Crowdfunding Follies: Debunking The Batteriser

June 6, 2015 by Brian Benchoff 144 Comments

It’s not on Kickstarter yet, but this product is already making its media debut, with features in all the tech blogs, an astonishing amount of print outlets, and spouted from the gaping maws of easily impressed rubes the world over. What is it? It’s the Batteriser, a tiny metal contraption that clips over AA, C, and D cells that reclaims the power trapped inside every dead battery. Yes, every dead battery you’ve ever thrown away still has up to 80% of its power remaining. Sounds like complete hogwash, right? That’s because it is.

[Dave Jones] put together a great video on the how comes and why nots of the Batteriser, and while doing so gives a great tutorial for debunking a product, heavily inspired by [Carl Sagan]’s Baloney Detection Kit. The real debunking starts by verifying any assumptions, and the biggest fault of the Batteriser campaign is claiming 80% of a battery’s power is unused. Lucky for us, [Dave] has tons of tools and graphs to demonstrate this is not the case.

To verify the assumption that battery-powered devices will brown out after using only 20% of a battery’s available power, [Dave] does the most logical thing and looks at the data sheets for a battery. After using 20% of available power, these datasheets claim these batteries should be around 1.3V. Do devices brown out at 1.3V? Hook it up to a programmable power supply and find out.

It turns out every battery-powered device [Dave] could find worked perfectly until around 1.1V. Yes, that’s only 0.3V difference from 1.4V claimed by the patent for the Batteriser, but because of the battery discharge curve, that means 80% of the power in a normal device is already being used up. The premise of the Batteriser is invalid, and [Dave] demonstrates it’s a complete scam.

If a through debunking of the Batteriser’s claims wasn’t enough, [Dave] goes on to explain how it may actually be dangerous. The positive terminal of a battery is also the metal can, while the negative terminal is just a tiny nib of metal seperated from the rest of the battery by a gasket. Since the Batteriser is made of metal and serves as the ground for the boost converter circuit, it’s very, very close to shorting through the branding and logo emblazoned on a mylar wrapping each battery is shrouded with. One tiny nick in this insulator, and you have a direct short across the battery. That’s going to turn to heat, and there’s a lot of energy in a D cell; a failure mode for the Batteriser is a fire. That’s just terrible product design.

Video below.

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Hacklet 44 – Teardowns

April 25, 2015 by Adam Fabio 14 Comments

Just about every hacker, maker and tinkerer out there received their early education the same way: A screwdriver in one and a discarded bit of electronics in the other. There is no better way to find out how something works than cracking it open and examining each piece. In recent years, teardown videos have become popular on YouTube, with some of the great examples coming from users like [EEVblog], [mikeselectricstuff], and [The Geek Group]. This week’s Hacklet is all about the best teardown projects on Hackaday.io!

We start with [zakqwy] and his Savin C2020 Teardown. Photocopiers (and multifunction machines) are the workhorses of the modern office. This means there are plenty of used, abused, and outdated photocopiers available to hackers. [Zakqwy] got this monster when it started misbehaving at his office. Copiers are a venerable cornucopia of motors, gears, sensors (lots and lots of breakbeam sensors) and optics. The downside is toner: it’s messy, really bad to breathe, and if you don’t wear gloves it gets down into the pores of your skin, which takes forever to get out. [Zakqwy] persevered and found some awesome parts in his copier – like an Archimedes’ screw used to transport black toner.

Next up is [Bob Blake] with Belkin WeMo Insight Teardown. [Bob] wanted a WiFi outlet, but wasn’t about to plug something in to both his power grid and his network without taking it apart first. [Bob] did an awesome job of documenting his teardown with lots of great high resolution photos – we love this stuff! He found a rather well thought out hardware design. The Insight has 3 interconnected PCBs inside. The power switching and supply circuits are all on one board. It includes slots and the proper creep distances one would expect in a design that will be carrying 120V AC mains power. A small daughter board holds an unknown chip – [Bob] is guessing it is the power sensing circuitry. A third board a tucked in at the top of the module holds the main CPU, a Ralink/MediaTek RT5350F SoC, RAM, and the all important WiFi antenna.

