Overengineered Freezer Monitor Fills Market Void

A lot of projects we see around here are built not just because they can be built, but because there’s no other option available. Necessity is the mother of invention, as they say. And for [Jeff] who has many thousands of dollars of food stowed in a chest freezer, his need for something to keep track of his freezer’s status was greater than any commercial offering available. Not only are freezers hard on batteries, they’re hard on WiFi signals as well, so [Jeff] built his own temperature monitor to solve both of these issues.

The obvious solution here is to have a temperature probe that can be fished through the freezer in some way, allowing the microcontroller, battery, and wireless module to operate outside of the harsh environment. [Jeff] is using K-type thermocouples here, wired through the back of the freezer. This one also is built into a block of material which allows him to get more diffuse temperature readings than a standard probe would provide. He’s also solving some other problems with commercially available probes here as well, as many of them require an Internet connection or store data in a cloud. To make sure everything stays local, he’s tying this in to a Home Assistant setup which also allows him to easily make temperature calibrations as well as notify him if anything happens to the freezer.

Although the build is very robust (or, as [Jeff] himself argues, overengineered) he does note that since he built it there have been some additional products offered for sale that fit this niche application. But even so, we always appreciate the customized DIY solution that avoids things like proprietary software, subscriptions, or cloud services. We also appreciate freezers themselves; one of our favorites was this restoration of a freezer with a $700,000 price tag.

There are a number of metal cylinders displayed in a line. Each cylinder has a rectangular brass plate mounted to each end, and these brass plates stand upright, with the metal cylinders held horizontally between them.

Home-casting Thermoelectric Alloys

If you want to convert heat into electrical power, it’s hard to find a simpler method than a thermoelectric generator. The Seebeck effect means that the junction of two dissimilar conductors will produce a voltage potential when heated, but the same effect also applies to certain alloys, even without a junction. [Simplifier] has been trying to find the best maker-friendly thermoelectric alloys, and recently shared the results of some extensive experimentation.

The experiments investigated a variety of bismuth alloys, and tried to determine the effects of adding lead, antimony, tin, and zinc. [Simplifier] mixed together each alloy in an electric furnace, cast it into a cylindrical mold, machined the resulting rod to a uniform length, and used tin-bismuth solder to connect each end to a brass electrode. To test each composition, one end of the cylinder was cooled with ice while the other was held in boiling water, then resistance was measured under this known temperature gradient. According to the Wiedemann-Franz law, this was enough information to approximate the metal’s thermal conductivity.

Armed with the necessary data, [Simplifier] was able to calculate each alloy’s thermoelectric efficiency coefficient. The results showed some useful information: antimony is a useful additive at about 5% by weight, tin and lead created relatively good thermoelectric materials with opposite polarities, and zinc was useful only to improve the mechanical properties at the expense of efficiency. Even in the best case, the thermoelectric efficiency didn’t exceed 6.9%, which is nonetheless quite respectable for a homemade material.

This project is a great deal more accessible for an amateur than previous thermoelectric material research we’ve covered, and a bit more efficient than another home project we’ve seen. If you just want to get straight to power generation, check out this project.

An Absolute Zero Of A Project

How would you go about determining absolute zero? Intuitively, it seems like you’d need some complicated physics setup with lasers and maybe some liquid helium. But as it turns out, all you need is some simple lab glassware and a heat gun. And a laser, of course.

To be clear, the method that [Markus Bindhammer] describes in the video below is only an estimation of absolute zero via Charles’s Law, which describes how gases expand when heated. To gather the needed data, [Marb] used a 50-ml glass syringe mounted horizontally on a stand and fitted with a thermocouple. Across from the plunger of the syringe he placed a VL6180 laser time-of-flight sensor, to measure the displacement of the plunger as the air within it expands.

Data from the TOF sensor and the thermocouple were recorded by a microcontroller as the air inside the syringe was gently heated. Plotting the volume of the gas versus the temperature results shows a nicely linear relationship, and the linear regression can be used to calculate the temperature at which the volume of the gas would be zero. The result: -268.82°C, or only about four degrees off from the accepted value of -273.15°. Not too shabby.

