Here’s a historical hack for you: you have a big, rolling pressurized kettle, also known as a steam locomotive. It needs water to make up for the steam constantly chuff-chuff-chuffing away, or bad things happen. How do you get water from an unpressurized tender into a high pressure boiler with no moving parts? What you need is a some way to inject steam with no moving parts — a steam injector, if you will. [Marc Flint] found that the steam injectors were the hardest part of a loco to understand, so he made a video for all of us once he’d figured it out.
The steam injector isn’t a new idea. [Henri Giffard] came up with it back in the 1850s to replace expensive and maintenance-hungry pumps. It’s rather ingenious and uses the fluid mechanics uncovered by another European bloke by the name of Bernoulli. First, the high-pressure steam from the boiler goes through a converging-diverging nozzle to drop its pressure and speed its flow up, just as you’d guess if you’ve seen Bernoulli’s laws. Even more vacuum-inducing is the presence of water: the steam, already cooled by its expansion, hits the water in the pipe open to the tender, and condenses into it, shrinking a couple of orders of magnitude, creating a vacuum that draws in no small quantity of feed water. That one we did not expect from Bernoulli, but it makes sense. So how to get from below atmospheric pressure to the 180-odd PSI or more in the boiler?
Well, the water is now moving at a good clip, between the Venturi effect and the momentum gained from absorbing that steam, so another converging nozzle is the trick. Bernoulli’s law, once more! A one-way valve lets the now-pressurized water into the boiler, with a gap in between to dump water while the pressure builds up. It’s a clever trick, and since the steam coming from the boiler makes it back inside along with at least some of its heat energy, it’s much more efficient in both coal and water than running a pump. It’s also a bit of a head scratcher how it works unless someone sits you down to explain it, so we’re glad [Marc] did.
Not many of us are likely to use this knowledge directly — unless we’re firing up a 90 year old boiler or building a new steam locomotive — but seeing how great engineers of years past made use of basic physical laws can serve both as education and inspiration.
Lately, this peculiar little single wheel monorail came to our attention. Built by [extraglide1976], all from Meccano. His build started with modest tests: one gyro obviously flopped. Two gyros geared together ran slightly better. But when he adds active gimbal control, things suddenly come to life – the model shudders, catches itself, and carries on. The final green-roofed locomotive, with LEDs signalling ‘system go’, trundles smoothly along a single rail on [extraglide1976]’s deck.
To be fair, it houses a lot of mechanics and engineering which we don’t find in the monorails of today. We do have quite a few monorails in our world, but none of them balance on a single wheel like this one. So, where did this invention derail?
Outside of theme parks, Japan is one of the few countries where monorails are still used as serious urban transport: though Germany’s century-old Wuppertal Schwebebahn, the lesser-known C-Bahn, China’s sprawling Chongqing and Shanghai systems, Malaysia’s Kuala Lumpur line, Brazil’s São Paulo network, the US links in Seattle and Las Vegas, and India’s Mumbai Monorail prove the idea has quietly taken root elsewhere.
The thing you’ll see in nearly all these monorails is how the carriages are designed to clamp onto the tracks. This is of course the most safe option, but it loses out on speed to the ones that sit on top of the tracks, balancing on one wheel. Such a train was actually invented, in 1910, by Louis Brennan. His original monorail promised faster, cheaper transport, even using existing rails. The carriages leaned into turns like a motorbike, without any intervention from the driver. Two counter-rotating gyroscopes kept the carriage upright, cancelling precession forces like a mechanical Jedi trick.
Back then, it failed commercially, but today? With cheap sensors, brushless motors, and microcontrollers, and intelligent software, why not let it make a comeback? It could carry freight through narrow urban tunnels. With high-speed single-rail pods?
Investors killed Brennan’s idea, but we live in a different time now. You could start out with a gimmicky ‘snacks and beer’ highline from your fridge to your garage. Share your take on it in the comments!
One of the most popular evergreen toys is also one of the simplest, wooden track with push-along trains. We all know the brand name, and savvy parents know to pick up the much cheaper knock-off because the kid won’t know the difference. But a really cool kid shouldn’t have to push their train around by hand, and thus [Lauri] has given the wooden track a real, powered, locomotive.
