Faux Aircon Units, Made Entirely From 2D Cuts

2D design and part fabrication doesn’t limit one to a 2D finished product, and that’s well-demonstrated in these Faux Aircon Units [Martin Raynsford] created to help flesh out the cyberpunk-themed Null Sector at the recent 2018 Electromagnetic Field hacker camp in the UK. Null Sector is composed primarily of shipping containers and creative lighting and props, and these fake air conditioner units helped add to the utilitarian ambiance while also having the pleasant side effect of covering up the occasional shipping container logo. Adding to the effect was that the fan blades can spin freely in stray air currents; that plus a convincing rust effect made them a success.

Fan hubs, showing spots for fan blades to be glued. With the exception of embedded bearings, the entire hub (like the rest of the unit) is made from laser-cut MDF.

The units are made almost entirely from laser-cut MDF. The fan blades are cut from the waste pieces left over from the tri-pronged holes, and really showing off the “making 3D assemblies out of 2D materials” aspect are the fan hubs which are (with the exception of bearings) made from laser-cut pieces; a close-up of the hubs is shown here.

Capping off the project is some paint and the rusted appearance. How did [Martin] get such a convincing rust effect? By using real rust, as it turns out. Some cyanoacrylate glue force-cured with misted water for texture, followed by iron powder, then vinegar and hydrogen peroxide with a dash of salt provided the convincing effect. He was kind enough to document the fake rust process on his blog, complete with photos of each stage.

Null Sector showcased a range of creativity; it’s where this unusual headdress was spotted, a device that also showed off the benefits of careful assembly and design.

Air Conditioner Remote Reverse Engineered Despite Esoteric Protocol

Infra-red remote control is something of a Done Deal when it comes to hardware hacking, it has been comprehensively reverse engineered, and there exist libraries and software packages to seamlessly take care of all its quirks. Just occasionally though, along comes an IR remote whose protocol doesn’t follow that well-worn path

[William Dudley] found himself in this position with an air-conditioning unit remote control. He found it sent a stream of data with all settings of the machine rather than the single command codes you might expect from a familiar TV remote. The solution was to reverse engineer and reimplement the IR codes.

His reverse engineering relied on an Arduino and IR receiver which he used to sniff the packets coming out of the remote. Eventually he was able to recognise some of the functions from the remote, and create his own protocol that can recreate most of the remote’s functions. This was pushed over to a Raspberry Pi Zero which uses an IR LED to command the air conditioner, joining the ranks of his growing home automation setup.

The write-up makes for a fascinating primer on analysis of obscure IR protocols, and is well worth a read for anybody with an interest in the topic. Meanwhile if you want more IR reverse engineering stories, try this tale of a bathroom scale.

Drag Your Office Aircon Into The 21st Century With Wi-Fi Control

We’ll all have worked in offices that have air-conditioning, but a little too much of it. It’s wonderful on a baking-hot day to walk into the blessèd cool of an air-conditioned office, but after an hour or two of the icy blast you’re shivering away in your summer clothing and you skin has dried out to a crisp. Meanwhile on the other side of the building [Ted] from Marketing has cranked up the whole system to its extreme because he’s got a high metabolism and an office in the full force of the midday sun.

Wouldn’t it be nice if individual air-conditioning units could be easily controlled. To that end, [Maya Posch] has made a rather nicely designed board that takes a NodeMCU board with its ESP8266 processor, and uses four of its outputs as PWM to produce 0-10 volt analogue outputs via filters and op-amps to control individual units. In addition there is an onboard CO2 sensor and a temperature sensor, with provision for an external temperature sensor. The whole fits very neatly into a standard electrical outlet enclosure.

Software wise, the system uses the Sming framework providing an MQTT  communication with a backend server that allows the users to control their aircon experience. This is very much a work in progress, so the software has yet to be put up. (Hint, [Maya], hint!) The whole project though is an extremely tidy build, in fact a thing of beauty to a standard you’d expect from a high-quality commercial product. It’s this that tipped the balance into our featuring it before the software is released, it’s one to keep an eye on, because quality like this doesn’t come every day.

This isn’t the first aircon control we’ve brought you, take a look at this one controlled through Slack.