Street-Legalize Your Ebike With A Magnet

March 1, 2021 by Bryan Cockfield 98 Comments

Getting into e-biking is a great hobby. It can get people on bikes who might otherwise not be physically able to ride, it can speed up commute times, and it can even make hauling lots of stuff possible and easy, not to mention it’s also fun and rewarding. That being said, there are a wide array of conflicting laws around what your e-bike can and can’t do on the road and if you don’t want to run afoul of the rules you may need a programmable device that ensures your e-bike is restricted in the appropriate way.

This build is specifically for Bafang mid drives, which can be up to 1000 W and easily power a bike beyond the speed limit where [Tomblarom] lives. A small microcontroller is housed in a waterproof box on the bike and wired between the motor’s display and controller. A small hall effect sensor and magnet sit by this microcontroller, and if the magnet is removed then the microcontroller reprograms the bike’s controller to limit the speed and also to disable the throttle, another feature that is illegal in some jurisdictions but not others. As an added bonus, the microcontroller also handles brake lights, turn signals, and automatic headlights for the bike as well.

While the project page mentions removing the magnet while getting pulled over to avoid fines and other punishments, that’s on you. We imagine this could still be useful for someone who wants to comply with local laws when riding on the road, but still wants to remove the restrictions when riding on private property or off-road where the wattage and speed restrictions might not apply.

Motor Controller Reverse Engineering Releases Smoke

February 5, 2021 by Tom Nardi 31 Comments

It may have been designed for a sewing machine, but [Haris Andrianakis] found his imported DC brushed motor was more than up to the challenge of powering his mini lathe. Of course there’s always room for improvement, so he set out to reverse engineer the motor’s controller to implement a few tweaks he had in mind. Unfortunately, things took an unexpected turn when plugging his AVR programmer into the board’s ISP socket not only released the dreaded Magic Smoke, but actually tripped the breaker and plunged his bench into darkness.

Studying how the Hall-effect sensors in the motor are wired.

Upon closer inspection, it turned out the board has no isolation between the high voltage side and its digital logic. When [Haris] connected his computer to it via the programmer, the 330 VDC coming from the controller’s rectifier shorted through the USB bus and tripped the Earth-leakage circuit breaker (ELCB). The good news is that his computer survived the ordeal, and even the board itself seemed intact. But the shock must have been too much for the microcontroller he was attempting to interface with, as the controller no longer functioned.

Now fully committed, [Haris] started mapping out the rest of the controller section by section. In the write-up on his blog, he visually masks off the various areas of the PCB so readers have an easier time following along and understanding how the schematics relate to the physical board. It’s a nice touch, and a trick worth keeping in mind during your own reverse engineering adventures.

In the end, [Haris] seems to have a good handle on what the majority of the components are up to on the board. Which is good, since getting it working again now means replacing the MCU and writing new firmware from scratch. Or perhaps he’ll just take the lessons learned from this controller and spin up his own custom hardware. In either event, we’ll be keeping an eye out for his next post on the subject.

Raspberry Pi Enters Microcontroller Game With $4 Pico

January 20, 2021 by Elliot Williams 351 Comments

Raspberry Pi was synonymous with single-board Linux computers. No longer. The $4 Raspberry Pi Pico board is their attempt to break into the crowded microcontroller module market.

The microcontroller in question, the RP2040, is also Raspberry Pi’s first foray into custom silicon, and it’s got a dual-core Cortex M0+ with luxurious amounts of SRAM and some very interesting custom I/O peripheral hardware that will likely mean that you never have to bit-bang again. But a bare microcontroller is no fun without a dev board, and the Raspberry Pi Pico adds 2 MB of flash, USB connectivity, and nice power management.

As with the Raspberry Pi Linux machines, the emphasis is on getting you up and running quickly, and there is copious documentation: from “Getting Started” type guides for both the C/C++ and MicroPython SDKs with code examples, to serious datasheets for the Pico and the RP2040 itself, to hardware design notes and KiCAD breakout boards, and even the contents of the on-board Boot ROM. The Pico seems designed to make a friendly introduction to microcontrollers using MicroPython, but there’s enough guidance available for you to go as deep down the rabbit hole as you’d like.

Our quick take: the RP2040 is a very well thought-out microcontroller, with myriad nice design touches throughout, enough power to get most jobs done, and an innovative and very hacker-friendly software-defined hardware I/O peripheral. It’s backed by good documentation and many working examples, and at the end of the day it runs a pair of familiar ARM MO+ CPU cores. If this hits the shelves at the proposed $4 price, we can see it becoming the go-to board for many projects that don’t require wireless connectivity.

But you want more detail, right? Read on.

Continue reading “Raspberry Pi Enters Microcontroller Game With $4 Pico” →

Arduino Wannabe Should Have Used A 555. Oh Wait, It Does.

