safety

104 Articles

Car Driving Simulators For Students, Or: When Simulators Make Sense

February 21, 2024 by 69 Comments

There are many benefits to learning to fly an airplane, drive a racing car, or operate some complex piece of machinery. Ideally, you’d do so in a perfectly safe environment, even when the instructor decides to flip on a number of disaster options and you find your method of transportation careening towards the ground, or the refinery column you’re monitoring indicating that it’s mere seconds away from going critical and wiping out itself and half the refinery with it.

Still, we send inexperienced drivers in cars onto the roads each day as they either work towards getting their driving license, or have passed their driving exam and are working towards gaining experience. It is this inexperience with dangerous situations and tendency to underestimate them which is among the primary factors why new teenage drivers are much more likely to end up in crashes, with the 16-19 age group having a fatal crash nearly three times as high as drivers aged 20 and up.

After an initial surge in car driving simulators being used for students during the 1950s and 1960s, it now appears that we might see them return in a modern format.

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How Airplanes Mostly Stopped Flying Into Terrain And Other Safety Improvements

February 8, 2024 by 13 Comments

We have all heard the statistics on how safe air travel is, with more people dying and getting injured on their way to and from the airport than while traveling by airplane. Things weren’t always this way, of course. Throughout the early days of commercial air travel and well into the 1980s there were many crashes that served as harsh lessons on basic air safety. The most tragic ones are probably those with a human cause, whether it was due to improper maintenance or pilot error, as we generally assume that we have a human element in the chain of events explicitly to prevent tragedies like these.

Among the worst pilot errors we find the phenomenon of controlled flight into terrain (CFIT), which usually sees the pilot losing track of his bearings due to a variety of reasons before a usually high-speed and fatal crash. When it comes to keeping airplanes off the ground until they’re at their destination, here ground proximity warning systems (GPWS) and successors have added a layer of safety, along with stall warnings and other automatic warning signals provided by the avionics.

With the recent passing of C. Donald Bateman – who has been credited with designing the GPWS – it seems like a good time to appreciate the technology that makes flying into the relatively safe experience that it is today.

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Ejector Seats: The Rocket Chairs That Save Lives

November 29, 2023 by 36 Comments

Once upon a time, escaping an aircraft was a tricky business. You had to unstrap yourself, fling open a heavy glass canopy, and try to wrench yourself out of a small opening without getting smacked by the tail or chopped up by the propeller. Many pilots failed this difficult task, to the tragic loss of their lives.

Eventually, the human cost was heavy enough and militaries grew strained at having to train new pilots to replace the experienced ones lost to accidents and enemy fire. The ejection seat was developed to make escaping a plane as simple as tucking yourself in and pulling a big red handle. Let’s dive in and learn how it came to be.

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Robots: How The Pros Keep Them Safe

November 15, 2023 by 4 Comments

Robotic safety standards are designed for commercial bots, but amateur robot builders should also consider ideas like the keepout zone where a mobile robot isn’t permitted to go or how to draw out the safety perimeter space for your experimental robot arm. After all, that robot arm won’t stop crushing your fingers because you built it yourself. So, it is worth looking at the standards for industrial robots, even if your aim is fun rather than profit.

The basics of this for fixed robots like robot arms are defined in the standard R15-06. You don’t need to read the full text (because it costs $325 and is *incredibly* tedious to read), but the Association for Advancing Automation has a good background on the details. The bottom line is to ensure that a user can’t reach into an area that the robot arm might move to and provide a quick and easy way to disable the motors if someone does reach in.

Robots that move, called Industrial Mobile Robots (IMRs) or Autonomous Mobile Robots (AMRs) bring in a whole new set of problems, though, because they are designed to move around under their own control and often share space with humans. For them, the standard is called R15.08. The AGV network has a good guide to the details, but again, it boils down to two things: make sure the robot is keeping an eye on its surroundings and that it can stop quickly enough to avoid injury.

Just How Dodgy Are Cheap USB Chargers Anyway?

