A Solar-Powered Box Of Sensors To Last 100 Years

June 25, 2019 by Tom Nardi 58 Comments

It’s a simple goal: build a waterproof box full of environmental sensors that can run continuously for the next century. OK, so maybe it’s not exactly “simple”. But whatever you want to call this epic quest to study and record the planet we call home, [sciencedude1990] has decided to make his mission part of the 2019 Hackaday Prize.

The end goal might be pretty lofty, but we think you’ll agree that the implementation keeps the complexity down to a minimum. Which is important if these solar-powered sensor nodes are to have any chance of going the distance. A number of design decisions have been made with longevity in mind, such as replacing lithium ion batteries that are only good for a few hundred recharge cycles with supercapacitors which should add a handful of zeros to that number.

At the most basic level, each node in the system consists of photovoltaic panels, the supercapacitors, and a “motherboard” based on the ATmega256RFR2. This single-chip solution provides not only an AVR microcontroller with ample processing power for the task at hand, but an integrated 2.4 GHz radio for uploading data to a local base station. [sciencedude1990] has added a LSM303 accelerometer and magnetometer to the board, but the real functionality comes from external “accessory” boards.

Along the side of the main board there’s a row of ports for external sensors, each connected to the ATmega through a UART multiplexer. To help control energy consumption, each external sensor has its own dedicated load switch; the firmware doesn’t power up the external sensors until they’re needed, and even then, only if there’s enough power in the supercapacitors to do so safely. Right now [sciencedude1990] only has a GPS module designed to plug into the main board, but we’re very interested in seeing what else he (and perhaps even the community) comes up with.

A Better Motor For Chickenwalkers

June 24, 2019 by Brian Benchoff 27 Comments

The last decade or so has seen remarkable advances in motor technology for robotics and hobby applications. We’re no longer stuck with crappy brushed motors, and now we have fancy (and cheap!) stepper motors, brushless motors for drones, and servo motors. This has led to some incredible achievements; drones are only barely possible with brushed motors, and you can’t build a robot without encoders.

For his entry into the Hackaday Prize, [Gabrael Levine] is taking on one of the hardest robotics challenges around: the bipedal robot. It’s a chickenwalker, or an AT-ST; either way, you need a lot of power in a very small space, and that’s where the OpenTorque Actuator comes in. It’s a quasi-direct-drive motor that was originally pioneered by the MIT Biomimetics Lab.

The key feature of the OpenTorque Actuator is using a big brushless motor, a rotation encoder, and a small, 8:1 planetary gear set. This allows the motor to be backdrivable, capable of force-sensing and open-loop control, and because this actuator is 3D printed, it’s really cheap to produce.

But a motor without a chassis is nothing, and that’s where the Blackbird Bipedal Robot comes in. In keeping with best practices of robotic design, the kinematics are first being tested in simulation, with the mechanical build happening in parallel. That means there’s some great videos of this chickenwalker strutting around (available below), and so far, everything looks great. This bipedal robot can turn, walk, yaw, and work is continuing on the efforts to get this bird-legged bot to stand still.

Bunnie Huang Talks Manufacturing And Component Choices During Hackaday Prize Mentoring Session

June 21, 2019 by Jenny List 4 Comments

Andrew “Bunnie” Huang’s mentor session for the Hackaday Prize shows off the kind of experience and knowledge hard to come by unless you have been through the hardware development gauntlet countless times. These master-classes match up experts in product development with Prize entrants working to turn their projects into products. We’ve been recording them so that all may benefit from the advice and guidance shared in each session.

The appealing little FunKey pocket gaming platform.

Bunnie is someone who is already familiar to most Hackaday readers. His notoriety in our community began nearly two decades ago with his work reverse engineering the original Microsoft X-box, and he quickly went on to design (and hack) the Chumby Internet appliance, he created the Novena open-source laptop, and through his writing and teaching, he provides insight into sourcing electronic manufacture in Shenzhen. He’s the mentor you want to have in your corner for a Hackaday Prize entry, and that’s just what a lucky group had in the video we’ve placed below the break.

While this session with Bunnie is in the bag it’s worth reminding you all that we are still running mentor sessions for Hackaday Prize entrants, so sign up your entry for a chance to get some great feedback about your project.

The first team to meet with Bunnie are FunKey, whose keychain Nintendo-like handheld gaming platform was inspired by a Sprite_tm project featuring a converted novelty toy. The FunKey team have produced a really well-thought-out design that is ready to be a product, but like so many of us who have reached that point they face the impossible hurdle of turning it into a product. Their session focuses on advice for finding a manufacturing partner and scaling up to production.

A prototype HotorNot Coffee Stirrer, showing their problem of having to maintain food-safe components.

HotorNot Coffee Stirrer is trying to overcome a problem unique to their food-related project. A hot drink sensor that has to go in the drink itself needs to be food safe, as well as easy enough to clean between uses. A variety of components are discussed including a thermopile on a chip that has the advantage of not requiring contact with the liquid, but sometimes the simplest ideas can be the most effective as Bunnie reminds us that a cheap medical thermometer teardown can tell us a lot about appropriate parts for this application.

The idea behing PhalangePad is an attractive one, but making those sensors reliable is no trivial eercise.

It’s another component choice problem that vexes PhalangePad, an input device that relies on the user tapping the inside of their fingers with their thumb. It’s a great idea, but how should these “keypresses” be detected? Would you use a capacitive or magnetic sensor, a force sensitive resistors, or maybe even machine vision? Here Bunnie’s encyclopaedic knowledge of component supply comes to the fore, and the result is a fascinating insight into the available technologies.

