People often get the impression that home built hardware is destined to have a certain amateurish look or feel to it. It’s as though just because you didn’t buy it in a store, it will look cheap or thrown together. While it’s true a hacked together device could look like it was built from the parts bin (and to be fair, sometimes it is), there are plenty of examples of DIY hardware that could give commercial offerings a run for their money.
A case in point is this fantastic ESP8266 air conditioner controller created by [Sitinut Waisara] (Google Translate). Between the simple yet elegant 3D printed enclosure to the very slick user interface on its OLED screen, this project could easily pass as a commercial device. In fact, we’ve seen commercial offerings that didn’t look half this good, let alone offer the same features for what this cost in components and printer filament. It’s a perfect example of what the modern hacker or maker is capable of with the wide array of tools and components currently available to us.
What’s perhaps the most impressive about this project, especially given how good it looks on the outside, is how little there really is on the inside. Beyond the NodeMCU board and SSD1332 OLED display, the only components inside the device are the three tactile buttons, a photoresistor so it can dim the display’s brightness based on ambient light level, an IR LED so it can send commands to the AC unit, and a handful of passives. The hardware side of this design is so simple that [Sitinut] was able to put the whole thing together on a scrap of perfboard. Not that you’d be able to tell when it gets installed into the 3D printed wall-mount enclosure, complete with printed button caps.
While the hardware side of the project might be rather light, the software is anything but. [Sitinut] really went all-in writing his code for the ESP, adding in the little features like the automatic screen dimming and pulling the current time from NTP that often get overlooked in our rush to get a project out the door. He even included a whole collection of icons to display on the OLED screen, which goes a long way towards selling that professional look. But his effort wasn’t limited to cosmetics or clever features, there was also plenty of work put into decoding the IR signals used to control the AC unit and getting all the features and functions plugged into MQTT.
We’ve seen a number of projects that aimed at dragging an existing HVAC system kicking and screaming onto the “Internet of Things”, some considerably less complex than others. But few have had the level of polish that [Sitinut] has put into his controller, so we take our hats off to him.
Continue reading “ESP8266 AC Controller Shows Whats Possible”
We got pointed by [packrat] to a 2015 presentation by [Dan Holohan] on the history and art of steam heating systems. At the advent of central heating systems for entire buildings, steam was used instead of water or air for the transport medium. These systems were installed in landmark buildings including the Empire State Building, which still use them to this day.
A major advantage of steam-based heating system is that no pump is required: the steam will naturally rise up through the piping, condenses and returns to the origin. This can be implemented as a single pipe where condensation returns through the same pipe as the steam, or a two-pipe system where the condensate returns through its own pipe.
In the presentation, Dan walks us through his experiences working on many of these steam heating systems in major US buildings, the types of systems, fixes implemented by engineers long since dead and the particularities of maintaining these systems.
Continue reading “The Lost Art Of Steam Heating”
There’s a fine line between a successful DIY project and one that ends in heartbreak. It’s subjective too; aside from projects that end up with fire trucks or ambulances in the driveway, what one DIYer would consider a disaster might be considered a great learning opportunity to someone else.
We’re pretty sure [Cressel] looks at his recent DIY mini-split AC installation for his shop as a series of teachable moments. Most folks leave HVAC work to the pros, but when you run a popular YouTube channel where you make your own lathe from scratch, you might be persuaded to give anything a go. [Cressel] did everything possible to do this job like a pro, going so far as to get training in the safe handling of refrigerants and an EPA certification so he knew how to charge the system correctly. He also sunk quite a bit of money into tools; between the manifold gauge set, vacuum pump, and various plumbing bits, that was a hefty $300 bite alone.
The install went well until he started charging the refrigerant, when a mistake with a fitting caused him to contaminate his nice, new batch of R-410A. Rather than back out and call a pro to finish up, [Cressel] stuck with it, to the tune of $900 in extra tools and materials needed to recover the old refrigerant safely and replace it with virgin R-410A. The video below has a condensed version of the whole tale.
It all worked out in the end, but at a cost that probably meets or exceeds what an HVAC contractor would have charged. [Cressel] seems like a glass-half-full kind of guy, though, so we expect he’s happy to have learned something new, and to have a bunch of neat new tools to boot.
Continue reading “Down the DIY Rabbit Hole with a Shop AC Installation”
If someone suggests you spend time working on boring projects, would you take that advice? In this case, I think Kipp Bradford is spot on. We sat down together at the Hackaday Superconference last fall and talked about medical device engineering, the infrastructure in your home, applying Sci-Fi to engineering, and yes, we spoke about boring projects.
