engineering

78 Articles

Converting Wind To Electricity Or: The Doubly-Fed Induction Generator

August 30, 2023 by 97 Comments

Humanity has been harvesting energy from the wind for centuries. The practice goes back at least to 8th century Persia where the first known historical records of windmills came, but likely extends even further back than that. Compared to the vast history of using wind energy directly to do things like mill grain, pump water, saw wood, or produce fabrics, the production of electricity is still relatively new. Despite that, there are some intriguing ways of using wind to produce electricity. Due to the unpredictable nature of wind from moment to moment, using it to turn a large grid-tied generator is not as straightforward as it might seem. Let’s take a look at four types of wind turbine configurations and how each deal with sudden changes in wind speeds. Continue reading “Converting Wind To Electricity Or: The Doubly-Fed Induction Generator” →

Clipper Windpower: Solutions In Search Of Problems

August 2, 2023 by 67 Comments

The first modern wind turbines designed for bulk electricity generation came online gradually throughout the 80s and early 90s. By today’s standards these turbines are barely recognizable. They were small, had low power ratings often in the range of tens to hundreds of kilowatts, and had tiny blades that had to rotate extremely quickly.

When comparing one of these tiny machines next to a modern turbine with a power rating of 10 or more megawatts with blades with lengths on the order of a hundred meters, one might wonder if there is anything in common at all. In fact, plenty of turbines across the decades share fundamental similarities including a three-blade design, a fairly simple gearbox, and a single electric generator. While more modern turbines are increasingly using direct-drive systems that eliminate the need for a gearbox and the maintenance associated with them, in the early 2000s an American wind turbine manufacturer named Clipper Windpower went in the opposite direction, manufacturing wind turbines with an elaborate, expensive, and heavy gearbox that supported four generators in each turbine. This ended up sealing the company’s fate only a few years after the turbines were delivered to wind farms.

Some history: the largest terrestrial wind turbines were approaching the neighborhood of 2 megawatts, but some manufacturers were getting to these milestones essentially by slapping on larger blades and generators to existing designs rather than re-designing their turbines from the ground up to host these larger components. This was leading to diminishing returns, as well as an increased amount of mechanical issues in the turbines themselves, and it was only a matter of time before the existing designs wouldn’t support this trend further. Besides increased weight and other mechanical stresses on the structure itself, another major concern was finding (and paying for) cranes with enough capacity to hoist these larger components to ever-increasing heights, especially in the remote locations that wind farms are typically located. And cranes aren’t needed just for construction; they are also used whenever a large component like a generator or blade needs to be repaired or replaced. Continue reading “Clipper Windpower: Solutions In Search Of Problems” →

PCIe For Hackers: An M.2 Card Journey

July 20, 2023 by 22 Comments

I’ve designed a few M.2 adapters for my own and my friends’ use, and having found those designs online, people have asked me for custom-made adapters. One of these requests is quite specific – an adapter that adds one more PCIe link to an E-key M.2 slot, the kind of slot you will see used in laptops for WiFi cards.

See, the M.2 specification allows two separate PCIe links connected to the E-key slot; however, no WiFi cards use this apart from some really old WiGig-capable ones, and manufacturers have long given up on connecting a second link. Nevertheless, there are some cards like the Google Coral M.2 E-key dual AI accelerator and the recently announced uSDR, that do indeed require the second link – otherwise, only half of their capacity is available.

It’s not clear why both Google and WaveletSDR designed for a dual-link E-key socket, since those are a rare occurrence; for the Google card, there are plenty of people complaining that the board they bought just doesn’t fully work. In theory, all you need to do to help such a situation, is getting a second PCIe link from somewhere, then wiring it up to the socket – and a perfect way to do it is to get a PCIe switch chip. You will lose out on some bandwidth because the uplink PCIe connection of the switch can only go so fast; for things like this AI accelerator, it’s not much of a problem since the main point is to get the second device accessible. For the aforementioned SDR, it might turn out useless, or you might win some but lose some – can’t know until you try! Continue reading “PCIe For Hackers: An M.2 Card Journey” →

DisplayPort: Under The Hood

July 17, 2023 by 14 Comments

Last time, we looked at all the things that make DisplayPort unique for its users. What about the things that make it unique for hackers? Let’s get into all the ways that DisplayPort can serve you on your modern tech wrangling adventures.

You Are Watching The AUX Channel

With DisplayPort, the I2C bus we’ve always seen come bundled with VGA, DVI and HDMI, is no more – it’s been replaced by the AUX bus. AUX is a 1 MHz bidirectional diffpair – just a bit too complex for a cheap logic analyzer, though, possibly, something you could wrangle with the RP2040’s PIOs. Hacking thoughts aside, it’s a transparent replacement for I2C, so that software doesn’t have to be rewritten – for instance, it usually does I2C device passthrough over AUX, so that EDID data can still be stored in a separate EEPROM chip on the monitor or eDP LCD panel.

