Hackaday Links: May 8, 2022

May 8, 2022 by Dan Maloney 13 Comments

Russia’s loose cannon of a space boss is sending mixed messages about the future of the International Space Station. Among the conflicting statements from Director-General Dmitry Rogozin, the Roscosmos version of Eric Cartman, is that “the decision has been made” to pull out of the ISS over international sanctions on Russia thanks to its war on Ukraine. But exactly when would this happen? Good question. Rogozin said the agency would honor its commitment to give a year’s notice before pulling out, which based on the current 2024 end-of-mission projections, means we might hear something definitive sometime next year. Then again, Rogozin also said last week that Roscosmos would be testing a one-orbit rendezvous technique with the ISS in 2023 or 2024; it currently takes a Soyuz about four orbits to catch up to the ISS. So which is it? Your guess is as good as anyones at this point.

At what point does falsifying test data on your products stop being a “pattern of malfeasance” and become just the company culture? Apparently, something other than the 40 years that Mitsubishi Electric has allegedly been doctoring test results on some of their transformers. The company has confessed to the testing issue, and also to “improper design” of the transformers, going back to the 1980s and covering about 40% of the roughly 8,400 transformers it made and shipped worldwide. The tests that were falsified were to see if the transformers could hold up thermally and withstand overvoltage conditions. The good news is, unless you’re a power systems engineer, these aren’t transformers you’d use in any of your designs — they’re multi-ton, multi-story beasts that run the grid. The bad news is, they’re the kind of transformers used to run the grid, so nobody’s stuff will work if one of these fails. There’s no indication whether any of the sketchy units have failed, but the company is “considering” contacting owners and making any repairs that are necessary.

For your viewing pleasure, you might want to catch the upcoming documentary series called “A League of Extraordinary Makers.” The five-part series seeks to explain the maker movement to the world, and features quite a few of the luminaries of our culture, including Anouk Wipprecht, Bunnie Huang, Jimmy DiResta, and the gang at Makers Asylum in Mumbai, which we assume would include Anool Mahidharia. It looks like the series will focus on the real-world impact of hacking, like the oxygen concentrators hacked up by Makers Asylum for COVID-19 response, and the influence the movement has had on the wider culture. Judging by the trailer below, it looks pretty interesting. Seems like it’ll be released on YouTube as well as other channels this weekend, so check it out.

But, if you’re looking for something to watch that doesn’t require as much commitment, you might want to check out this look at the crawler-transporter that NASA uses to move rockets to the launch pad. We’ve all probably seen these massive beasts before, moving at a snail’s pace along a gravel path with a couple of billion dollars worth of rocket stacked up and teetering precariously on top. What’s really cool is that these things are about as old as the Space Race itself, and still going strong. We suppose it’s easier to make a vehicle last almost 60 years when you only ever drive it at half a normal walking speed.

And finally, if you’re wondering what your outdoor cat gets up to when you’re not around — actually, strike that; it’s usually pretty obvious what they’ve been up to by the “presents” they bring home to you. But if you’re curious about the impact your murder floof is having on the local ecosystem, this Norwegian study of the “catscape” should be right up your alley. They GPS-tagged 92 outdoor cats — which they dryly but hilariously describe as “non-feral and food-subsidized” — and created maps of both the ranges of individual animals, plus a “population-level utilization distribution,” which we think is a euphemism for “kill zone.” Surprisingly, the population studied spent almost 80% of their time within 50 meters of home, which makes sense — after all, they know where those food subsidies are coming from.

NASA’s Giant SLS Rocket Rolled Back For Repairs

April 27, 2022 by Tom Nardi 33 Comments

There’s little debate that the most exciting move in a rocket’s repertoire is when it launches itself skywards on a column of flame. But failing that, it’s still pretty interesting to see how these massive vehicles get juggled around down here on terra firma before getting fired off into the black. Which is great for anyone interested in NASA’s towering Space Launch System (SLS), as it’s been doing an awful lot of milling about on the ground for a vehicle designed to return humanity to the Moon.

Most recently, the SLS completed a trek from the iconic Vehicle Assembly Building (VAB) to launch pad 39B and back again aboard the same “crawler” that moved the Space Shuttle and Saturn V before it. While the nearly 60-year-old tracked vehicle has received some updates to carry the 98 meter (322 ft) tall booster, clearly the space agency subscribes to the “if it ain’t broke, don’t fix it” school of thought.