November 3, 2023 by 48 Comments

Aside from apparently having both the ability to reproduce on their own and simultaneously never being around when you need one, USB chargers seem innocuous enough. The specs are simple: convert mains voltage to 5 volts, and don’t kill anyone while doing it. Both specs are typically met by most designs, but judging by [DiodeGoneWild]’s latest USB charger teardown, the latter only just barely, and with a whole lot of luck.

The sad state of plug-in USB power supplies is one of [DiodeGoneWild]’s pet gripes, and deservedly so. Most USB chargers cram a lot of electronics into a mighty small volume, and are built to a price point, meaning that something has to give in the design. In the case of the two units he tears apart in the video below, it’s pretty clear where the compromises are. Neither unit met the specs on the label in terms of current supplied and voltage regulation, even the apparently more capable quick charger, which is the first to go under the knife. The PCB within holds some alarming surprises, like the minimal physical isolation between the mains part of the circuit and the low-voltage section, but the real treat is the Schottky diode that gets up to 170°C under full load. Safety tip: when you smell plastic burning, throw the thing out.

The second charger didn’t fare any better; although it didn’t overheat, that’s mainly because it shut itself off before it could deliver a fraction of its rated 1 amp output. The PCB construction was shoddy in the extreme, with a squiggly trace standing in for a proper fuse and a fraction of a millimeter separation between primary and secondary traces. The flyback transformer was a treat, too; who doesn’t want to rely on a whisper-thin layer of cheap lacquer to keep mains voltage out of your phone?

All in all, these designs are horrible, and we have to thank [DiodeGoneWild] for the nightmares we’ll have whenever we plug into one of these things from now on. On the other hand, this was a great introduction to switch-mode power supply designs, and what not to do with our own builds. Continue reading “Just How Dodgy Are Cheap USB Chargers Anyway?” →

Custom Fume Hood For Safe Electroless Plating

October 22, 2023 by 10 Comments

There are plenty of chemical processes that happen commonly around the house that, if we’re really following safety protocols to the letter, should be done in a fume hood. Most of us will have had that experience with soldering various electronics, especially if we’re not exactly sure where the solder came from or how old it is. For [John]’s electroless plating process, though, he definitely can’t straddle that line and went about building a fume hood to vent some of the more harmful gasses out of a window.

This fume hood is pretty straightforward and doesn’t have a few of the bells and whistles found in commercial offerings, but this process doesn’t really require things like scrubbing or filtering the exhaust air so he opted to omit these pricier and more elaborate options. What it does have, though, is an adjustable-height sash, a small form factor that allows it to easily move around his shop, and a waterproof, spill-collecting area in the bottom. The enclosure is built with plywood, allowing for openings for an air inlet, the exhaust ducting, and a cable pass-through, and then finished with a heavy-duty paint. He also included built-in lighting and when complete, looks indistinguishable from something we might buy from a lab equipment supplier.

While [John] does admit that the exhaust fan isn’t anything special and might need to be replaced more often than if he had gone with one that was corrosion-resistant, he’s decided that the cost of this maintenance doesn’t outweigh the cost of a specialized fan. He also notes it’s not fire- or bomb-proof, but nothing he’s doing is prone to thermal anomalies of that sort. For fume hoods of all sorts, we might also recommend adding some automation to them so they are used any time they’re needed.

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Hackaday Links: August 27, 2023

August 27, 2023 by 26 Comments

We mentioned last week how robotaxi provider Cruise was having a no-good, very bad week, after one of their driverless taxis picked a fight with a semi, and it was revealed that amorous San Franciscans were taking advantage of the privacy afforded by not having a driver in the front seat. It appears that we weren’t the only ones to notice all the bad news, since California’s Department of Motor Vehicles issued an order to the company to cut its robotaxi fleet in half. The regulatory move comes after a recent Cruise collision with a fire truck, which injured a passenger in the taxi. Curiously, the DMV order stipulates that Cruise can only operate 50 vehicles during the day, while allowing 150 vehicles at night. We’d have thought the opposite would make more sense, since driving at night is generally more difficult than during daylight hours. But perhaps the logic is that the streets are less crowded at night, whereas daytime is a more target-rich environment.

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