AUX isn’t just a differential bus, it’s more pseudodifferential, like USB2 – for instance, AUX_P and AUX_N are used separately, with a combination of 1 MΩ and 100 kΩ pullups and pulldowns signaling different states of the physical connection – for instance, a pullup on AUX+ and a pulldown on AUX- means that an external device has been connected. If you’d like to learn which combination of resistors means what, you can find in the DisplayPort specification, which isn’t distributed openly but isn’t hard to come by, either.

Also, DisplayPort link training happens over AUX, and in order to facilitate that, a piece of DisplayPort controller’s external memory is usually exposed over the AUX channel, through a mechanism that’s called DPCD. If you dig a bit, using “DPCD” as the keyword, you can easily reach into the lower-level details of your DisplayPort connection. Some of the DPCD memory map is static, and some parts are FIFOs you can funnel data into, or out of. You can find a wide variety of documents online which describe the DPCD structure – for now, here’s a piece of Bash that works on Linux graphics drivers for AMD and Intel, and will show you you the first 16 bytes of DPCD:

# sudo dd if=/dev/drm_dp_aux0 bs=1 skip=256 count=16 |xxd
00000000: 0084 0000 0000 0000 0108 0000 0000 0000 ................
[...]

In particular, the 4th nibble (digit) here describes the amount of lanes for the DisplayPort link established – as you can see, my laptop uses a four-lane link. Also, the /dev/drm_dp_aux0 path might need to be adjusted for your device. In case you ever want to debug your DP link, having direct access to the DPCD memory space like this might help you quite a bit! For now, let’s move onto other practical aspects. Continue reading “DisplayPort: Under The Hood” →

Bridging The Gap Between Dissimilar Road Types With Foam

February 10, 2023 by 27 Comments

When you think of driving up or down an embankment, do you ever wonder how much foam you’re currently driving on? Probably not, because it hardly seems like a suitable building material. But as explained by [Practical Engineering] in the video below the break, using an expanded material to backfill an embankment isn’t as dense as it sounds.

In many different disciplines, mating dissimilar materials can be difficult: Stretchy to Firm; Soft to Hard; Light to Heavy. It’s that last one, Light to Heavy, that is a difficult match for roadways. A bridge may be set down in bedrock, but the embankments approaching it won’t be. The result? Over time, embankment settles lower than the bridge does, causing distress for cars and motorists alike. What’s the solution?

To mitigate this, engineers have started to employ less dirty materials to build their otherwise soil based embankments. Lightweight concrete is one solution, but another is Expanded Polystyrene (EPS) foam. Its light weight makes installation simple in anything but a strong breeze, and it’s inexpensive and durable. When used properly, it can last many years and provide a stable embankment that won’t settle as far or as quickly as one made of dirt. Because as it turns out, dirt is heavy. Who knew?

Aside from roadways and bespoke aircraft, EPS foam has also been used for making home insulation. What’s your favorite use for EPS foam? Let us know in the comments below.

Continue reading “Bridging The Gap Between Dissimilar Road Types With Foam” →

An iPhone sits in a users hand open to the YouTube app. What is unusual is that the iPhone is bent in an L shape and is still functioning properly.

First Folding IPhone Doesn’t Come From Apple

November 11, 2022 by 26 Comments

Folding phones are all the rage these days, with many of the major smartphone manufacturer’s having something in this form factor. Apple has been conspicuously absent in this market segment, so [KJMX] decided to take matters into their own hands with the “iPhone V.” (YouTube – Chinese w/subtitles via MacRumors).

Instead of trying to interface an existing folding phone’s screen with the iPhone, these makers delaminated an actual iPhone X screen to use in the mod. It took 37 attempts before they had a screen with layers that properly separated to be both flexible and functional. Several different folding phones were disassembled, and [KJMX] found a Motorola Razr folding mechanism would work best with the iPhone X screen. Unfortunately, since the iPhone screen isn’t designed to fold, it still will fail after a relatively small number of folds.

Other sacrifices were made, like the removal of the Taptic Engine and a smaller battery to fit everything into the desired form factor. The “iPhone V” boasts the worst battery life of any iPhone to date. After nearly a year of work though, [KJMX] can truly claim to have made what Apple hasn’t.

Curious about other hacks to let an iPhone do more than Apple intended? Check out how to add USB-C to an iPhone, try to charge it faster, or give one a big memory upgrade.

The Importance Of Physical Models: How Not To Shoot Yourself In The Foot Or Anywhere Else

November 10, 2022 by 73 Comments

We take shortcuts all the time with our physical models. We rarely consider that wire has any resistance, for example, or that batteries have a source impedance. That’s fine up until the point that it isn’t. Take the case of the Navy’s Grumman F11F Tiger aircraft. The supersonic aircraft was impressive, although it suffered from some fatal flaws. But it also has the distinction of being the first plane ever to shoot itself down.

So here’s the simple math. A plane traveling Mach 1 is moving about 1,200 km/h — the exact number depends on a few things like your altitude and the humidity. Let’s say about 333 m/s. Bullets from a 20 mm gun, on the other hand, move at more than 1000 m/second. So when the bullet leaves the plane it would take the plane over three seconds to catch up with it, by which time it has moved ever further away, right?

Continue reading “The Importance Of Physical Models: How Not To Shoot Yourself In The Foot Or Anywhere Else” →