The SLS itself however is definitely in need of some work. The rocket was brought out to the pad for the first time on March 18th, where it was to conduct what’s known as a “wet dress rehearsal” — a test of the pre-flight operations, propellant loading, and countdown that includes everything except engine ignition. Unfortunately, the test was plagued with technical issues, and after three attempts, it was decided to bring the rocket back into the VAB to make the necessary repairs to both it and the ground support equipment.

One issue involves a valve in the Interim Cryogenic Propulsion Stage (ICPS), a propulsion module that’s being used on the early SLS flights to provide the trans-lunar injection (TLI) burn that will send the Orion spacecraft on a course towards the Moon. As the name implies, the ICPS is destined to be replaced with the larger Exploration Upper Stage on later missions. There’s also a leak on the launch tower itself that will need to be addressed. After the identified problems are repaired and some adjustments are made, the SLS will once again be rolled out to the pad to reattempt the launch rehearsal.

Now in development for over a decade, the Space Launch System has been plagued with technical issues and delays. At the same time, commercial launch providers like SpaceX have moved the state of the art forward considerably, leading many to wonder if the mind-bogglingly expensive rocket will be able to compete with in-development vehicles such as Starship and New Glenn. The fact that missions which were previously assigned to the SLS have started to get shifted over to commercial rockets would seem to indicate that even NASA is losing confidence in their flagship program.

The Apollo Digital Ranging System: More Than Meets The Eye

April 25, 2022 by Ryan Flowers 15 Comments

If you haven’t seen [Ken Shirriff]’s teardowns and reverse engineering expeditions, then you’re in for a treat. His explanation and demonstration of the Apollo digital ranging system is a fascinating read, even if vintage computing and engineering aren’t part of your normal fare.

The average Hackaday reader should be familiar with the concept of determining the distance of a faraway object by measuring how long it takes a sound or radio wave to be reflected, such as in sonar and radar. Going another step and measuring Doppler Shift – the difference in the returned signal’s frequency – will tell us the velocity of the object relative to our position. It’s so simple that an Arduino can do it. But in the days of Apollo, there was no Arduino. In fact, there were no Integrated Circuits. And Apollo missions went all the way to the moon- far too distant for relatively simple Radar measurements. Continue reading “The Apollo Digital Ranging System: More Than Meets The Eye” →

Explosion Welding Goes Off With A Bang

April 25, 2022 by Lewin Day 25 Comments

Welding is often a hot and noisy process. It generally involves some fancy chemistry and proper knowledge to achieve good results. Whether you’re talking about arc, TIG, or MIG, these statements all apply.

The same is true for explosion welding, though it’s entirely unlike any traditional hand welding methods you’ve ever seen before. Today, we’ll explore how this technique works and the applications it’s useful for. Fire in the hole!

Don’t Blow Them Apart, Blow Them Together!

Explosion welding occurs near-instantaneously, but is done in a progressive fashion. The angle of collision, as well as the speed of the explosive front, is key to getting a quality weld. Image credit: NASA, public domain

The technique of explosion welding is relatively new compared to other metal-joining techniques. In the two World Wars of the 20th century, pieces of shrapnel were often found stuck to armor plating. Close observation showed that shrapnel was in fact welding on to metal armor, rather than simply being embedded in such. Given that collisions between shrapnel and armor often occur without the extreme heat of typical welding operations, it indicated that it was instead great velocity of the impact between shrapnel and armor that was melding the metals together.

The same results were later recreated in the lab, and explosoin welding was developed into a refined technique after World War II. 1962 saw DuPont patent a process for explosion welding later to be known under the “Detaclad” trademark.

Continue reading “Explosion Welding Goes Off With A Bang” →

NASA Hardware Techniques: Soldering Space Electronics Like It’s 1958

April 13, 2022 by Dave Rowntree 44 Comments

[PeriscopeFilms] on YouTube has many old TV adverts and US government reels archived on their channel, with some really interesting subjects to dive in to. This first one we’re highlighting here is a 1958 film about NASA Soldering Techniques (Video, embedded below), which has some fascinating details about how things were done during the Space Race, and presumably, continue to be done. The overall message about cleanliness couldn’t really be any clearer if they tried — it’s so critical it looks like those chaps in the film spend far more time brushing and cleaning than actually wielding those super clean soldering irons.