January 17, 2021 by Dan Maloney 89 Comments

It’s a little known secret that when the Hackaday writers gather in their secret underground bunker to work on our plans for world domination, we often take breaks to play our version of the corporate “Buzzword Bingo”, where paradigms are leveraged and meetings circle back to loop in offline stakeholders, or something like that. Our version, however, is “Comment Line Bingo”, and right in the middle of the card is the seemingly most common comment of all: “You should have used a 555,” or variations thereof.

So it was with vicious glee that we came across the Trollduino V1.0 by the deliciously named [Mild Lee Interested]. It’s the hardware answer to the common complaint, which we’ll grant is often justified. The beautiful part of this is that Trollduino occupies the same footprint as an Arduino Uno and is even pin-compatible with the microcontroller board, or at least sort of. The familiar line of components and connectors sprout from the left edge of the board, and headers for shields line the top and bottom edges too. “Sketches” are implemented in hardware, with jumpers and resistors and capacitors of various values plugged in to achieve all the marvelous configurations the indispensable timer chip can be used for. And extra points for the deliberately provocative use of Comic Sans in the silkscreen.

Hats off to [Lee] for a thoroughly satisfying troll, and a nice look at what the 555 chip can really do. If you want a more serious look at the 555, check out this 555 modeled on a breadboard, or dive into the story of the chip’s development.

Hacking A 3D Pen For Better Performance

January 13, 2021 by Bryan Cockfield 9 Comments

When 3D pens first became available, many assumed them to be gimmicky or part of a general fad that would eventually die out. Like most revolutionary technologies, though, they’ve found a firm foothold, especially in the art community where the ability to 3D print in freehand is incredibly valuable. There are still some shortcomings with the technology, though, but [tterev3] recently tore into a 3doodler pen to make some necessary upgrades.

First, this pen has some design choices that are curious, to say the least. The cooling fan runs regardless of temperature, and it has pushbuttons for start and stop rather than a momentary button that controls the extrusion. To fix these issues, as well as change the filament size, improve the cooling, and provide greater control over the extrusion speed, [tterev3] completely rewrote the firmware, changed the microcontroller on the PCB, and made several hardware upgrades to accommodate these changes. He also went ahead and installed a USB-C port for charging, which should be standard practice on all low-voltage consumer electronics by now anyway.

The detail work on this project is impressive, given the small size of the pen itself and the amount of precision hardware needed to make the changes. Especially regarding the replacement of the microcontroller on the board itself, which is an impressive feat even without the incredibly small dimensions. The firmware upgrade is available on his GitHub page as well if you have your own 3doodler that needs modifications, and if you’re still struggling to find uses for these handy devices, we’ve seen them used with interesting effect to build drones.

Squeezing Every Bit From An ATMega

December 26, 2020 by Bryan Cockfield 16 Comments

While the ATMega328 is “mega” for a microcontroller, it’s still a fairly limited platform. It has plenty of I/O and working memory for most tasks, but this Battleship game that [thorlancaster328] has put together really stretches the capabilities of this tiny chip. Normally a Battleship game wouldn’t be that complicated, but this one has audio, an LED display, and can also play a fine rendition of Nyan Cat to boot, which really puts the Atmel chip through its paces.

The audio is played through a 512-byte buffer and an interrupt triggers the microcontroller when to fill the buffer while it works on the other processes. The 12×12 LED display is also fed through a shift register triggered by the same interrupt as the audio, and since the build uses so many shift registers the microcontroller can actually output four separate displays (two players, each with a dispaly for shots and one for ships). It will also eventually support a player-vs-computer mode for the battleship game, and also has a mode where it plays Nyan cat just to demonstrate its own capabilities.

We’re pretty impressed with the amount of work this small microcontroller is doing, largely thanks to code optimization from its creator [thorlancaster328]. If there’s enough interest he also says he will provide the source code too. Until then, be sure to check out this other way of pushing a small microcontroller to its limits.

Thanks to [Thinkerer] for the tip!

Micropython On Microcontrollers

November 14, 2020 by Bryan Cockfield 54 Comments

There are plenty of small microcontrollers available for all kinds of tasks, each one with its unique set of features and capabilities. However, not all of us want to spend time mucking about in C or assembly to learn the intricacies of each different chip. If you prefer the higher planes of Python instead, it’s not impossible to import Python on even the smallest of microcontrollers thanks to MicroPython, which [Rob] shows us in this project based on the ESP32.

[Rob] has been working on a small robot called Marty which uses an ESP32 as its brain, so the small microcontroller is already tasked with WiFi/Bluetooth communications and driving the motors in the robot. Part of the problem of getting Python to run on a platform like this is that MicroPython is designed to be essentially the only thing running on the device at any one point, but since the ESP32 is more powerful than the minimum requirements for MicroPython he wanted to see if he could run more than just Python code. He eventually settled on a “bottum-up” approach to build a library for the platform, rather than implementing MicroPython directly as a firmware image for the ESP32.

The blog post is an interesting take on running Python code on a small platform, and goes into some details with the shortcomings of MicroPython itself which [Rob] ended up working around for this project. He’s also released the source code for his work on his GitHub page. Of course, for a different approach to running Python and C on the same small processor, there are some libraries that accomplish that as well.