emf

23 Articles

EMF Forming Was A Neat Aerospace Breakthrough

May 23, 2025 by 9 Comments

Typically, when we think about forming metal parts, we think about beating them with hammers, or squeezing them with big hydraulic presses. But what if magnets could do the squeezing? As it turns out—Grumman Aerospace discovered they can, several decades ago! Even better, they summed up this technique in a great educational video which we’ve placed below the break.

The video concerns the development of the Grumman EMF Torque Tube. The parts are essentially tubes with gear-like fittings mounted in either end, which are fixed with electromagnetic forming techniques instead of riveting or crimping. Right away, we’re told the key benefits—torque tubes built this way are “stronger, lighter, and more fatigue resistant” than those built with conventional techniques. Grumman used these torque tubes in such famous aircraft as the F-14 Tomcat, highlighting their performance and reliability.

Continue reading “EMF Forming Was A Neat Aerospace Breakthrough” →

A Treasure Trove In An English Field

June 3, 2024 by 12 Comments

This is being written in a tent in a field in Herefordshire, one of the English counties that borders Wales. It’s the site of Electromagnetic Field, this year’s large European hacker camp, and outside my tent the sky is lit by a laser light show to the sound of electronic music. I’m home.

One of the many fun parts of EMF is its swap table. A gazebo to which you can bring your junk, and from which you can take away other people’s junk. It’s an irresistible destination which turns a casual walk into half an hour pawing through the mess in search of treasure, and along the way it provides an interesting insight into technological progress. What is considered junk in 2024?

Something for everyone

As always, the items on offer range from universal treasures of the I-can’t-believe-they-put that-there variety, through this-is-treasure-to-someone-I’m-sure items, to absolute junk. Some things pass around the camp like legends; I wasn’t there when someone dropped off a box of LED panels for example, but I’ve heard the story relayed in hushed tones several times since, and even seen some of the precious haul. A friend snagged a still-current AMD processor and some Noctua server fans as another example, and I’m told that amazingly someone deposited a Playstation 5. But these are the exceptions, in most cases the junk is either very specific to something, or much more mundane. I saw someone snag an audio effects unit that may or may not work, and there are PC expansion cards and outdated memory modules aplenty.

Finally, there is the absolute junk, which some might even call e-waste but I’ll be a little more charitable about. Mains cables, VGA cables, and outdated computer books. Need to learn about some 1990s web technology? We’ve got you covered. Continue reading “A Treasure Trove In An English Field” →

Looking Forward To EMF 2024

May 29, 2024 by 10 Comments

It’s that time of year again when some parts of our community travel out into the countryside to spend time with each other under canvas in a field somewhere with power and fast internet — it’s hacker camp season. Here in Europe that means it’s the turn of the British hackers to have the year’s large event, in the form of the latest incarnation of Electromagnetic Field. We’ll be there, camera and microphone in hand, and with luck we’ll be able to bring you a flavour of the event.

The atmosphere that comes from being in the company of several thousand like minds is stimulating enough, but what makes these outdoor events special is that the villages become so much more than simply a group of geeks at a table with their laptops. Where else can one find a tea room run by a hackerspace except courtesy of MK Makerspace, or a fully functional pop-up motor racing circuit from Hacky Racers?

This year’s event badge is an interesting one, the ESP32-S3 powered and hexagon-shaped Tildagon. It’s a bold attempt to redefine the event badge away from a one-off trinket into one that lasts across multiple events, with custom “Hexpansions” like the petals on a flower, intended to have new ones appear on an event by event basis.

If you’re going to be at EMF then maybe we can join you for a pint, otherwise we’ll be bringing you the best that we find there. To whet your appetite, here’s something of the last one.

Recreating The “Stuck Throttle” Problem On A Toyota

October 30, 2022 by 68 Comments

A few years ago, Toyota was in the news for a major safety issue with a number of their passenger vehicles. Seemingly at random, certain cars were accelerating without concern for driver input, causing many crashes and at least 37 confirmed deaths. They issued recalls both for the floor mats which were reported to have slid forward to jam the accelerator pedal, but this didn’t explain all of these crashes. There was another recall for stuck throttles, which [Colin O’Flynn] demonstrates a possible cause for on his test bench.

