Anatomy Of A Power Outage: Explaining The August Outage Affecting 5% Of Britain

September 7, 2019 by Jenny List 18 Comments

Without warning on an early August evening a significant proportion of the electricity grid in the UK went dark. It was still daylight so the disruption caused was not as large as it might have been, but it does highlight how we take a stable power grid for granted.

The story is a fascinating one of a 76-second chain of unexpected shutdown events in which individual systems reacted according to their programming, resulted in a partial grid load shedding — what we might refer to as a shutdown. [Mitch O’Neill] has provided an analysis of the official report which translates the timeline into easily accessible text.

It started with a lightning strike on a segment of the high-voltage National Grid, which triggered a transient surge and a consequent disconnect of about 500MW of small-scale generation such as solar farms. This in turn led to a large offshore wind farm deloading itself, and then a steam turbine at Little Barford power station. The grid responded by bringing emergency capacity online, presumably including the Dinorwig pumped-storage plant we visited back in 2017.

Perhaps the most interesting part followed is that the steam turbine was part of a combined cycle plant, processing the heat from a pair of gas turbine generators. As it came offline it caused the two gas turbines feeding it to experience high steam pressure, meaning that they too had to come offline. The grid had no further spare capacity at this point, and as its frequency dropped below a trigger point of 48.8 Hz an automatic deloading began, in effect a controlled shutdown of part of the grid to reduce load.

This is a hidden world that few outside the high-power generation and transmission industries will ever see, so it’s very much worth a read. It’s something we’ve touched on before with the South American grid shutdown back in June, and for entirely different reasons in 2018 when an international disagreement caused the entire European grid to slow down.

Header image: Little Barford combined-cycle power station against the sunset. Tony Foster, (CC BY-SA 2.0).

Spin Me Right Round, Baby: Generator Building Experiments For Mere Mortals

August 13, 2019 by Brian McEvoy 38 Comments

How many of you plan to build a wind-powered generator in the next year? Okay, both of you can put your hands down. Even if you don’t want to wind your coils manually, learning about the principles in an electric generator might spark your interest. There is a lot of math to engineering a commercial model, but if we approach a simple version by looking at the components one at a time, it’s much easier to understand.

For this adventure, [K&J Magnetics] start by dissect a commercial generator. They picked a simple version that might serve a campsite well, so there is no transmission or blade angle apparatus to complicate things. It’s the parts you’d expect, a rotor and a stator, one with permanent magnets and the other with coils of wire.

The fun of this project is copying the components found in the commercial hardware and varying the windings and coil count to see how it affects performance. If you have ever wound magnet wire around a nail to make an electromagnet, you know it is tedious work so check out their 3D printed coil holder with an embedded magnet to trigger a winding count and a socket to fit on a sewing machine bobbin winder. If you are going to make a bunch of coils, this is going to save headaches and wrist tendons.

They use an iterative process to demonstrate the effect of multiple coils on a generator. The first test run uses just three coils but doesn’t generate much power at all, even when spun by an electric drill. Six windings do better, but a dozen finally does the trick, even when turning the generator by hand. We don’t know about their use of cheap silicone diodes though, that seems like unintentional hobbling, but we digress.

Making turbine blades doesn’t have to be a sore chore either, and PVC may be the ticket there, you may also consider the vertical axis wind turbine which is safer at patio level. Now, you folks building generators, remember to tip us off!

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Pop-Up Outlet Helps Make The Most Of A Tiny Shop

August 9, 2019 by Dan Maloney 8 Comments

You’ve got to admire the steps some people take to squeeze a shop into a small space. Finding ways to pack in ever more tools and to work on bigger and bigger projects become ends to themselves for some, and the neat little tricks they find to do so can be really instructive.

Take this workbench pop-up outlet strip for example. The shop that [Woodshop Junkies] occupies appears to be a single-car garage, on the smallish size in the first place, that is almost entirely filled with a multipurpose workbench. It provides tons of storage underneath and a massive work surface on top, but working with small power tools means stretching extension cords across the already limited floor space and creating a tripping hazard. So he claimed a little space on the benchtop for a clever trap door concealing a small tray holding an outlet strip.

