Brasilia Espresso Machine PID Upgrade Brews Prefect Cup of Energy

Coffee, making and hacking addictions are just bound to get out of control. So did [Rhys Goodwin’s] coffee maker hack. What started as a little restoration project of a second-hand coffee machine resulted in a complete upgrade to state of the art coffee brewing technology.

coffee_hack_arduinoThe Brasilia Lady comes with a 300 ml brass boiler, a pump and four buttons for power, coffee, hot water and steam. A 3-way AC solenoid valve, wired directly to the buttons, selects one of the three functions, while a temperamental bimetal switch keeps the boiler roughly between almost there and way too hot.

To reduce the temperature swing, [Rhys] decided to add a PID control loop, and on the way, an OLED display, too. He designed a little shield for the Arduino Nano, that interfaces with the present hardware through solid state relays. Two thermocouples measure the temperature of the boiler and group head while a thermal cut-off fuse protects the machine from overheating in case of a malfunction.

Also, the Lady’s makeup received a complete overhaul, starting with a fresh powder coating. A sealed enclosure along with a polished top panel for the OLED display were machined from aluminum. [Rhys] also added an external water tank that is connected to the machine through shiny, custom lathed tube fittings. Before the water enters the boiler, it passes through a custom preheater, to avoid cold water from entering the boiler directly. Not only does the result look fantastic, it also offers a lot more control over the temperature and the amount of water extracted, resulting in a perfect brew every time. Enjoy [Rhys’s] video where he explains his build:

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Hacking a coffee machine

The folks at Q42 write code, lots of it, and this implies the copious consumption of coffee. In more primitive times, an actual human person would measure how many cups were consumed and update a counter on their website once a day. That had to be fixed, obviously, so they hacked their coffee machine so it publishes the amount of coffee being consumed by itself. Their Jura coffee machine makes good coffee, but it wasn’t hacker friendly at all. No API, no documentation, non-standard serial port and encrypted EEPROM contents. It seems the manufacturer tried every trick to keep the hackers away — challenge accepted.

The folks at Q42 found details of the Jura encryption protocol from the internet, and then hooked up a Raspberry-Pi via serial UART to the Jura. Encryption consisted of taking each byte and breaking it up in to 4 bytes, with the data being loaded in bit positions 2 and 5 of each of the 4 bytes, which got OR’ed into 0x5B. To figure out where the counter data was stored by the machine in the EEPROM, they took a data dump of the contents, poured a shot of coffee, took another memory dump, and then compared the two.

Once they had this all figured out, the Raspberry-Pi was no longer required, and was replaced with the more appropriate Particle Photon. The Photon is put on a bread board and stuck with Velcro to the back of the coffee machine, with three wires connected to the serial port on the machine.

If you’d like to dig in to their code, checkout their GitHub repository. Seems the guys at Q42 love playing games too – check out 0h h1 and 0h n0.

Thanks [Max] for letting us know about this.