps no sweeter form of locomotion in the hacker arsenal.

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Social Engineering By Railways

June 7, 2018 by Brian McEvoy 29 Comments

Where do you travel every day? Are there any subtle ploys to manipulate your behavior? Would you recognize them or are they just part of the location? Social engineering sometimes gets a bad rap (or is it rep?) in the mainstream, but the public-facing edge of that sword can keep order as it does in Japanese train stations. They employ a whirlwind of psychological methods to make the stations run like clockwork.

The scope of strategies ranges from the diabolical placement of speakers emitting high-frequency tones to discourage youthful loitering to the considerate installation of blue lights to deter suicides. Not every tactic is as enlightened as suicide prevention, sometimes, just changing the grating departure buzzer to a unique tune for each station goes a long way to relieving anxiety. Who wants to stand next to an anxious traveler who is just getting more and more sweaty? Listen below the break to hear what Tokyo subway tunes sound like.

Maybe you can spot some of these tricks where you live or something similar can ease your own commute. Perhaps the nearest subway has a piano for stairs or a 3D printing cyborg.

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Tesla Model 3 Battery Pack Teardown

June 4, 2018 by Tom Nardi 53 Comments

The Tesla Model 3 has been available for almost a year now, and hackers and tinkerers all over the world are eager to dig into Elon’s latest ride to see what makes it tick. But while it’s considerably cheaper than the Model S that came before it, the $35,000+ USD price tag on the new Tesla is still a bit too high to buy one just to take it apart. So for budget conscious grease monkeys, the only thing to do is wait until somebody with more money than you crashes one and then buy the wreckage cheaply.

Which is exactly what electric vehicle connoisseur [Jack Rickard] did. He bought the first wrecked Model 3 he could get his hands on, and proceeded to do a lengthy teardown on what’s arguably the heart and soul of the machine: its 75 kWh battery pack. Along the way he made some interesting discoveries, and gained some insight on to how Tesla has been able to drop the cost of the Model 3 so low compared to their previous vehicles.

On a Tesla, the battery pack is a large flat panel which takes up effectively the entire underside of the vehicle. To remove it, [Jack] and his assistant raise the wreck of the Model 3 up on a standard lift and then drop the battery down with a small lift table. Here the first differences are observed: while the Model S battery was made for rapid swapping (a feature apparently rarely utilized in practice), the battery in the Model 3 battery is obviously intended to be a permanent piece of the car; removing it required taking out a good portion of the interior.

With the battery out of the car and opened up, the biggest change for the Model 3 becomes apparent. The battery pack actually contains the charger, DC-DC converter, and battery management system in one integrated unit. Whereas on the Model S these components were installed in the vehicle itself, on the Model 3, most of the primary electronics are stored in this single module.

That greatly reduces the wiring and complexity of the car, and [Jack] mentions the only significant hardware left inside the Model 3 (beyond the motors) would be the user interface computer in the dashboard. When the communication protocol for this electronics module is reverse engineered, it may end up being exceptionally useful for not only electric vehicle conversions but things like off-grid energy storage.

A little over a year ago we featured a similar teardown for the battery back in the Tesla Model S, as well as the incredible project that built a working car from multiple wrecks.

[Thanks to DarksideDave for the tip.]

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[GreatScott] Tests His DIY Battery Pack On His E-Bike

May 28, 2018 by Steven Dufresne 19 Comments

[GreatScott] has now joined the ranks of Electric Bike users. Or has he? We previously covered how he made his own lithium-ion battery pack to see if doing so would be cheaper than buying a commercially made one. But while it powered his E-bike conversion kit on his benchtop, turning the motor while the wheel was mounted in a vice, that’s no substitution for a real-world test with him on a bike on the road.

Since then he’s designed and 3D printed an enclosure for his DIY battery pack and mounted it on his bike along with most of the rest of his E-bike kit. He couldn’t use the kit’s brake levers since his existing brake levers and gear-shift system share an enclosure. There also weren’t enough instructions in the kit for him to mount the pedal assistance system. But he had enough to do some road testing.

Based on a GPS tracker app on his phone, his top speed was 43 km/h (27 miles per hour). His DIY 5 Ah battery pack was half full after 5 km (3.1 miles) and he was able to ride 11.75 km (7.3 miles) on a single charge. So, success! The battery pack did the job and if he needs to go further then he can build a bigger pack with some idea of how it would improve his travel distance.