[Drhatch] took things into the danger zone with an X-ray Head Teardown. We’re not sure if [Drhatch] is a real doctor, but he does have a Heliodent MD dental X-ray head. Modern X-ray machines are generally radiation safe if they’re not powered up. Radiation isn’t the only dangers to worry about though – there are latent charged capacitors and cooling oils which may contain nasty chemicals like PCBs, among other things. [Drhatch] found some pretty interesting design decisions in his X-ray head. The tube actually fires through the cylindrical high voltage transformer. This means the transformer acts as a beam collimator, focusing the X-ray beam down like a lens. He also found plenty of lead shielding. Interestingly there are two thickness of lead in the housing. Shielding close to the tube is 1 mm thick, while shielding a bit further away is only 0.7 mm thick.

Finally, we have [danielmiester] with Inside a 3ph AC Motor Controller(VFD). [Daniel] tore down a Hitachi Variable-Frequency Drive (VFD) with the hopes of creating a frequency converter for a project. These high voltage, high power devices have quite a bit going on inside, so the conversion became a teardown project all its own. VFDs such as this one are used in industry to drive high power AC motors at varying speeds efficiently. As [Daniel] says, the cheaper ones are ” just really fancy PWM modules”. Handling 1.5 kW is no joke though. This VFD had a large brick of power transistors potted into its heat sink. The controller board was directly soldered to the transistors, as well as the rectifier diodes for the DC power supply. [Daniel] was doing some testing with the unit powered up, so he built a custom capacitor discharge unit from 3 C7 Christmas lights. Not only did they keep the capacitors discharged, they provided an indication that the unit was safe. No light means no charge.

Not satisfied? Want more teardown goodness? Check out our freshly minted Teardown List!

That’s about all the time we have for this week’s Hacklet. As always, see you next week. Same hack time, same hack channel, bringing you the best of Hackaday.io!

Reverse Engineer A VFD After Exploring How They Work

March 4, 2015 by Mike Szczys 21 Comments

[Dave Jones] got his hands on a really wide, 2-row Vacuum Fluorescent Display. We’ve come across these units in old equipment before and you can get them from the usual sources, both new and used, but you need to know how to drive them. This recent installment of the EEVblog reverse engineers this VFD.

The function of these displays is pretty easy to understand, and [Dave] covers that early in the video after the break. There is a cathode wire and phosphorescent coated anodes. When current is applied the anodes glow. To add control of which anodes are glowing a mesh grid is placed between the anodes and the cathode wire. Applying negative potential to the grid prevents the electrons from traveling to the anode so that area will not be lit.

Now driving this low-level stuff is not easy, but rest assured that most VFDs you find are going to have a driver attached to them. The reverse engineering is to figure out the protocol used to control that driver. On this board there is a 2-pin connector with a big electrolytic filtering cap which is a dead giveaway for power rails. Looking at the on-board processor which connects directly he ascertains that the input will be 5V regulated since this is what that chip will expect. Connecting his bench supply yields a blinking cursor! [Dave] goes on to pump parallel data and test out the control pins all using an Arduino. He finds success, sharing many great reverse engineering tips along the way.

We often call this type of thing a dark art, but that’s really just because there aren’t a lot of people who feel totally comfortable giving it a try. We think that needs to change, so follow this example and also go look at [Ben Heckendorn’s] recent LCD reverse engineering, then grab some equipment and give it a try for yourself. We want to hear about your accomplishments!

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EEVblog Tears Into The White Van Speaker Scam

October 8, 2014 by Adam Fabio 91 Comments

[Dave Jones] shows us just how bad audio equipment can get with his white van speaker scam teardown (YouTube link). Hackaday Prize judge [Dave] has some great educational videos on his EEVblog YouTube channel, but we can’t get enough of his rants – especially when he’s ranting about cheap electronics. Check out his world’s “cheapest” camcorder teardown for a classic example

This week [Dave] is tearing down some white van speaker scam A/V equipment. The White Van Speaker Scam (WVSS) is an international hustle which has been around for decades. A pair of guys in a white van stop you in a parking lot, gas station, or other public area. They tell you they’ve got some brand new A/V equipment in the back of their van that they’ll give you for a “great deal”. The speakers are always in fancy packaging, and have a name that sounds like it could be some sort of high-end audiophile brand worth thousands.

Needless to say anyone who buys this equipment finds they’ve been duped and are now the proud owner of some equipment which only sounds good when hitting the bottom of a dumpster. Coincidentally, a dumpster is exactly where [Dave] found his WVSS equipment.

