repair

248 Articles

Fixing A Reflow Oven’s Conveyer Belt With An NE555 And Stepper Motors

February 23, 2023 by 10 Comments

Some design choices on manufacturing equipment really leave you scratching your head for a while, as recently happened to [Chris Cecil] when the belt on a reflow oven’s conveyer snapped. Although the solution seems simple enough, getting a new belt on the thing would involve essentially taking the entire machine apart, before reassembling it again. Thus the frayed belt went through the oven over and over until during a recent production run of Smoothieboard controller boards until [Chris] heard a funny noise and the conveyer ground to a halt.

Moving the conveyer by hand kind of worked, but with a more permanent fix urgently needed to finish the production run, two stepper motors took the place of the belt, which just left driving these steppers to keep the conveyer moving in sync. Lacking a simple Arduino board to toss at it, and with a Smoothieboard being absolute overkill, [Chris] figured that a humble NE555 timer IC ought to do the job just as well.

Using a project on Hackaday.io by [KushagraK7] as the starting point, and a 1992-vintage NE555 IC harvested from an old project, [Chris] managed to put together a basic stepper driver that uses the NE555 to provide the timing signal. In addition to restoring basic functionality like starting and stopping the conveyer belt, [Chris] added a new feature with the reversing of the conveyer direction. Along with some cobbled together components to physically rotate the conveyer’s two rollers, it restored the reflow oven to working condition.

And one day the prototyped driver board will be updated to a proper PCB. It’s only temporary, after all :)

Continue reading “Fixing A Reflow Oven’s Conveyer Belt With An NE555 And Stepper Motors” →

Top left of image shows a picture of a purplish-grey sea cucumber. Above the cucumber is the word "bio-inspiration." Arrows come from the cucumber to anthropomorphized cartoons of it saying "rigid" at the top with a cartoon sea cucumber standing straight up with spikes and the arrow captioned "soft" pointing down showing a crawling sea cucumber that looks more like a slug. To the right of the cucumber images is a set of three images stacked top to bottom. The top image is of a silver sphere with a zoomed-in atomic diagram with aligned magnetic poles next to it saying "solid state." The middle image shows arrows going up and down next to a snowflake and an artistic rendering of magnetic fields labeled "transition." The bottom image of this section shows a reddish sphere next to a zoomed-in atomic diagram where the magnetic poles are not aligned labeled "liquid state."

Phase Change Materials For Flexible And Strong Robots

February 19, 2023 by 21 Comments

Shape shifters have long been the stuff of speculative fiction, but researchers in China have developed a magnetoactive phase transitional matter (MPTM) that makes Odo slipping through an air vent that much more believable.

Soft robots can squeeze into small spaces or change shape as needed, but many of these systems aren’t as strong as their more mechanically rigid siblings. Inspired by the sea cucumber’s ability to manipulate its rigidity, this new MPTM can be inductively heated to a molten state to change shape as well as encapsulate or release materials. The neodymium-iron-boron (NdFeB) microparticles suspended in gallium will then return to solid form once cooled.

An image of a LEGO minifig behind bars. It moves toward the bars, melts, and is reconstituted on the other side after solidifying in a mold.

Applications in drug delivery, foreign object removal, and smart soldering (video after the break) probably have more real world impact than the LEGO minifig T1000 impersonation, despite how cool that looks. While a pick-and-place can do better soldering work on a factory line, there might be repair situations where a magnetically-controlled solder system could come in handy.

We’ve seen earlier work with liquid robots using gallium and bio-electronic hybrids also portending the squishy future of robotics.

Continue reading “Phase Change Materials For Flexible And Strong Robots” →

A closeup of a black flexible PCB with an out-of-focus quarter in the background, approximately the same size as the end of the PCB we're looking at. One the right is a USB C connector and to its left are two SMD components with visible pins. Several smaller SMD components (resistors or caps?) are soldered to other parts of the board.

Making The AirPods Pro Case Repairable

February 13, 2023 by 8 Comments

Apple is often lauded for its design chops, but function is often sacrificed at the altar of form, particularly when repair is involved. [Ken Pillonel] has made it easier for everyone to replace the batteries or lightning port in the AirPods Pro case. (YouTube)

With such notable hacks as adding USB C to the iPhone already under his belt, [Pillonel] has turned his attention to fixing the notoriously poor repairability of AirPods and AirPods Pro, starting with the cases. While the batteries for these devices are available, replacement Lightning ports are not, and taking the housing apart for the case is an exercise in patience where the results can’t be guaranteed.

He designed a USB C replacement port for broken Lightning ports that is a perfect fit if you happen to get the case apart in one piece. If you’re less successful, he has you covered there too with a 3D printable enclosure replacement.

We sure miss the days of schematic proliferation here at Hackaday, but we know you don’t let glued enclosures or unobtainium parts stand in the way of repairs.

Continue reading “Making The AirPods Pro Case Repairable” →

Dishwasher Repair Nightmare: Chasing Down 3 Faults

February 5, 2023 by 42 Comments

It all started with a vague error code (shown in the image above) on [nophead]’s Bosch SMS88TW01G/01 dishwasher, and it touched off a months-long repair nightmare that even involved a logic analyzer. [nophead] is normally able to handily diagnose and repair electronic appliances, but this time he had no idea what he was in for.