[Marb] has been on a tear lately with science projects like these; check out his open-source blood glucose measurement method or his all-in-one electrochemistry lab.

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How Hot Is That Soldering Iron?

It is common these days to have a soldering iron where you can set the temperature using some sort of digital control. But how accurate is it? Probably pretty accurate, but [TheHWCave] picked up a vintage instrument on eBay that was made to read soldering iron temperature. You can see the video below, which includes an underwhelming teardown.

The device is a J thermocouple and a decidedly vintage analog meter. What’s inside? Nearly nothing. So why did the meter not read correctly? And where is the cold junction compensation?

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Clay Makes For DIY Power Source, Just Add Water

[Robert Murray] starts out showing us some clay formations that house bees. He couldn’t take any of that clay home, but that’s no problem — clay is plentiful, and apparently, you can make a battery with it. Well, perhaps not really a battery. Adding water to zeolite — a clay often used as a filter material — generates heat, and where there’s heat, there can be electricity.

[Robert] uses a salvaged Peltier device, as you find in small electric refrigerators. These solid-state heat pumps usually convert electricity into a temperature differential, but in this case, it is used as a thermocouple, generating electricity from a temperature difference.

The clay used is a very fine aluminosilicate crystal known as zeolite 13X. Once it comes into contact with plain ordinary water, it immediately starts to boil. It’s a neat experiment, and with the Peltier underneath the metal container holding the clay, enough power is produced to spin a small motor. Of course this won’t power anything large, but on the other hand, plenty of things these days don’t take much power. This technique would work with any exothermic reaction of course, but there’s something compelling about the shelf-stability of water and clay.

Beats a potato, we suppose. Batteries don’t have to be difficult to make. It is only hard to make really good ones.

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Long-Range Thermocouple Sensor Sips Battery Power

Sometimes you need to know the temperature of something from a ways away. That might be a smoker, a barbecue, or even a rabbit hutch. This project from [Discreet Mayor] might just be what you’re looking for.

[Discreet Mayor] remotely keeps an eye on the meat, but doesn’t blab about it.
It consists of a MAX31855 thermocouple amplifier, designed for working with commonly-available K-type thermocouples. This is hooked up to a Texas Instruments CC1312 microcontroller, which sends the thermal measurements out over the 802.15.4 protocol, the same which underlies technologies like Zigbee and Thread. It’s able to send radio messages over long distances without using a lot of power, allowing the project to run off a CR2023 coin cell battery. Combined with firmware that sleeps the system when it’s not taking measurements, [Discreet Mayor] expects the project to run up to several years on a single battery.

The messages are picked up and logged in a Grafana setup, where they can readily be graphed. For extra utility, any temperatures outside a preset range will trigger a smartphone alert via IFTTT.

Keeping a close eye on temperatures is a key to making good food with a smoker, so this project should serve [Discreet Mayor] well. For anyone else looking to monitor temperatures remotely with a minimum of fuss, it should also do well!

Power For Nothing And Your Kicks For Free

We all know that you can convert heat into electricity. Usually, you do that with some form of steam, but there are other methods, too, including thermocouples. If you’ve ever seen something producing waste heat, you’ll appreciate Penn State’s work to harvest power from hot pipes. The idea is simple in theory: create a flexible thermoelectric generator that can wrap around hot pipes or other surfaces to gather otherwise lost heat. The full (paywalled) paper is also available.

The devices can produce up to 150% more power per unit area compared to other thermoelectric generators. A three-square-inch test device produced over 50 watts. Scale that up to an industrial pipe hundreds of feet long, and you could create some serious power. To accomplish this, the scientists used strips of six thermocouples and connected them for a total of 72 thermocouples. Liquid metal between layers improved the device’s performance.

This isn’t a totally new idea. Russia was famous for making radios in the 1950s that operated using a generator that went around the flue of a kerosene lamp. Since the Russians were pulling this off in the 1950s, converting heat into electricity is obviously nothing new. Of course, your body creates heat, too, so why not use that?