In the 3D printed chassis goes a small geared motor driving one axle, with an ESP32 and a motor driver taking care of the smarts. Power comes from an 18650 cell, which almost looks like the right scale for a fake steam boiler. The surprise with this train comes in the front axle, this machine has steering. We’re curious, because isn’t the whole point of a train that the track directs it where it needs to go? Or perhaps a little help is required in the absence of a child’s guidance when it comes to points. Either way, with remote control we guess there would be few kids who wouldn’t want one. We certainly do.
There’s nothing more guaranteed to excite a grizzled old railway enthusiast than the sight of a steam locomotive. The original main-line rail propulsion technology still clings on in a few places, but for practical purposes, it disappeared a lifetime ago. It’s interesting then to hear of a brand new steam locomotive prototype being considered for revenue freight use on British metals. Is it yet another rebuild of a heritage design to be used for enthusiasts only? No, it’s an entirely new design with nothing in common with the locomotives of the past, as [Terrier55Stepney] tells us in the video below the break.
Gone is the huge boiler and reciprocating pistons of old, as indeed is the notion of boiling anything. Instead, this is a steam turbine, nothing like the 1920s and 30s experiments with conventional locomotives, nor even the Union Pacific’s oil-fired condensing turbo-electrics. The new idea here from the British company Steamology is to create steam directly from the combustion of hydrogen in a series of small modular steam generators, and the resulting prototype turbo-generator will replace the diesel engine in a redundant British Rail class 60 freight locomotive. It’s unclear whether it will incorporate a condenser, but since it has no need to retain the water for a boiler we’re not sure it would need one.
Prototype locomotives featuring new technologies have a long and inglorious history of not making the grade, so while this is definitely an exciting and interesting development we’re not guaranteed to see it in widespread use. But it could offer a way to ensure a low-carbon replacement for diesel heavy freight locomotives, and unexpectedly provide engine upgrades for existing classes. The fact it’s technically a steam locomotive is incidental.
If you were to visit a railway almost anywhere in the world, you would find that unless it was in some way running heritage trains, the locomotives would bear a similarity to each other. Electric traction is the norm, whether it comes from a trackside supply or from a diesel generator. In the middle of the last century, as the industry moved away from steam traction though, this was far from a certainty. Without much in the way of power electronics, it was a challenge to reliably and efficiently control a large traction motor, so there were competing traction schemes using mechanical gearboxes or hydraulic drives. One of these is the subject of an archive film released by the oil company Shell, and it’s a fascinating journey into a technology that might have been.
The Fell differential gearbox.
All diesel locomotive designs struggle with the problem of transmitting the huge torque required to start a fully loaded train at low speeds, and because of the huge force required, it’s impossible to design a locomotive-sized conventional gearbox to do the job in the way it might be managed on a truck. Electric and hydraulic drives exploit the beneficial torque characteristics of electric and hydraulic motors, but the mechanical gearbox isn’t quite done for. The subject of the video is British Rail number 10100, otherwise commonly known as the Fell locomotive, and it was a one-off prototype that took to the rails at the start of the 1950s designed to test a very novel gearbox design.
At the heart of the Fell gearbox is a set of differential gears the same as you’d find in the axle of a car, and in the locomotive they are used to combine the output of more than one engine. The loco had four smaller-than-normal diesel traction motors that could be combined, but even then, it wasn’t done. To achieve variable torque, they employed superchargers driven by a set of even-smaller diesel engines, resulting in an ungainly multi-engined beast but with the desired characteristics for both starting heavy trains and for moving them at high speed. Continue reading “Retrotechtacular: The Fell Locomotive”→
Cutting straight to the punchline, the manufacturer of the engines in question apparently also makes a lot of money on the service contracts, and included logic bombs in the firmware that would ensure that revenue stream while thwarting independent repair shops. They also included “cheat codes” that simply unlocked the conditions, which the Polish hackers uncovered as well. Perhaps the most blatant evidence of malfeasance, though, was that there were actually checks in some versions of the firmware that geofenced out the competitors’ repair shops.
We shouldn’t spoil too much more of the talk, and there’s active investigation and legal action pending, but the smoking guns are incredibly smoky. The theme of this year’s Chaos Communication Congress is “Unlocked”, and you couldn’t ask for a better demonstration of why it’s absolutely in the public interest that hackers gotta hack. Of course, [Daniel Lange] and [Felix Domke]’s reverse engineering of the VW Dieselgate ECU shenanigans, another all-time favorite, also comes to mind.
