relay

183 Articles

Design Constraints Bring Lockbox To Life

April 27, 2025 by 1 Comment

One of the most paradoxical aspects of creating art is the fact that constraints, whether arbitrary or real, and whether in space, time, materials, or rules, often cause creativity to flourish rather than to wither. Picasso’s blue period, Gadsby by Ernest Vincent Wright, Tetris, and even the Volkswagen Beetle are all famous examples of constraint-driven artistic brilliance. Similarly, in the world of electronics we can always reach for a microcontroller but this project from [Peter] has the constraint of only using passive components, and it is all the better for it.

The project is a lockbox, a small container that reveals a small keypad and the associated locking circuitry when opened. When the correct combination of push buttons is pressed, the box unlocks the hidden drawer. This works by setting a series of hidden switches in a certain way to program the combination. These switches are connected through various diodes to a series of relays, so that each correct press of a button activates the next relay. When the final correct button is pushed, power is applied to a solenoid which unlocks the drawer. An incorrect button push will disable a relay providing power to the rest of the relays, resetting the system back to the start.

The project uses a lot of clever tricks to do all of this without using a single microcontroller, including using capacitors that carefully provide timing to the relays to make them behave properly rather than all energizing at the same time. The woodworking is also notable as well, with the circuit components highlighted when the lid is opened (but importantly, hiding the combination switches). Using relays for logic is not a novel concept, though; they can be used for all kinds of complex tasks including replacing transistors in single-board computers.

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Multifunctional USB controlled PCB on blue background

How A Tiny Relay Became A USB Swiss Army Knife

April 5, 2025 by 17 Comments

Meet the little board that could: [alcor6502]’s tiny USB relay controller, now evolved into a multifunction marvel. Originally built as a simple USB relay to probe the boundaries of JLCPCB’s production chops, it has become a compact utility belt for any hacker’s desk drawer. Not only has [alcor6502] actually built the thing, he even provided instructions. If you happened to be at Hackaday in Berlin, you now might even own one, as he handed out twenty of them during his visit. If not, read on and build it yourself.

This thing is not just a relay, and that is what makes it special. Depending on a few solder bridges and minimal components, it shape-shifts into six different tools: a fan controller (both 3- and 4-pin!), servo driver, UART interface, and of course, the classic relay. It even swaps out a crystal oscillator for USB self-sync using STM32F042‘s internal RC – no quartz, less cost, same precision. A dual-purpose BOOT0 button lets you flash firmware and toggle outputs, depending on timing. Clever reuse, just like our mothers taught us.

It’s the kind of design that makes you want to tinker again. Fewer parts. More function. And that little smile when it just works. If this kind of clever compactness excites you too, read [alcor6502]’s build log and instructions here.

Decoy Killswitch Triggers Alarm Instead

February 17, 2025 by 43 Comments

There are a few vehicles on the road that are targeted often by car thieves, whether that’s because they have valuable parts, the OEM security is easily bypassed, or even because it’s an antique vehicle that needs little more than a screwdriver to get started. For those driving one of these vehicles an additional immobilization feature is often added, like a hidden switch to deactivate the fuel pump. But, in the continual arms race between thieves and car owners, this strategy is easily bypassed. [Drive Science] hopefully took one step ahead though and added a decoy killswitch instead which triggers the alarm.

The decoy switch is placed near the steering column, where it would easily be noticed by a thief. Presumably, they would think that this was the reason the car wouldn’t start and attempt to flip the switch and then start the ignition. But secretly, the switch activates a hidden relay connected to the alarm system, so after a few seconds of the decoy switch activating, the alarm will go off regardless of the position of this switch. This build requires a lot of hiding spots to be effective, so a hidden method to deactivate the alarm is also included which resets the relay, and another killswitch which actually disables the fuel pump is also added to another secret location in the car.

As far as “security through obscurity” goes, a build like this goes a long way to demonstrate how this is an effective method in certain situations. All that’s generally needed for effective car theft prevention is to make your car slightly more annoying to steal than any other car on the road, and we think that [Drive Science] has accomplished that goal quite well. Security through obscurity is generally easily broken on things deployed on a much larger scale. A major European radio system was found to have several vulnerabilities recently thanks in part to the designers hoping no one would look to closely at them.

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Quick And Very Dirty Repair Gets Smoked PLC Back In The Game

November 21, 2024 by 11 Comments

When electronics release the Magic Smoke, more often than not it’s a fairly sedate event. Something overheats, the packaging gets hot enough to emit that characteristic and unmistakable odor, and wisps of smoke begin to waft up from the defunct component. Then again, sometimes the Magic Smoke is more like the Magic Plasma, as was the case in this absolutely smoked Omron programmable logic controller.

