flux

34 Articles

Jigsaw Motor Uses PCB Coils For Radial Flux

July 16, 2019 by 7 Comments

Electric motors are easy to make; remember those experiments with wire-wrapped nails? But what’s easy to make is often hard to engineer, and making a motor that’s small, light, and powerful can be difficult. [Carl Bugeja] however is not one to back down from a challenge, and his tiny “jigsaw” PCB motor is the latest result of his motor-building experiments.

We’re used to seeing brushless PCB motors from [Carl], but mainly of the axial-flux variety, wherein the stator coils are arranged so their magnetic lines of force are parallel to the motor’s shaft – his tiny PCB motors are a great example of this geometry. While those can be completely printed, they’re far from optimal. So, [Carl] started looking at ways to make a radial-flux PCB motor. His design has six six-layer PCB coils soldered perpendicular to a hexagonal end plate. The end plate has traces to connect the coils in a star configuration, and together with a matching top plate, they provide support for tiny bearings. The rotor meanwhile is a 3D-printed cube with press-fit neodymium magnets. Check out the build in the video below.

Connected to an ESC, the motor works decently, but not spectacularly. [Carl] admits that more tweaking is in order, and we have little doubt he’ll keep optimizing the design. We like the look of this, and we’re keen to see it improved.

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The Fascinating World Of Solder Alloys And Metallurgy

May 30, 2019 by 57 Comments

Solder is the conductive metal glue that one uses to stick components together. If you get the component and the PCB hot enough, and melt a little solder in the joint, it will stay put and conduct reliably. But it’s far from simple.

There are many different solder alloys, and even the tip of the soldering iron itself is a multi-material masterpiece. In this article, we’ll take a look at the metallurgy behind soldering, and you’ll see why soldering tip maintenance, and regular replacement, is a good idea. Naturally, we’ll also touch upon the role that lead plays in solder alloys, and what the effect is of replacing it with other metals when going lead-free. What are you soldering with? Continue reading “The Fascinating World Of Solder Alloys And Metallurgy” →

Hacking The Ionosphere, For Science

May 10, 2019 by 14 Comments

Imagine what it must have been like for the first human to witness an aurora. It took a while for our species to migrate from its equatorial birthplace to latitudes where auroras are common, so it was a fairly recent event geologically speaking. Still, that first time seeing the shimmers and ribbons playing across a sky yet to be marred by light pollution must have been terrifying and thrilling, and like other displays of nature’s power, it probably fueled stories of gods and demons. The myths and legends born from ignorance of what an aurora actually represents seem quaint to most of us, but it was as good a model as our ancestors needed to explain the world around them.

Our understanding of auroras needs to be a lot deeper, though, because we now know that they are not only a beautiful atmospheric phenomenon but also a critical component in the colossal electromagnetic system formed by our planet and our star. Understanding how it works is key to everything from long-distance communication to keeping satellites in orbit to long-term weather predictions.

But how exactly does one study an aurora? Something that’s so out of reach and so evanescent seems like it would be hard to study. While it’s not exactly easy science to do, it is possible to directly study auroras, and it involves some interesting technology that actually changes them, somehow making the nocturnal light show even more beautiful.

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Get To Know The Physics Behind Soldering And The Packaging Of ICs

May 3, 2019 by 22 Comments

Often it feels as if soldering is deemed to be more of an art form than something that’s underpinned by the cold, hard reality of physics and chemistry. From organic chemistry with rosin, to the material properties of fragile gold bond wires and silicon dies inside IC packages and the effects of thermal stress on the different parts of an IC package, it’s a complicated topic that deserves a lot more attention than it usually gets.

A casual inquiry around one’s friends, acquaintances, colleagues and perfect strangers on the internet usually reveals the same pattern: people have picked up a soldering iron at some point, and either figured out what seemed to work through trial and error, or learned from someone else who has learned what seemed to work through trial and error. Can we say something scientific about soldering?

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Ask Hackaday: Get The Lead Out Or Not?

March 26, 2019 by 159 Comments

For most of the history of industrial electronics, solder has been pretty boring. Mix some lead with a little tin, figure out how to wrap it around a thread of rosin, and that’s pretty much it. Sure, flux formulations changed a bit, the ratio of lead to tin was tweaked for certain applications, and sometimes manufacturers would add something exotic like a little silver. But solder was pretty mundane stuff.

Source: RoHS Guide

Then in 2003, the dull gray world of solder got turned on its head when the European Union adopted a directive called Restriction of Hazardous Substances, or RoHS. We’ve all seen the little RoHS logos on electronics gear, and while the directive covers ten substances including mercury, cadmium, and hexavalent chromium, it has been most commonly associated with lead solder. RoHS, intended in part to reduce the toxicity of an electronic waste stream that amounts to something like 50 million tons a year worldwide, marked the end of the 60:40 alloy’s reign as the king of electrical connections, at least for any products intended for the European market, when it went into effect in 2006.

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Visual Magnetic Fields

February 25, 2019 by 18 Comments

If you need help visualizing magnetic fields, these slow-motion video captures should educate or captivate you. Flux lines are difficult to describe in words, because magnet shape and strength play a part. It might thus be difficult to visualize what is happening with a conical magnet, for a person used to a bar magnet. We should advise you before you watch the video below the break, if you are repelled by the sight of magnetite sand clogging a bare magnet then flying on the floor, this is your only warning.

The technique and equipment are simple and shown in the video. A layer of black sand is spread on a piece of tense plastic to make something like a dirty trampoline, and a neodymium magnet is dropped in the middle. The bouncing action launches the sand and magnet simultaneously so they are hanging in the air and the particles can move with little more than air resistance.

These videos were all taken with a single camera and a single magnet. Multiple cameras would yield 3D visuals, and the intertwining fields of multiple magnets can be beautiful. Perhaps a helix of spherical magnets? What do you have lying around the hosue? In a twist, we can use magnets to simulate gas atoms and trick them into performing unusual feats.

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Cheap Muon Detectors Go Aloft On High-Altitude Balloon Mission

January 15, 2019 by 15 Comments

There’s something compelling about high-altitude ballooning. For not very much money, you can release a helium-filled bag and let it carry a small payload aloft, and with any luck graze the edge of space. But once you retrieve your payload package – if you ever do – and look at the pretty pictures, you’ll probably be looking for the next challenge. In that case, adding a little science with this high-altitude muon detector might be a good mission for your next flight.

[Jeremy and Jason Cope] took their inspiration for their HAB mission from our coverage of a cheap muon detector intended exactly for this kind of citizen science. Muons constantly rain down upon the Earth from space with the atmosphere absorbing some of them, so the detection rate should increase with altitude. [The Cope brothers] flew two of the detectors, to do coincidence counting to distinguish muons from background radiation, along with the usual suite of gear, like a GPS tracker and their 2016 Hackaday prize entry flight data recorder for HABs.

The payload went upstairs on a leaky balloon starting from upstate New York and covered 364 miles (586 km) while managing to get to 62,000 feet (19,000 meters) over a five-hour trip. The [Copes] recovered their package in Maine with the help of a professional tree-climber, and their data showed the expected increase in muon flux with altitude. The GoPro died early in the flight, but the surviving footage makes a nice video of the trip.

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