Ask the average person about steam power and they’ll probably imagine a bygone era, a time when the sky was thick with smoke belched out by coal-burning locomotives and paddle-wheel ships. Steam is ancient technology they’ll say, and has as much to do with modern living as the penny-farthing.
Naturally, the real story is a bit more complex than that. Sure the reciprocating steam engine has fallen out of favor as a means of propulsion, but the concept of running machinery with steam is alive and well. In fact, unless you’re running on wind or solar power, there’s an excellent chance that a steam turbine is responsible for keeping the lights on in your house.
In honor of all things steam, we invited Quinn Dunki to host this week’s Hack Chat. Those who follow her exploits on YouTube will know that over the last several years she’s built a number of steam engines, from miniature scratch-built models to commercial kits that can do useful work. Who better to answer your burning steaming questions?
The first questions in the Chat were logical enough, with several users wanting to know just how hard it is to build a functional steam engine if you don’t have access to a mill or other means of high precision machining. According to Quinn, while better equipment will certainly allow you to build a more powerful and efficient engine, the basic premise is so simple that it doesn’t take much to get one going. If you’ve got a mini lathe and some bar stock, you’re half way there. In fact, they are so forgiving that she opines you’d struggle to build a steam engine that didn’t at least turn over — though that doesn’t mean it will necessarily run well.
Naturally some comparisons were drawn between the complexity of building a steam engine and putting together a small internal combustion engine (ICE). But while they might seem conceptually similar, Quinn cautions that building a working ICE from scratch is far more difficult and dangerous. She explains that steam engines have a tendency to fail gracefully, that is, mistakes in the design or poor tolerances generally result in little worse than wasted steam and extra noise. Comparatively, a faulty ICE design could easily turn into a bomb on your workbench.
Of course, that’s not to say working with steam is without danger. You certainly don’t want to underestimate high pressure steam, which is why boilers that are over 6 in (15 cm) in diameter or that produce more than 100 PSI will often require the operator to be licensed. They may also need to be inspected, though Quinn notes that your local government official probably won’t be able to make heads or tails of your homebrew build — so if you need an official stamp of approval, your best bet is to find a local model engineering club or society that would have the appropriate connections. All that being said, most hobbyists make it a point to try and get their engine running at the lowest pressure possible, so unless you’ve got something really massive in mind, you’ll probably never need to build up more than 60 PSI or so.
A DIY electric boiler and small steam engine.
Another topic of discussion was how to fuel the boiler itself. An electrically powered boiler is perhaps the easiest option, but is somewhat counterproductive if you hope to put your steam engine to useful work. Coal and wood fires are an option, and indeed were commonly used in the old days, but the soot and ash they produce can be a problem.
Quinn also notes that if you’re using such fuels, you need a way to quickly remove the firebox from the boiler in an emergency; something she likens to the starship Enterprise having to eject its warp core before it explodes. For her own projects, Quinn says she uses either an electric element or a camping gas burner.
While most of the questions during this Hack Chat had to do with the work Quinn has already featured on her blog and YouTube channel, naturally there were questions about where things go from here. After she completes the steam engine kit she’s working on currently, she says she’ll likely to back to another scratch-built engine. She also plans on coupling some of her engines to generators, as she’s gotten many requests about seeing these machines put to useful work. Looking further ahead Quinn says she’s interested in casting her own bronze and aluminum components, and specifically wants to work with “lost PLA” casting, which is a variant of lost wax casting that uses a mold based on a 3D printed part.
We’d like to thank Quinn Dunki for stopping by the Hack Chat and sharing some insights into this unique hobby. While a handcrafted boiler or a desktop steam reciprocating engine might not be on the average Hackaday reader’s list of future projects, it’s still fascinating to see how they work. We owe much of our modern life to steam power, so the least we can do is show it some respect.
The Hack Chat is a weekly online chat session hosted by leading experts from all corners of the hardware hacking universe. It’s a great way for hackers connect in a fun and informal way, but if you can’t make it live, these overview posts as well as the transcripts posted to Hackaday.io make sure you don’t miss out.