Normally, one tasked with repairing such a thing would just write the unit off and order a replacement. But [Defpom] needed to get the pump controlled by this PLC back online immediately, leading to the somewhat unorthodox repair in the video below. Whatever happened to this poor device happened rapidly and energetically, taking out two of the four relay-controlled outputs. [Defpom]’s initial inspection revealed that the screw terminals for one of the relays no longer existed, one relay enclosure was melted open, its neighbor was partially melted, and a large chunk of the PCB was missing. Cleaning up the damaged relays revealed what the “FR” in “FR4” stands for, as the fiberglass weave of the board was visible after the epoxy partly burned away before self-extinguishing.

With the damaged components removed and the dangerously conductive carbonized sections cut away, [Defpom] looked for ways to make a temporary repair. The PLC’s program was locked, making it impossible to reprogram it to use the unaffected outputs. Instead, he redirected the driver transistor for the missing relay two to the previously unused and still intact relay one, while adding an outboard DIN-mount relay to replace relay three. In theory, that should allow the system to work with its existing program and get the system back online.

Did it work? Sadly, we don’t know, as the video stops before we see the results. But we can’t see a reason for it not to work, at least temporarily while a new PLC is ordered. Of course, the other solution here could have been to replace the PLC with an Arduino, but this seems like the path of least resistance. Which, come to think of it, is probably what caused the damage in the first place.

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Automating 3D Printer Support Hardware

June 6, 2024 by 22 Comments

While 3D printers have evolved over the past two decades from novelties to powerful prototyping tools, the amount of support systems have advanced tremendously as well. From rudimentary software that required extensive manual input and offered limited design capabilities, there’s now user-friendly interfaces with more features than you could shake a stick at. Hardware support has become refined as well with plenty of options including lighting, ventilation, filament recycling, and tool changers. It’s possible to automate some of these subsystems as well like [Caelestis Workshop] has done with this relay control box.

This build specifically focuses on automating or remotely controlling the power, enclosure lighting, and the ventilation system of [Caelestis Workshop]’s 3D printer but was specifically designed to be scalable and support adding other features quickly. A large power supply is housed inside of a 3D printed enclosure along with a Raspberry Pi. The Pi controls four relays which are used to control these various pieces hardware along with the 3D printer. That’s not the only thing the Pi is responsible for, though. It’s also configured to run Octoprint, a piece of open-source software that adds web interfaces for 3D printers and allows their operation to be monitored and controlled remotely too.

With this setup properly configured, [Caelestis Workshop] can access their printer from essentially any PC, monitor their prints, and ensure that ventilation is running. Streamlining the print process is key to reducing the frustration of any 3D printer setup, and this build will go a long way to achieving a more stress-free environment. In case you missed it, we recently hosed a FLOSS Weekly episode talking about Octoprint itself which is worth a listen especially if you haven’t tried this piece of software out yet.

Reinventing Rotary Switches With Stepper Motors

May 27, 2024 by 22 Comments

When you need to make very tiny measurements, even noise in closed relays can throw you off. [Marco] was able to observe this effect and wanted to build a switch that didn’t have this problem. He found a technical paper that used rotary switches operated by stepper motors instead of relays. So he decided to try making his own version. The video below shows how it turned out.

The first part of the video talks about why relays sometimes inject a tiny voltage into a closed circuit. He then looks at costly switches that would work. However, since he needed many switches, he decided to roll his own.

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A Smart Power Distribution Unit For Home Automation

April 25, 2024 by 28 Comments

Power distribution units, as the name implies, are indispensable tools to have available in a server rack. They can handle a huge amount of power for demands of intensive computing and do it in a way that the wiring is managed fairly well. Plenty of off-the-shelf solutions have remote control or automation capabilities as well, but finding none that fit [fmarzocca]’s needs or price range, he ended up building his own essentially from scratch that powers his home automation system.

Because it is the power supply for a home automation system, each of the twelve outlets in this unit needed to be individually controllable. For that, three four-channel relay boards were used, each driven by an output on an ESP32. The ESP32 is running the Tasmota firmware to keep from having to reinvent the wheel, while MQTT was chosen as a protocol for controlling these outlets to allow for easy integration with the existing Node-RED-based home automation system. Not only is control built in to each channel, but the system can monitor the power consumption of each outlet individually as well. The entire system is housed in a custom-built sheet metal enclosure and painted to blend in well with any server rack.

Adding a system like this to a home automation system can simplify a lot of the design, and the scalable nature means that a system like this could easily be made much smaller or much larger without much additional effort. If you’d prefer to keep your hands away from mains voltage, though, we’ve seen similar builds based on USB power instead, with this one able to push around 2 kW.