These Lessons Were Learned In Enclosure Design, But Go Far Beyond

December 18, 2019 by Donald Papp 12 Comments

[Foaly] has been hard at work making an open-source long range camera remote, and recently shared a deeply thoughtful post about how it is never too early to consider all aspects of design, lest it cost you in the end. It all started with designing an enclosure for a working prototype, and it led to redesigning the PCB from scratch. That took a lot of guts, and we recommend you make some time to click that link and read up on what he shared. You’ll either learn some valuable tips, or just enjoy nodding sagely as he confirms things you already know. It’s win-win.

Note the awkward buttons right next to the antenna connector, for example.

The project in question is Silver, and calling it a camera remote is selling it a bit short. In any case, [Foaly] had a perfectly serviceable set of prototypes and needed a small batch of enclosures. So far so normal, but in the process of designing possible solutions, [Foaly] ran into a sure-fire sign that a project is in trouble: problems cropping up everywhere, and in general everything just seeming harder than it should be. Holding the mounting-hole-free PCB securely never seemed quite right. Buttons were awkward to reach, ill-proportioned, and didn’t feel good to use. The OLED screen’s component was physically centered, but the display was off-center which looked wrong no matter how the lines of the bezel were sculpted. The PCB was a tidy rectangle, but the display ended up a bit small and enclosures always looked bulky by the time everything was accounted for. The best effort is shown here, and it just didn’t satisfy.

[Foaly] says the real problem was that he designed the electronics and did the layout while giving some thought (but not much thought) to their eventual integration into a case. This isn’t necessarily a problem for a one-off, but from a product design perspective it led to so many problems that it was better to start over, this time being mindful of how everything integrates right from the start: the layout, the components, the mechanical bits, the assembly, and the ultimate user experience. The end result is wonderful, and we’re delighted [Foaly] took the time to document his findings.

Enclosure design is a big deal and there are many different ways to go about it. For a more unique spin, be sure to check out our how-to make enclosures from the PCBs themselves. For a primer on more traditional enclosure manufacture and design, take a few minutes to familiarize yourself with injection molding.

WWII Aircraft Radio Roars To Life: What It Takes To Restore A Piece Of History

December 12, 2019 by Gregory L. Charvat 59 Comments

I’ve been told all my life about old-timey Army/Navy surplus stores where you could buy buckets of FT-243 crystals, radio gear, gas masks, and even a Jeep boxed-up in a big wooden crate. Sadly this is no longer the case. Today surplus stores only have contemporary Chinese-made boots, camping gear, and flashlights. They are bitterly disappointing except for one surplus store that I found while on vacation in the Adirondacks: Patriot of Lake George.

There I found a unicorn of historical significance; an un-modified-since-WW2 surplus CBY-46104 receiver with dynamotor. The date of manufacture was early-war, February 1942. This thing was preserved as good as the day it was removed from its F4F Hellcat. No ham has ever laid a soldering iron or a drill bit to it. Could this unit have seen some action in the south Pacific? Imagine the stories it could tell!

My unconventional restoration of this radio followed strict rules so as to minimize the evidence of repair both inside and out yet make this radio perform again as though it came fresh off the assembly line. Let’s see how I did.

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Keep An Eye On The Neighborhood With This Passive Radar

November 8, 2019 by Dan Maloney 25 Comments

If your neighborhood is anything like ours, walking across the street is like taking your life in your own hands. Drivers are increasingly unconcerned by such trivialities as speed limits or staying under control, and anything goes when they need to connect Point A to Point B in the least amount of time possible. Monitoring traffic with this passive radar will not do a thing to slow drivers down, but it’s a pretty cool hack that will at least yield some insights into traffic patterns.

The principle behind active radar – the kind police use to catch speeders in every neighborhood but yours – is simple: send a microwave signal towards a moving object, measure the frequency shift in the reflected signal, and do a little math to calculate the relative velocity. A passive radar like the one described in the RTL-SDR.com article linked above is quite different. Rather than painting a target with an RF signal, it relies on signals from other transmitters, such as terrestrial TV or radio outlets in the area. Two different receivers are used, both with directional antennas. One points to the area to be monitored, while the other points directly to the transmitter. By comparing signals reflected off moving objects received by the former against the reference signal from the latter, information about the distance and velocity of objects in the target area can be obtained.

