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121 Articles

Solar System Wars: Walmart Versus Tesla

September 19, 2019 by 61 Comments

It seems like hardly a day goes by that doesn’t see some news story splashed across our feeds that has something to do with Elon Musk and one or another of his myriad companies. The news is often spectacular and the coverage deservedly laudatory, as when Space X nails another double landing of its boosters after a successful trip to space. But all too often, it’s Elon’s baby Tesla that makes headlines, and usually of the kind that gives media relations people ulcers.

The PR team on the automotive side of Tesla can take a bit of a breather now, though. This time it’s Elon’s solar power venture, Tesla Energy Operations, that’s taking the heat. Literally — they’ve been sued by Walmart for rooftop solar installations that have burst into flames atop several of the retail giant’s stores. While thankfully no lives have been lost and no major injuries were reported, Walmart is understandably miffed at the turn of events, leading to the litigation.

Walmart isn’t alone in their exposure to potential Tesla solar problems, so it’s worth a look to see what exactly happened with these installations, why they failed, and what we as hackers can learn from the situation. As we’ll see, it all boils down to taking electrical work very seriously and adhering to standards designed to keep everyone safe, even when they just seem like a nuisance.

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Hackaday Links: September 15, 2019

September 15, 2019 by 28 Comments

It’s probably one of the first lessons learned by new drivers: if you see a big, red fire truck parked by the side of the road, don’t run into it. Such a lesson appears not to have been in the Tesla Autopilot’s driver education curriculum, though – a Tesla Model S managed to ram into the rear of a fire truck parked at the scene of an accident on a southern California freeway. Crash analysis reveals that the Tesla was on Autopilot and following another vehicle; the driver of the lead vehicle noticed the obstruction and changed lanes. Apparently the Tesla reacted to that by speeding up, but failed to notice the stationary fire truck. One would think that the person driving the car would have stepped in to control the vehicle, but alas. Aside from beating up on Tesla, whose AutoPilot feature seems intent on keeping the market for batteries from junked vehicles fully stocked, this just points out how far engineers have to go before self-driving vehicles are as safe as even the worst human drivers.

The tech press is abuzz today with stories about potential union-busting at Kickstarter. Back in March, Kickstarter employees announced their intent to organize under the Office and Professional Employees International Union (OPEIU). On Thursday, two of the union organizers were fired. Clarissa Redwine, who recently hosted a Hack Chat, was one of those released; both she and Taylor Moore are protesting their terminations as an illegal attempt to intimidate Kickstarter employees and keep them from voting for the union. For their part, Kickstarter management says that both employees and two more were released as a result of documented performance issues during the normal review cycle, and that fourteen employees who are in favor of the union were given raises during this cycle, with three of them having been promoted. There will no doubt be plenty more news about this to come.

Would you pay $900 for a Nixie clock? We wouldn’t, but if you choose to buy into Millclock’s high-end timepiece, it may help soften the blow if you think about it being an investment in the future of Nixie tubes. You see, Millclock isn’t just putting together an overpriced clock that uses surplus Russian Nixies – they’re actually making brand new tubes. Techmoan recently reviewed the new clock and learned that the ZIN18 tubes are not coming from Czech Republic-based Dalibor Farný, but rather are being manufactured in-house. That’s exciting news for Nixie builders everywhere; while Dalibor’s tubes are high-quality products, it can’t hurt to have a little competition in the market. Nixies as a growth industry in 2019 – who’da thunk it?

We ran across an interesting project on Hackaday.io the other day, one that qualifies as a true hack. How much house can you afford? A simple question, but the answer can be very difficult to arrive at with the certainty needed to sign papers that put you on the hook for the next 30 years. Mike Ferarra and his son decided to answer this question – in a circuit simulator? As it turns out, circuit simulators are great at solving the kinds of non-linear simultaneous equations needed to factor in principle, interest, insurance, taxes, wages, and a host of other inflows and outflows. Current sources represent money in, current sinks money paid out. Whatever is left is what you can afford. Is this how Kirchoff bought his house?

And finally, is your parts inventory a bit of a mystery? Nikhil Dabas decided that rather than trying to remember what he had and risk duplicating orders, he’d build an application to do it for him. Called WhatDidIBuy, it does exactly what you’d think; it scrapes the order history pages of sites like Adafruit, Digi-Key, and Mouser and compiles a list of your orders as CSV files. It’s only semi-automated, leaving the login process to the user, but something like this could save a ton of time. And it’s modular, so adding support for new suppliers is a simple as writing a new scraper. Forgot what you ordered from McMaster, eBay, or even Amazon? Now there’s an app for that.

Fail Of The Week: Taking Apart A Tesla Battery

September 7, 2019 by 86 Comments

It takes a lot of energy to push a car-sized object a few hundred miles. Either a few gallons of gasoline or several thousand lithium batteries will get the job done. That’s certainly a lot of batteries, and a lot more potential to be unlocked for their use than hurling chunks of metal around on wheels. If you have an idea for how to better use those batteries for something else, that’s certainly an option, although it’s not always quite as easy as it seems.

