Printed Robotic Arm Pumps Up With Brushless Motors

April 8, 2025 by Tom Nardi 17 Comments

[JesseDarr] recently wrote in to tell us about their dynamic Arm for Robitc Mischief (dARM), a mostly 3D printed six degrees of freedom (6DOF) robotic arm that’s designed to be stronger and more capable than what we’ve seen so far from the DIY community.

The secret? Rather than using servos, dARM uses brushless DC (BLDC) motors paired with ODrive S1 controllers. He credits [James Bruton] and [Skyentific] (two names which regular Hackaday readers are likely familiar with) for introducing him to not only the ODrive controllers, but the robotics applications for BLDCs in the first place.

dARM uses eight ODrive controllers on a CAN bus, which ultimately connect up to a Raspberry Pi 4B with a RS485 CAN Hat. The controllers are connected to each other in a daisy chain using basic twisted pair wire, which simplifies the construction and maintenance of the modular arm.

As for the motors themselves, the arm uses three different types depending on where they are located, with three Eaglepower 8308 units for primary actuators, a pair of GB36-2 motors in the forearm, and finally a GM5208-24 for the gripper. Together, [JesseDarr] says the motors and gearboxes are strong enough to lift a 5 pound (2.2 kilogram) payload when extended in a horizontal position.

The project’s documentation includes assembly instructions for the printed parts, a complete Bill of Materials, and guidance on how to get the software environment setup on the Raspberry Pi. It’s not exactly a step-by-step manual, but it looks like there’s more than enough information here for anyone who’s serious about building a dARM for themselves.

If you’d like to start off by putting together something a bit easier, we’ve seen considerably less intimidating robotic arms that you might be interested in.

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Supercon 2024: Yes, You Can Use The Controller Area Network Outside Of Cars

March 27, 2025 by Lewin Day 21 Comments

Ah, the CAN bus. It’s become a communication standard in the automotive world, found in a huge swathe of cars built from the mid-1990s onwards. You’ll also find it in aircraft, ships, and the vast majority of modern tractors and associated farm machines, too.

As far as [Randy Glenn] is concerned, though, the CAN bus doesn’t have to be limited to these contexts. It can be useful far beyond its traditional applications with just about any hardware platform you care to use! He came down to tell us all about it at the 2024 Hackaday Supercon.

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Extracting SecOC Keys From A 2021 Toyota RAV4 Prime

March 8, 2024 by Maya Posch 7 Comments

With the recently introduced SecOC (Secure Onboard Communication) standard, car manufacturers seek to make the CAN bus networks that form the backbone of modern day cars more secure. This standard adds a MAC (message authentication code) to the CAN messages, which can be used to validate that these messages come from a genuine part of the car, and not from a car thief or some third-party peripheral.

To check that it isn’t possible to circumvent SecOC, [Willem Melching] and [Greg Hogan] got their hands on the power steering (EPS) unit of a Toyota RAV4 Prime, as one of the first cars to implement this new security standard.

As noted by [Willem], the ultimate goal is to be able to run the open source driver assistance system openpilot on these SecOC-enabled cars, which would require either breaking SecOC, or following the official method of ‘rekeying’ the SecOC gateway.

After dumping the firmware of the EPS Renesas RH850/P1M-E MCU via a voltage fault injection, the AES-based encryption routines were identified, but no easy exploits found in the main application. This left the bootloader as the next target.

Ultimately they managed to reverse-engineer the bootloader to determine how the update procedure works, which enabled them to upload shellcode. This script then enabled them to extract the SecOC keys from RAM and send these over the CAN bus. With these keys the path is thus opened to allow any device to generate CAN messages with valid SecOC MACs, effectively breaking encryption. Naturally, there are many caveats with this discovery.

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A Dashboard Outside The Car

January 11, 2024 by Bryan Cockfield 11 Comments

One of the biggest upsides of open communications standards such as CAN or SPI is that a whole world of vehicle hacking becomes available, from simple projects like adding sensors or computers to a car or even building a complete engine control unit from the ground up. The reverse is true as well; sensors and gauges using one of these protocols can be removed from a car and put to work in other projects. That’s the idea that [John] had when he set about using a vehicle’s dashboard as a information cluster for his home.

The core of the build is an Astra GTE dashboard cluster, removed from its host vehicle, and wired to an Arduino-compatible board, in this case an ESP32. The code that [John] wrote bit-bangs an SPI bus and after some probing is able to address all of the instrument gauges on the dashboard. For his own use at home, he’s also configured it to work with Home Assistant, where each of the gauges is configured to represent something his home automation system is monitoring using a bit mask to send data to specific dials.