The tray rides on short drawer glides and, thanks to a small pneumatic spring, pops up when the door is unlatched. There was a little trouble with some slop in the glides causing the tray to jam, but that was taken care of with a simple roller bearing. The video below shows its construction and how it stays entirely out of the way until needed.

As cool as this build is, it’s just icing on the small shop cake when compared to the workbench. [Woodshop Junkies] has a complete playlist covering the build which is worth watching. And you might want to refer to our tiny shop roundup for more tips on getting a lot done in a little space.

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Wireless Charging Without So Many Chargers

January 15, 2019 by Brian McEvoy 11 Comments

[Nikola Tesla] believed he could wirelessly supply power to the world, but his calculations were off. We can, in fact, supply power wirelessly and we are getting better but far from the dreams of the historical inventor. The mainstream version is the Qi chargers which are what phones use to charge when you lay them on a base. Magnetic coupling is what allows the power to move through the air. The transmitter and receiver are two halves of an air-core transformer, so the distance between the coils exponentially reduces efficiency and don’t even think of putting two phones on a single base. Well, you could but it would not do any good. [Chris Mi] at San Diego State University is working with colleagues to introduce receivers which feature a pass-through architecture so a whole stack of devices can be powered from a single base.

Efficiency across ten loads is recorded at 83.9% which is phenomenal considering the distance between each load is 6 cm. Traditional air-gap transformers are not designed for 6 cm, much less 60 cm. The trick is to include another transmitter coil alongside the receiving coil. By doing this, the coils are never more than 6 cm apart, even when the farthest unit is a long ways from the first supply. Another advantage to this configuration is that tuned groups continue to work even when a load changes in the system. For this reason, putting ten chargeables on a single system is a big deal because they don’t need to be retuned when one finishes charging.

We would love to see more of this convenient charging and hope that it catches on.

Via IEEE Spectrum.

Old Wattmeter Uses Magnetics To Do The Math

December 18, 2018 by Dan Maloney 19 Comments

Measuring power transfer through a circuit seems a simple task. Measure the current and voltage, do a little math courtesy of [Joule] and [Ohm], and you’ve got your answer. But what if you want to design an instrument that does the math automatically? And what if you had to do this strictly electromechanically?

That’s the question [Shahriar] tackles in his teardown of an old lab-grade wattmeter. The video is somewhat of a departure for him, honestly; we’re used to seeing instruments come across his bench that would punch a seven-figure hole in one’s wallet if acquired new. These wattmeters are from Weston Instruments and are beautiful examples of sturdy, mid-century industrial design, and seem to have been in service until at least 2013. The heavy bakelite cases and sturdy binding posts for current and voltage inputs make it seem like the meters could laugh off a tumble to the floor.

But as [Shahriar] discovers upon teardown of a sacrificial meter, the electromechanical movement behind the instrument is quite delicate. The wattmeter uses a moving coil meter much like any other panel meter, but replaces the permanent magnet stator with a pair of coils. The voltage binding posts are connected to the fine wire of the moving coil through a series resistance, while the current is passed through the heavier windings of the stator coils. The two magnetic fields act together, multiplying the voltage by the current, and deflect a needle against a spring preload to indicate the power. It’s quite clever, and the inner workings are a joy to behold.

We just love looking inside old electronics, and moving coil meters especially. They’re great gadgets, and fun to repurpose, too.

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Scott Swaaley On High Voltage

December 14, 2018 by Jenny List 29 Comments

If you were to invent a time machine and transport a typical hardware hacker of the 1970s into 2018 and sit them at a bench alongside their modern counterpart, you’d expect them to be faced with a pile of new things, novel experiences, and exciting possibilities. The Internet for all, desktop computing fulfilling its potential, cheap single-board computers, even ubiquitous surface-mount components.