The case of his “Marc Vincent” surround sound system turned out to be nothing more than thin chipboard hot glued together. The electronics were of such shoddy quality that few words describe them – though [Dave] is always ready to improvise. From the ultra cheap subwoofer driver to the 1990’s era vacuum fluorescent display, everything was built down to the lowest cost while still looking nice from the outside. Even the ground wire was just tack soldered to the frame. We especially liked the three vacuum tubes that weren’t even soldered in. The leads were bent over to hold them onto a PCB, while a blue LED lit the tube from below.

Click past the break to see what [Dave] found inside his “3D Optics” projector.

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The Reason Dead Batteries Bounce

September 5, 2014 by Brian Benchoff 23 Comments

For the last few years, very well-informed people have been able to tell if an alkaline battery is good or not simply by dropping them. When dropped from an inch or two above a hard surface, a good battery won’t bounce, and will sometimes land standing up. A dead battery, on the other hand, will bounce. Thanks to [Lee] and a few of his friends, we now know why this happens.

While hanging out with a few of his buddies, [Lee] was able to condense all the arguments on why dead batteries bounce to two theories. The first theory, the ‘bounce theory’ said dead batteries had an increase in outgassing in the battery, increasing the pressure in the battery, which increases the spring constant of the battery itself. The second theory, the ‘anti-bounce theory’, said the gel-like properties of the electrolyte worked as a sort of mass damper.

[Lee] designed an experiment to test the outgassing ‘bounce theory’ of bouncing batteries. Instead of dropping a battery, an object – in this case a brass slug – was dropped onto both good and bad batteries. There was no difference. Even after holes were drilled to vent any gasses inside the battery, the brass slug bounced off both good and bad batteries the same way.

This means the reason dead alkaline batteries bounce is due to the electrolyte. [Lee] cut open a few AA cells and found the electrolyte in a good battery was a mushy mess of chemicals. In the dead battery, this same electrolyte hardened into a solid mass. [Lee] compares this to an anti-bounce hammer.

Finally, more than a year after most of us learned about bouncing dead batteries thanks to [Dave Jones]’ video, we have an answer. It’s a chemical change in the electrolyte that turns it from a goo to a solid that makes dead batteries bounce.

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Judge Spotlight: Dave Jones

July 1, 2014 by Mike Szczys 23 Comments

This week’s Judge Spotlight features [Dave Jones] who posted a video reponse to our slate of questions. If you’ve spent much time around here chances are you know of [Dave] quite well. He is the man behind the EEVblog and also hosts The Amp Hour podcast along with [Chris Gammell].

It’s great to pick [Dave’s] brain a bit. He’s seen a lot during his career, with insights on professional engineering from the point of view of job seeker, employer, job interviewer, and more. His time with the EEVblog and Amp Hour have furthered his experience with looks inside of all manner of equipment, adventures in crowd funding, and interactions with a multitude of hardware start-ups. Check out his video, as well as a list of the questions with timestamps, after the jump.

We’re sure you know by now, he’s judging The Hackaday Prize which will award a trip to space and hundreds of other prizes for showing off your connected device built using Open Design.

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US Government Screws Up Terrorist Watchlist, Few Surprised

February 25, 2014 by Brian Benchoff 107 Comments

Dave

It looks like [Dave Jones] got himself on a US government watch list. We don’t mean [Dave L. Jones], awesomesauce electronic wizard and host of eevblog, though. Some three-letter agency is just looking at someone named [David Jones]. Is this going to screw over our Aussie friend? You betcha.

[Dave] bought a few things through Element 14 that he would later pick up at their Sydney warehouse. When he got there, he discovered the parts were ‘on hold’. Out of curiosity, he asked what the holdup was and discovered his name was flagged on a US government watch list.

If you’re keeping score, this is an Australian citizen buying stuff from an Australian subsidiary of a UK company, and being told ‘no’ by the US government.

The folks behind the counter at the Element 14 warehouse were extremely helpful, clearing the hold and getting [Dave]’s parts in just a few minutes. This has, apparently, been going on for a while; [Dave] recalled a few times when orders showed up a few days late with the Farnell/Element 14 people apologizing with the word ‘hold’ in there somewhere.

Of course this means it’s possible for someone working at the Element 14 warehouse to clear one of these US government holds, and even if they don’t the order will still go through in a day or two. Government efficiency at its best.

At the time of this writing, [David Bowie], the singer for The Monkees, the creator of Grand Theft Auto, and the British author famous for perpetual motion machines were unavailable for comment. -ed.