We all amass a huge repository of knowledge as we pass through life, some of the most valuable of which is difficult to pass on in a structured form and instead comes out as incidental insights. An engineer with exceptional experience such as Bunnie can write the book on manufacturing electronics in China but still those mere pages can only scratch the surface of what he knows about the subject. There lies the value of these mentor sessions, because among them the gems of knowledge slip out almost accidentally, and if you’re not watching, you’ll miss them.

This is the second in our series of Hackaday Prize mentoring sessions this year, but we have more already in the can and further sessions to record. We’re constantly looking for more participants though, so make sure if you haven’t already that you put your entry in for Hackaday Prize and check out the list of mentors who are here to share their knowledge and experience. Continue reading “Bunnie Huang Talks Manufacturing And Component Choices During Hackaday Prize Mentoring Session” →

Finally, An Open Source Multimeter

June 20, 2019 by Brian Benchoff 18 Comments

For his Hackaday Prize entry, [Martin] is building an Open Source Multimeter that can measure voltage, current, and power. It’s an amazing build, and you too can build one yourself.

The features for this multimeter consist of voltage mode with a range of +/-6V and +/-60V. There’s a current mode, basically the same as voltage, with a range of +/-60 mA and +/-500mA. Unlike our bright yellow Fluke, there’s also a power mode that measures voltage and current at the same time, with all four combinations of ranges available. There’s a continuity test that sounds a buzzer when the resistance is below 50 Ω, and a component test mode that measures resistors, caps, and diodes. There’s a fully isolated USB interface capable of receiving commands and transmitting data, a real-time clock, and in the future there might be frequency measurement.

This build is based on the STM32F103 microcontroller, uses an old Nokia phone screen, and unlike so many other multimeters, this thing is small. It’s very small. More than small enough to fit in your pocket and forget about it, unlike nearly every other multimeter available. There’s one thing about multimeters, and it’s that the best multimeter is the one that you have in your hands when you need it, and this one certainly fits the bill.

The entire project is being written up on hackaday.io, there’s a GitHub repo for all the hardware and software, and there’s also a video demo covering all the features (available below). This is a stand-out project, and something we desperately want to get our hands on.

Continue reading “Finally, An Open Source Multimeter” →

Trash Printer Directly Uses Recycled Plastics

June 19, 2019 by Lewin Day 23 Comments

3D printing is all well and good, but it can get expensive having to purchase roll after roll of filament. Various projects exist that attempt to take unwanted 3D prints and turn them back into filament to be used again. However, [Sam Smith] took a different path. The Trash Printer is a 3D print head that works with recycled plastic, with less intermediate processing steps.

The Trash Printer is a print head is intended to work with shredded plastics directly, rather than by first turning them back into a filament. Thus far, [Sam] has tested the Polypropylene and HDPE, and results are promising. While the prints aren’t of the same quality as using pre-prepared filament, the parts are still viable and fit for purpose.

The print head consists of an auger, along with a cartridge heater, which work together to push plastic to the print head. The head is constructed out of laser-cut parts and a few off-the-shelf components, making it easy to replicate. [Sam] has spent significant time honing the design, and has several ideas for ways in which it could be developed further. We’re eager to see how far this technology can go, and can’t wait to see what comes next. We’ve seen other attempts to recycle plastics for 3D printing, too. Expect to see further developments in this space coming thick and fast.

Tiny Tank Inspects Your Crawlspace

June 18, 2019 by Brian Benchoff 30 Comments

If you’ve got some drone or FPV part lying around, this is the build for you. It’s a remote controlled tank, with a camera and video transmitter, that’s only 65 mm x 40 mm x 30 mm in size. Why on Earth would you ever build something so small? You can look around in your crawlspace, I guess. Any way you look at, this thing is tiny.

The tank has traditional tank skid steering through two brushless motors. The battery is one cell, as that’s just about the largest battery you can put in a vehicle so small, and the camera is just off-the-shelf quadcopter stuff set into a 3D printed enclosure. There are a few LEDs for lights. Other than that, it’s just so tiny and so cute.

The builder behind this tank, [honnnest], put up a video going through the build and demonstrating what kind of video you can expect from a tank this small. It’s a bit fast for a tank, and that’s not even considering the scale effects, but if the chassis is 3D printed, you can always print a few reduction gears, too.

Continue reading “Tiny Tank Inspects Your Crawlspace” →

DIY Raspberry Pi Multi FX Stomp Box

June 17, 2019 by Rich Hawkes 3 Comments

From building your own analog effects pedal to processing audio through micro controllers, a lot of musicians love building their own boxes of sound modification. In his entry for the 2019 Hackaday Prize, [Craig Hissett] has a project to build an all-in-one multi-effects stomp box.

At the center of the box is a Raspberry Pi with an AudioInjector stereo sound card. The card takes care of stereo in and out, and passing the signal to the Pi. The software is Modep, an open source audio processor that allows the setup of a chain of digital effects plugins to be run on the Pi. After finding some foot switches, [Craig] connected them to an Arduino Pro Micro which he set up as a MIDI device that sends MIDI messages to the Modep software running on the Pi.

There are still a few steps to go, but [Craig] has the basic layout covered. Next up is wiring it up and building a proper case for it, as well as working on latency. A few years ago, another multi-effects stomp box was featured in the Hackaday Prize, and last year, this multi-effects controller was featured.