Sadly though, he had to remove it all from his bike since he lives in Germany and European rules state that for it to be considered an electric bike, it must be pedal assisted and the speed must the be progressively reduced as it reaches a cut-off speed of 25 km/h (15 miles per hour). In other words, his E-bike was more like a moped or small motorcycle. But it did offer him some good opportunities for hacking, and that’s often enough. Check out his final assembly and testing in the video below.

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Animated Bluetooth Bike Turn Signals

May 24, 2018 by Tom Nardi 40 Comments

Tired of risking his life every time he had to signal a turn using his hands while riding his bicycle in rainy Vancouver, [Simon Wong] decided he needed something a bit higher tech. But rather than buy something off the shelf, he decided to make it into his first serious Arduino project. Given the final results and the laundry list of features, we’d say he really knocked this one out of the park. If this is him getting started, we’re very keen to see where he goes from here.

So what makes these turn signals so special? Well for one, he wanted to make it so nobody would try to steal his setup. He wanted the main signal to be easily removable so he could take it inside, and the controls to be so well-integrated into the bike that they wouldn’t be obvious. In the end he managed to stuff a battery pack, Arduino Nano, and an HC-05 module inside the handlebars; with just a switch protruding from the very end to hint that everything wasn’t stock.

On the other side, a ATMEGA328P microcontroller along with another HC-05 drives two 8×8 LED matrices with MAX7219 controllers. Everything is powered by a 18650 lithium-ion battery with a 134N3P module to bring it up to 5 VDC. To make the device easily removable, as well as keep the elements out, all the hardware is enclosed in a commercial waterproof case. As a final touch, [Simon] added a Qi wireless charging receiver to the mix so he could just pull the signal off and drop it on a charging pad without needing to open it up.

It’s been some time since we’ve seen a bike turn signal build, so it’s nice to see one done with a bit more modern hardware. But the real question: will he be donning a lighted helmet for added safety?

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Spared No Expense: Cloning The Jurassic Park Explorer

May 22, 2018 by Tom Nardi 53 Comments

While you’d be hard pressed to find any serious figures on such things, we’d wager there’s never been a vehicle from a TV show or movie that has been duplicated by fans more than the Staff Jeeps from Jurassic Park. Which is no great surprise: not only do they look cool, but it’s a relatively easy build. A decent paint job and some stickers will turn a stock Wrangler into a “JP Jeep” that John Hammond himself would be proud of.

While no less iconic, there are far fewer DIY builds of the highly customized Ford Explorer “Tour Vehicles”. As a rather large stretch of the film takes place within them, the interiors were much more detailed and bears little resemblance to the stock Explorer. Building a truly screen accurate Jurassic Park Tour Vehicle was considered so difficult that nobody has pulled it off since the movie came out in 1993. That is until [Brock Afentul] of PropCulture decided to take on the challenge.

In an epic journey spanning five years, [Brock] has created what he believes is the most accurate Jurassic Park Tour Vehicle ever produced; and looking at the side by side shots he’s done comparing his Explorer to the ones from the movie, it’s hard to disagree. A massive amount of work went into the interior, leaving essentially nothing untouched. While previous builds have tried to modify the stock dashboard to look like the one from the movie, he built a completely new dash from MDF and foam and coated it in fiberglass. The center console featuring the large display was also faithfully reproduced from the movie, and runs screen accurate animations, maps, and tour information. The seats also had to be replaced, multiple times in fact, as he had a considerable amount of trouble getting somebody to upholster them to his standards.

But perhaps the most difficult component of all was the clear acrylic roof bubble. These were critical to filming the movie, as they not only let the viewer see down into the Tour Vehicles but also let the characters see out during the iconic tyrannosaurus attack. But because the roof bubble was created only for the movie and never existed as a real aftermarket product, it usually gets ignored in Tour Vehicle builds. It’s simply too difficult to produce for most people. The omission of the bubble was always considered a case of artistic license; in the same way nobody expects a replica DeLorean from Back to the Future to actually fly or travel through time.

But [Brock] wanted to take his Tour Vehicle all the way, so he partnered up with a local glass shop that let him rent time in their oven so he could heat up acrylic sheets. Once heated to the appropriate temperature, they could be removed and wrapped around a mold to make the bubble. The process took weeks to perfect, but in the end he and a few friends got the hang of it and were able to produce a gorgeous roof bubble that they fitted to the already very impressive Explorer.

While previous Jurassic Park Tour Vehicle replicas were unquestionably awesome, this build really does take it to the next level. Short of equipping the garage with a movie-accurate super computer, it’s hard to see how the bar can get any higher.