What you might not expect though is that the 2018 hacker might discover a whole field of equivalent unfamiliarity while being very relevant from their grizzled guest. It’s something Scott Swaaley touches upon in his Superconference talk: “Lessons Learned in Designing High Power Line Voltage Circuits” in which he describes his quest for an electronic motor brake, and how his experiences had left him with a gap in his knowledge when it came to working with AC mains voltage.

When Did You Last Handle AC Line voltages?

If you think about it, the AC supply has become something we rarely encounter for several reasons. Our 1970s hacker would have been used to wiring in mains transformers, to repairing tube-driven equipment or CRT televisions with live chassis’, and to working with lighting that was almost exclusively provided by mains-driven incandescent bulbs. A common project of the day would have been a lighting dimmer with a triac, by contrast we work in a world of microcontroller-PWM-driven LEDs and off-the-shelf switch-mode power supplies in which we have no need to see the high voltages. It may be no bad thing that we are rarely exposed to high-voltage risk, but along the way we may have lost a part of our collective skillset.

Scott’s path to gaining his mains voltage experience started in a school workshop, with a bandsaw. Inertia in the saw kept the blade moving after the power had been withdrawn, and while that might be something many of us are used to it was inappropriate in that setting as kids are better remaining attached to their fingers. He looked at brakes and electrical loads as the solution to stopping the motor, but finally settled on something far simpler. An induction motor can be stopped very quickly indeed by applying a DC voltage to it, and his quest to achieve this led along the path of working with the AC supply. Eventually he had a working prototype, which he further developed to become the MakeSafe power tool brake.

Get Your AC Switching Right First Time

The full talk is embedded below the break, and gives a very good introduction to the topic of switching AC power. If you’ve never encountered a thryristor, a triac, or even a diac, these once-ubiquitous components make an entrance. We learn about relays and contactors, and how back EMF can destroy them, and about the different strategies to protect them. Our 1970s hacker would recognise some of these, but even here there are components that have reached the market since their time that they would probably give anything to have. We see the genesis of the MakeSafe brake as a panel with a bunch of relays and an electronic fan controller with a rectifier to produce the DC, and we hear about adequate safety precautions. This is music to our ears, as it’s a subject we’ve touched on before both in terms of handling mains on your bench and inside live equipment.

So if you’ve never dealt with AC line voltages, give this talk a look. The days of wiring up transformers to power projects might be largely behind us, but the skills and principles contained within it are still valid.

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A Sub-$1000, Non-X86 Motherboard

November 26, 2018 by Brian Benchoff 101 Comments

If you’re building a computer, your options are nearly limitless. You can get a motherboard with red LEDs, with blue LEDs, green LEDs, or if you’re feeling spendy, RGB LEDs. You can get custom-milled heat spreaders in any shape you want, as long as it’s angular and screams ‘gamer’. If you want a motherboard that doesn’t use x86 — either AMD or Intel — you’re kind of out of luck. Either it doesn’t exist, or it’s going to cost a small fortune.

Raptor Engineering have just released a motherboard that isn’t x86 and doesn’t cost as much as a cheap car. The Blackbird mainboard is designed for an IBM Power9 CPU and it only costs $800. Add in a four-core CPU and the total cost comes out to about $1200. Add in some ECC RAM and you’re still under two grand. Building with a non-x86 CPU has never been cheaper. This is a significant change from earlier releases from Raptor Engineering, where just the motherboard cost $3700.

The Blackbird mainboard features dual DDR4 ECC DIMM slots, one PCI Express 4.0 x16 slot, one PCI Express 4.0 x8 slot, dual Gigabit Ethernet ports, 4 x SATA 3.0 ports, 4 x USB 3.0 ports, 1 x USB 2.0 port, and an HDMI display output.

The only reason you would build a Power9-based computer is simply to get around the black box that has become Intel and AMD CPUs. No one is really sure what’s going on in the Intel Management Engine, AMD has similar black boxes littered around. However, using a Power9 CPU has a secure boot mode and provided your computer is physically secure, you’re more or less assured you’re running your firmware and your kernel and your userspace apps. It’s security for the security-minded. RISC architecture is going to change everything.