In this video, [Kerry] at [EVEngineering] has acquired a Tesla Model 3 battery pack and begins to take it apart. Unlike other Tesla batteries, and even more unlike Leaf or Prius packs, the Model 3 battery is extremely difficult to work with. As a manufacturing cost savings measure, it seems that Tesla found out that gluing the individual cells together would be less expensive compared to other methods where the cells are more modular and serviceable. That means that to remove the individual cells without damaging them, several layers of glue and plastic have to be removed before you can start hammering the cells out with a PEX wedge and a hammer. This method tends to be extremely time consuming.

If you just happen to have a Model 3 battery lying around, [Kerry] notes that it is possible to reuse the cells if you have the time, but doesn’t recommend it unless you really need the energy density found in these 21700 cells. Apparently they are not easy to find outside of Model 3 packs, and either way, it seems as though using a battery from a Nissan Leaf might be a whole lot easier anyway.

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What Happens To Tesla When The Sleeping Auto Giants Awake?

August 12, 2019 by 158 Comments

The history of automotive production is littered with the fallen badges of car companies that shone brightly but fell by the wayside in the face of competition from the industry’s giants. Whether you pine for an AMC, a Studebaker, or a Saab, it’s a Ford or a Honda you’ll be driving in 2019.

In the world of electric cars it has been a slightly different story. Though the big names have dipped a toe in the water they have been usurped by a genuinely disruptive contender. If you drive an electric car in 2019 it won’t be that Ford or Honda, it could be a Nissan, but by far the dominant name in EV right now is Tesla.

Motor vehicles are standing at the brink of a generational shift from internal combustion to electric drive. Will Tesla become the giant it hopes, or will history repeat itself?

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Tesla Eyes Ultracapacitor Future With Maxwell Acquisition

February 4, 2019 by 29 Comments

As reported by Bloomberg, Tesla has acquired the innovative energy storage company Maxwell Technologies for $218 Million. The move is a direct departure from Tesla’s current energy storage requirements; instead of relying on lithium battery technology, this acquisition could signal a change to capacitor technology.

The key selling point of capacitors, either of the super- or ultra- variety, is the much shorter charge and discharge rates. Where a supercapacitor can be used to weld metal by simply shorting the terminals (don’t do that, by the way), battery technology hasn’t yet caught up. You can only charge batteries at a specific rate, and you can only discharge them at a specific rate. The acquisition of an ultracapacitor manufacturer opens the possibility of these powerhouses finding their way into electric vehicles.

While there is a single problem with super- and ultra-capacitors — the sheer volume and the fact that a module of ultracaps will hold much less energy than a module of batteries of the same size — the best guess is that Tesla won’t be replacing all their batteries with caps in the short-term. Analysts think that future Teslas may feature a ‘co-battery’ of sorts, allowing for fast charging and discharging through a series of ultracapacitors, with the main energy storage in the car still being the lithium battery modules. This will be especially useful for regenerative braking, as slowing down a three thousand pound vehicle produces a lot of energy, and Tesla’s current battery technology can’t soak all of it up.

Wireless Charging Without So Many Chargers

January 15, 2019 by 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.

Fail Of The Week: How Not To Electric Vehicle

December 3, 2018 by 92 Comments

If you ever doubt the potential for catastrophe that mucking about with electric vehicles can present, check out the video below. It shows what can happen to a couple of Tesla battery modules when due regard to safety precautions isn’t paid.

The video comes to us by way of [Rich], a gearhead with a thing for Teslas. He clearly knows his way around the EV world, having rebuilt a flood-soaked Tesla, and aspires to open an EV repair shop. The disaster stems from a novelty vehicle he and friend [Lee] bought as a side project. The car was apparently once a Disney prop car, used in parades with the “Mr. Toad’s Wild Ride” theme. It was powered by six 6-volt golf cart batteries, which let it maintain a stately, safe pace on a crowded parade route. [Rich] et al would have none of that, and decided to plop a pair of 444-cell Tesla modules into it. The reduced weight and increased voltage made it a real neck-snapper, but the team unwisely left any semblance of battery management out of the build.

You can guess what happened next, or spin up to the 3:00 mark in the video to watch the security camera mayhem. It’s not clear what started the fire, but the modules started cooking off batteries like roman candles. Quick action got it pushed outside to await the fire department, but the car was a total loss long before they showed up. Luckily no other cars in the garage were damaged, nor were there any injuries – not that the car didn’t try to take someone out, including putting a flaming round into [Lee]’s chest and one into the firetruck’s windshield.

[Rich] clearly knew he was literally playing with fire, and paid the price. The lesson here is to respect the power of these beefy batteries, even when you’re just fooling around.

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