While this specific gauge cluster has a lot of vehicle-specific instrumentation and needs a legend or good memory to tie into a home automation system without any other modification, plenty of vehicle gauges are more intuitive and as long as they have SPI they’d be perfect targets for builds that use this underlying software. This project takes a similar tack and repurposes a few analog voltmeters for home automation, adding a paper background to the meters to make them easier to read.

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Vehicle-to-Grid Made Easy

May 25, 2023 by Bryan Cockfield 37 Comments

As electric cars continue to see increased adoption, one associated technology that was touted long ago that still hasn’t seen widespread adoption is vehicle-to-grid or vehicle-to-home. Since most cars are parked most of the time, this would allow the cars to perform load-levelling for the grid or even act as emergency generators on an individual basis when needed. While this hasn’t panned out for a variety of reasons, it is still possible to use an EV battery for use off-grid or as part of a grid tie solar system, and now you can do it without needing to disassemble the battery packs at all.

Normally when attempting to use a scrapped EV battery for another use, the cells would be removed from the OEM pack and reorganized to a specific voltage. This build, however, eliminates the need to modify the packs at all. A LilyGO ESP32 is used to convert the CAN bus messages from the battery pack to the Modbus communications protocol used by the inverters, in this case a Fronius Gen24, so the inverter and battery can coordinate energy delivery from one to the other automatically. With the hard part out of the way, the only other requirements are to connect a high voltage DC cable from the battery pack to the inverter.

[Dala], the creator of this project, has taken other steps to ensure safety as well that we’d recommend anyone attempting to recreate this build pays close attention to, as these battery packs contain an extremely large amount of energy. The system itself supports battery packs from Nissan Leafs as well as the Tesla Model 3, which can usually be found for comparably low prices. Building battery energy storage systems to make up for the lack of commercially-available vehicle-to-home systems isn’t the only use for an old EV battery, though. For example, it’s possible to use Leaf batteries to triple the range of other EVs like [Muxsan] did with this Nissan van.

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A Smart Home That CAN Do It All

March 15, 2023 by Matthew Carlson 41 Comments

In an ideal smart home, the explosion of cheap WiFi and Bluetooth chips has allowed hundreds of small wireless devices to control the switches, lights, and everything else required for a “smart home” at a relatively low price. But what if you don’t want hundreds of internet-connected devices in your home polluting the wireless spectrum and allowing potential security holes into your network? If you’re like [Lucas Teske], you might reach for something wired and use cheap and (currently) available Raspberry Pi Picos to create PicoHome.

The unique twist of PicoHome is that it uses a CAN bus for communication. One of [Lucas’] goals was to make the boards easily swappable when hardware failed. This meant board-to-board communication and protocols like I2C were susceptible to noise (every time a relay triggered, the bus would lock up briefly). The CAN bus is designed to work in an electrically noisy environment.

There are two parts to the system: pico-relay and pico-input. The first connects to a 16 relay board and can control 16 different 24v relays. The second has 16 optoisolators to read from 12v-24v switches and various buttons throughout the house. These can be placed in a giant metal box in a central wiring location and not worry about it.

The firmware and board files are all released under an Apache 2.0 license, but the CAN2040 library this project relies on is under GPL. We covered the CAN2040 library when it was first released, and it’s lovely to see it being used for something entirely unexpected.

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All Aboard The Garbage Express

January 2, 2023 by Bryan Cockfield 39 Comments

Cog railways are a somewhat unusual way of train locomotion, typically only installed when a train needs to climb steep terrain. Any grade above about 10% needs the extra traction since the friction between the wheels and rails won’t be enough to push the train forward or keep it from falling backwards. Even without a steep hill to climb, sometimes a cog railway is necessary for traction as [Max Maker] discovered while building a train for his garbage cans.

The build started out as a way to avoid having to wheel his seven waste bins to the curb every month. Originally he built a more standard railway with a simple motor to drive the train, but he quickly realized that there wasn’t enough grip even when using plastic wheels, even though this track follows fairly flat terrain. Since the rail is built out of steel he quickly welded up a rack-and-pinion system to one of the rails. The build goes through many iterations before he finally settles on a design that solves the problem, and it includes several other features as well such as remote control and a spring-loaded automatic charger for the train at its station in the back yard.

While we always appreciate the eccentricity of those who would automate a relatively simple task that only happens once a month, [Max Maker] hopes to build this into a commercial product aimed at the elderly or disabled who would really benefit from a reliable, semi-automatic system that takes their trash bins to the curb for them. And, if your system only involves a single trash can, there are other ways of automating the task of taking the garbage to the curb.

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