Of particular note are some of the details of wire stripping and jointing with components, such as the use of a hot-wire device to remove the insulation from wire, rather than use the kind of stripper we have lying around that cuts into the insulation and slightly distorts the wire in the process. That just won’t do. If they did have to use a cutting-type stripper, it must be precisely the right size for job, and calibrated daily.

The road to the Moon is paved with calibrated wire strippers.

When soldering a pre-tinned wire to a leaded component, a clamp is required to prevent movement of the wire, as is a thermal shunt on the component lead to protect the delicate component from excess heat. They even specify how much to wrap a wire around a terminal to be soldered, never bending the wire more than 180 degrees.

The bottom line in all this is, is that the work must be as perfect as is possible, as there is very little chance of sending someone up to fix a dodgy soldering job, once the assembly is hurtling around the planet. They call it too much of a science to be called an art and too much art to be called a science, and we can sure appreciate that.

As you would expect (and it’s not exactly a big secret) NASA has some very exacting standards for assembly of all hardware, like this great workmanship standard, which is well worth studying. Soldering is an important subject for many of us, we’ve covered the subject of solder metallurgy, as well as looking at how ancient hardware hackers soldered without the benefit of much modern knowledge.

Continue reading “NASA Hardware Techniques: Soldering Space Electronics Like It’s 1958” →

NASA Continues Slow And Steady Pace Towards Moon

March 28, 2022 by Tom Nardi 61 Comments

It’s often said that the wheels of government turn slowly, and perhaps nowhere is this on better display than at NASA. While it seems like every week we hear about another commercial space launch or venture, projects helmed by the national space agency are often mired by budget cuts and indecisiveness from above. It takes a lot of political will to earmark tens or even hundreds of billions of dollars on a project that could take decades to complete, and not every occupant of the White House has been willing to stake their reputation on such bold ambitions.

In 2019, when Vice President Mike Pence told a cheering crowd at the U.S. Space & Rocket Center that the White House was officially tasking NASA with returning American astronauts to the surface of the Moon by 2024, everyone knew it was an ambitious timeline. But not one without precedent. The speech was a not-so-subtle allusion to President Kennedy’s famous 1962 declaration at Rice University that America would safely land a man on the Moon before the end of the decade, a challenge NASA was able to meet with fewer than six months to spare.

Unfortunately, a rousing speech will only get you so far. Without a significant boost to the agency’s budget, progress on the new Artemis lunar program was limited. To further complicate matters, less than a year after Pence took the stage in Huntsville, there was a new President in the White House. While there was initially some concern that the Biden administration would axe the Artemis program as part of a general “house cleaning”, it was allowed to continue under newly installed NASA Administrator Bill Nelson. The original 2024 deadline, at this point all but unattainable due to delays stemming from the COVID-19 pandemic, has quietly been abandoned.

So where are we now? Is NASA in 2022 any closer to returning humanity to the Moon than they were in 2020 or even 2010? While it might not seem like it from an outsider’s perspective, a close look at some of the recent Artemis program milestones and developments show that the agency is at least moving in the right direction.

Continue reading “NASA Continues Slow And Steady Pace Towards Moon” →

One Giant Leap (Backwards) For Humankind: What The Russia-Ukraine War Means For The ISS

March 21, 2022 by Adam Zeloof 89 Comments

The International Space Station was built not only in the name of science and exploration, but as a symbol of unity. Five space agencies, some representing countries who had been bitter Cold War rivals hardly a decade before the ISS was launched, came together to build something out of a sci-fi novel: a home among the stars (well, in Low Earth Orbit) for humans from around the globe to work with one another for the sake of scientific advancement, high above the terrestrial politics that governed rock below. That was the idea, at least.

So far, while there has been considerable sound and fury in social media channels, international cooperation in space seems to continue unhindered. What are we to make of all this bluster, and what effects could it have on the actual ISS?

Continue reading “One Giant Leap (Backwards) For Humankind: What The Russia-Ukraine War Means For The ISS” →