While most passenger vehicles older than about 15-20 years controlled the throttle with a cable connected directly from the throttle body to the accelerator pedal, most manufacturers have switched to a fly-by-wire system which takes sensor input from the accelerator pedal and sends that position information to the vehicle’s computer which in turn adjusts the throttle position. This might be slightly cheaper to manufacture, but introduces a much larger number of failure modes to a critical system. Continue reading “Recreating The “Stuck Throttle” Problem On A Toyota” →

The Hackaday Summer Camp Survival Guide

August 3, 2022 by 19 Comments

It’s a feature of summer for us, the round of hacker camps in which members of our community gather in fields and spend a few days relaxing and doing what we do best. This summer I’ll have been to four of them by September, one of which was unexpected because a last-minute ticket came my way. For Hackaday they’re a chance to connect with our readers and maybe see come of the coolest stuff in person.

If you consult the wiki for your hacker camp of choice then you’ll usually find a page of tips about what to bring. Starting with a tent and a sleeping bag and probably going on to sunscreen, a hat, and maybe how to avoid dehydration. I’d probably add spare toilet paper and disinfectant spray in case the toilets are nightmarish. All very practical stuff, but expressed in a dry list format that doesn’t really tell you what to expect. A hacker camp can be overwhelming if you’ve not been to one before, so how do you get the best out of it? Here are a few tips based on our experience. Continue reading “The Hackaday Summer Camp Survival Guide” →

Badges Of 2022: EMF TiDAL

July 8, 2022 by 5 Comments

As we slowly return to a summer of getting together in fields for our festivals of hackery, it’s time to look at another of this year’s crop of badges. The UK’s Electromagnetic Field, or EMF, is normally a two-yearly event, but its return this year comes after a four year absence due to the pandemic. The EMF 2022 badge is a departure from previous outings, gone is the handheld game console form factor and in its place is a svelte USB-C stick with a nod to the first generation of EMF badges in its wave shape.

The text is a little small on the tiny screen.
On the rear is this pattern.

Physically the badge is formed of two PCBs that plug together with the LiPo battery sandwiched between them, the upper one carrying the display and battery while the lower holds the ESP32-S3 MCU and the various peripherals. These include a QMA7981 accelerometer, a QMC7983 magnetometer, and perhaps most intriguingly, an ATECC108A cryptographic accelerator. This last component gives it the potential to be a 2-factor authentication key, which we think is probably a first for a badge.

In use, the TFT display and joystick interface is usable, but hard to read for a Hackaday scribe whose eyes maybe aren’t as sharp as they used to be. Programming is via MicroPython, using an app format through the same online hatchery system that will be familiar to owners of other European badges. There are already quite a few apps, which we hope will help this badge have some longevity.

This is just the latest of a long line of EMF badges, of which the 2016 version is probably our favourite.

The circuit, assembled on a purple PCB, with a large capacitor and a sizeable white resistor, wires soldered to holes in the PCB

Protect Your Drivers When The Motor Stalls

June 13, 2022 by 47 Comments

[Mark Rehorst] tells us about a tragic incident involving an untimely demise of $200 worth of motor driving hardware, and shares a simple circuit so that we can prevent such tragedies in the future. His Arrakis sand table project has quite a few motors involved, and having forgotten to add limits into the software, he slammed a motor-driven mechanism into a well-fixed part of the table. The back EMF of the motor created a burst of energy, taking out the motor driver, the controller board, and the power supply.

With the postmortem done, he had to prevent this from happening again – preferably, in hardware. Based on a small appnote from Gecko Drives, he designed a simple PCB that shunts the motor with a high-power resistor, as soon as the current starts flowing into a direction it’s not supposed to flow into. He goes in depth about the way that the circuit works and the reasoning behind parts selection, as well as shows an LTSpice simulation and shares the PCB files. This was his first time designing PCBs in KiCad, and we believe he’s done a great job! This worklog is certainly worth reading if you’d like to understand how such circuits work and what goes into building one.

He dubs this a “bank account protection” circuit, and we can absolutely relate. It’s not just CNC tables that need such protections of course – we’ve seen a solution for small hacky makeshift electric vehicles, for instance. A motor’s generative properties aren’t always a problem, however – here’s just one example of a hacker trying to put them to good use.

Continue reading “Protect Your Drivers When The Motor Stalls” →