Kipp presented a talk on Devices for Controlling Climates at Supercon last year. It could be argued that this is one of those boring topics, but very quickly you begin to grasp how vitally important it is. Think about how many buildings on your street have a heating or cooling system in them. Now zoom out in your mind several times to neighborhood, city, state, and country level. How much impact will a small leap forward have when multiplied up?
The next Hackaday Superconference is just around the corner. Before you join us below for the interview with Kipp, make sure you grab your 2018 Hackaday Superconference ticket to be there for great talks like Kipp’s!
Continue reading “Kipp Bradford on the Importance of Boring Projects, Medical Tech, and Sci Fi Novels”
We’d wager most readers aren’t intimately acquainted with wax motors. In fact, a good deal of you have probably never heard of them, let alone used one in a project. Which isn’t exactly surprising, as they’re very niche and rarely used outside of HVAC systems and some appliances. But they’re fascinating devices, and once you’ve seen how they work, you might just figure out an application for one.
[AvE] recently did a complete teardown on a typical wax motor, going as far as cutting the thing in half to show the inner workings. Now we’ve seen some readers commenting that everyone’s favorite foul-mouthed destroyer of consumer goods has lost his edge, that his newer videos are more about goofing off than anything. Well we can’t necessarily defend his signature linguistic repertoire, but we can confidently say this video does an excellent job of explaining these little-known gadgets.
The short version is that a wax motor, which is really a linear actuator, operates on the principle that wax expands when it melts. If a solid block of wax is placed in a cylinder, it can push on a piston during the phase change from solid to liquid. As the liquid wax resists compression, the wax motor has an exceptionally high output force for such a small device. The downside is, the stroke length is usually rather short: for the one [AvE] demonstrates, it’s on the order of 2 mm.
By turning heat directly into mechanical energy, wax motors are often used to open valves and vents when they’ve reached a specific temperature. The common automotive engine thermostat is a classic example of a wax motor, and they’re commonly found inside of dishwashers as a way to open the soap dispenser at the proper time during the cycle.
This actually isn’t the first time we’ve featured an in-depth look at wax motors, but [AvE] actually cutting this one in half combined with the fact that the video doesn’t look like it was filmed on a 1980’s camera makes it worth revisiting the subject. Who is going to build a wax motor power device for the Power Harvesting Challenge in the 2018 Hackaday Prize?
Continue reading “Dissecting the Elusive Wax Motor”
Putting everything on the Internet is getting easier and easier, what with the profusion of Internet-ready appliances as well as cheap and plentiful IoT modules to integrate legacy devices. Think IoT light bulbs, refrigerators and dishwashers that can be controlled from a smartphone, and the ubiquitous Sonoff modules. But once these things are on the net, what are they talking about? Are they saying things behind your back? Are they shipping data about your fridge contents off to some foreign land, to be monetized against your will?
Maybe, maybe not, but short of a tinfoil helmet the only way to protect yourself is to build your own system. This IoT control for ceiling fans is a good example, with the added benefit that most wireless ceiling fan remotes are kind of lousy. [microentropie] didn’t like the idea of going the Sonoff route, so his custom controller is based on that IoT workhorse, the ESP8266. There are two versions, one switching the light and fan loads with relays, and one with triacs. The ESP serves up its own web page for control rather than using a cloud service, and is capable of setting up the fan to turn on and off automatically at preset times or temperatures. Everything sits in an unobtrusive box on the ceiling near the fan, but we bet this could be miniaturized enough to fit right inside the fan housing.
If some of [microentropie]’s code looks familiar, it might be because he borrowed it from his IoT rice cooker project.
Infrared remote controls are simple and ubiquitous. Emulating them with the aid of a microcontroller is a common project that hackers use to control equipment as diverse as televisions, cable boxes, and home stereos. Some air conditioners can be a little more complicated, however, but [Ken]’s here to help.
The root of the problem is that the air conditioner remote was using a non-obvious checksum to verify if commands received were valid. To determine the function generating the checksum, [Ken] decided to bust out the tools of differential cryptanalysis. This involves carefully varying the input to a cryptographic function and comparing it to the differences in the output.
With 35 signals collected from the remote, a program was written to find input data that varied by just one bit. The checksum outputs were then compared to eventually put together the checksum function.
[Ken] notes that the function may not be 100% accurate, as they’re only using a limited sample of data in which not all the bytes change significantly. However, it shows that a methodical approach is valuable when approaching such projects.
Thirsty for more checksum-busting action? Check out this hacked weather station.