Not many dishwashers require breaking out a logic analyzer and 3D-printed custom adapters, but this one did.

Not only were three separate and unrelated faults at play (one of them misrepresented as a communications error that caused a lot of head-scratching) but to top it all off, the machine is just not very repair-friendly. The Bosch device utilized components which are not easily accessible. In the end [nophead] prevailed, but it truly was a nightmare repair of the highest order. So what went wrong?

One error appears to have been due to a manufacturing problem. While reverse-engineering the electronics in the appliance, [nophead] noticed a surface-mounted transistor that looked crooked. It was loose to the touch and fell into pieces when he attempted to desolder it. This part was responsible for switching an optical sensor, so that was one problem solved.

Another issue was a “communications error”. This actually came down to ground leakage due to a corroded and faulty heater, and to say that it was a pain to access is an understatement. Accessing this part requires the machine to be turned upside down, because the only way to get to it is by removing the base of the dishwasher, which itself requires a bizarre series of awkward and unintuitive steps to remove. Oh, and prior to turning the machine upside down, one has to purge the sump pump, which required a 3D-printed adapter… and the list goes on.

And the E02 error code, the thing that started it all? This was solved early in troubleshooting by changing a resistor value by a tiny amount. [nophead] is perfectly aware that this fix makes no sense, but perhaps it was in fact related to the ground leakage problem caused by the corroded heater. It may return to haunt the future, but in the meantime, the machine seems happy.

It goes to show that even though every fault has a cause and a reason, sometimes they are far from clear or accessible, and the road to repair is just a long slog. Heck, even phones these days can be bricked by accidentally swapping a 1.3 mm screw for a 1.2 mm screw.

Surgery On An LED To Preserve Vintage Aesthetics

January 29, 2023 by 53 Comments

[Chris Jones] recently found himself in a pickle. An indicator LED off an old piece of stereo equipment had failed. It was a strange rectangular type for which he could source no modern substitute. Using a different LED would ruin the aesthetic. Thus, what else was [Chris] to do, but attempt surgery on an LED!

The first attempt was the simplest. [Chris] tried soldering a small SMD LED between the legs of the existing part, which was open circuit. It worked, but the light didn’t really propagate to the top of the LED’s plastic. It was too dim to do the job.

Unperturbed, [Chris] instead elected to cut the LED apart. he soldered the SMD LED to the original LED’s leads, inside its body this time. The top part of the plastic lens was then notched to fit snugly over the new SMD part. A bit of superglue then joined everything back together. The finished product looks a touch messy on the PCB. However, installed back inside the stereo, it’s a perfectly stealth fix that looks great.

Some will consider this fix frivolous and a waste of time. Others will appreciate the way it preserved the attractive retro look of a piece of vintage audio gear. In any case, we can all agree that modern LEDs are often a great replacement for older parts in many cases. If you’ve pulled off your own weird, oddball repair hacks, don’t hesitate to share us with them on the tipsline!

Dead Washer Lives Again With ATTiny

January 11, 2023 by 59 Comments

We aren’t saying that appliances are a scam, but we have noticed that when your appliances fail, there’s a good chance it will be some part you can no longer get from the appliance maker. Or in some cases, it’s a garden-variety part that should cost $2, but has been marked up to $40. When [Balakrishnan] had a failure of the timer control board for a Whirlpool washing machine, it was time to reverse engineer the board and replace it with a small microcontroller.

Of course, this kind of hack is one of those that won’t help you unless you need exactly that timer board. However, the process is generally applicable. Luckily, the motherboard chip was documented and the timer control board used a simple ATmega88, so it was easy to see that the devices were communicating via I2C.

Reading the I2C  bus is easy with a logic analyzer, and this revealed the faulty device’s I2C address. The board that failed was only for display, so a simple program that does nothing other than accept I2C data put the washer in working order. Once it was working with an Arduino, an ATTiny45 did the work with a lot less space and cost.

If you don’t want to reverse engineer the washing machine, you could just replace all the controls. That even works if the old washer wasn’t electronic to start.

Ask Hackaday: What’s Your Worst Repair Win?

January 9, 2023 by 191 Comments

Like many of you, I’ve become the designated “fix-it” person for my family and friends. While it can be a lot of work — I just finished an oil change that required me to lay in a cold, wet driveway and I can’t mention in polite company the substances I was bathed in while fixing a clogged pipe last week  — I generally relish my role. I enjoy solving problems, I love working with my hands and my head, and who doesn’t like saving money and time?

But for me, the best part of being the fix-it guy is the satisfaction that comes from doing something others can’t do. I find this especially true with automotive repairs, which conventional wisdom says is strictly the province of factory-trained experts. A little bit of a hero complex, perhaps? Absolutely! After all, I don’t get paid for my repairs, so I’ve got to get a little something for the effort.

This is why a recent pair of unrelated fixes left me feeling thoroughly unsatisfied. Neither of these jobs was a clear win, at least in terms of getting the rush of being able to do something that nobody else could. At best, these were qualified wins, which both still left me feeling a little defeated. And that got me thinking that I’m probably not the only one who has had marginal repair wins like these.

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