The RTL-SDR test used a pair of cheap Yagi antennas for a nearby DVB-T channel to feed their KerberosSDR four-channel coherent SDR, a device we last looked at when it was still in beta. Essentially four SDR dongles on a common board, it’s available now for $149. Using it to build a passive radar might not save the neighborhood, but it could be a lot of fun to try.

Hacking The IKEA TRÅDFRI LED Power Supply

October 8, 2019 by Donald Papp 22 Comments

Just because something is being actively documented and tampered with by enthusiastic hackers doesn’t mean the information is handily centralized. There can be a lot of value in gathering disparate resources in one place, and that’s exactly what [Trammell Hudson] has done with his resource page for hacking the IKEA TRÅDFRI LED power supply with wireless interface. Schematic teardown, custom firmware images, it’s all there in one convenient spot.

Back in 2017, the IKEA TRÅDFRI hacking scene was centered around the LED light bulbs but as the group of products expanded, the rest of the offerings have also gotten some attention.

Why bother tampering with these units? One reason is to add features, but another is to make them communicate over your own MQTT network. And MQTT is the reason you are only a Raspberry Pi and a trip to IKEA away from the beginnings of a smart home that is under no one’s control or influence but your own.

Alarm System Defeated By $2 Wireless Dongle, Nobody Surprised

August 23, 2019 by Dan Maloney 83 Comments

It seems a bit unfair to pile on a product that has already been roundly criticized for its security vulnerabilities. But when that product is a device that is ostensibly deployed to keep one’s family and belongings safe, it’s plenty fair. And when that device is an alarm system that can be defeated by a two-dollar wireless remote, it’s practically a responsibility.

The item in question is the SimpliSafe alarm system, a fully wireless, install-it-yourself system available online and from various big-box retailers. We’ve covered the system’s deeply flawed security model before, whereby SDRs can be used to execute a low-effort replay attack. As simple as that exploit is, it looks positively elegant next to [LockPickingLawyer]’s brute-force attack, which uses a $2 RF remote as a jammer for the 433-MHz wireless signal between sensors and the base unit.

With the remote in close proximity to the system, he demonstrates how easy it would be to open a door or window and enter a property guarded by SimpliSafe without leaving a trace. Yes, a little remote probably won’t jam the system from a distance, but a cheap programmable dual-band transceiver like those offered by Baofeng would certainly do the trick. Not being a licensed amateur operator, [LockPickingLawyer] didn’t test this, but we doubt thieves would have the respect for the law that an officer of the court does.

The bottom line with alarm systems is that you get what you pay for, or sadly, significantly less. Hats off to [LockPickingLawyer] for demonstrating this vulnerability, and for his many other lockpicking videos, which are well worth watching.

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Fail Of The Week: The Arduino Walkie That Won’t Talkie

July 28, 2019 by Dan Maloney 33 Comments

There’s something seriously wrong with the Arduino walkie-talkie that [GreatScott!] built.

The idea is simple: build a wireless intercom so a group of motor scooter riders can talk in real-time. Yes, such products exist commercially, but that’s no fun at all. With a little ingenuity and a well-stocked parts bin, such a device should be easy to build on the cheap, right?

Apparently not. [GreatScott!] went with an Arduino-based design, partly due to familiarity with the microcontroller but also because it made the RF part of the project seemingly easier due to cheap and easily available nRF24 2.4 GHz audio streaming modules. Everything seems straightforward enough on the breadboard – an op-amp to boost the signal from the condenser mic, a somewhat low but presumably usable 16 kHz sampling rate for the ADC. The radio modules linked up, but the audio quality was heavily distorted.

[GreatScott!] assumed that the rat’s nest of jumpers on the breadboard was to blame, so he jumped right to a PCB build. It’s a logical step, but it seems like it might be where he went wrong, because the PCB version was even worse. We’d perhaps have isolated the issue with the breadboard circuit first; did the distortion come from the audio stage? Or perhaps did the digitization inject some distortion? Or could the distortion be coming from the RF stage? We’d want to answer a few questions like that before jumping to a final design.

We love that [GreatScott!] has no issue with posting his failures – we’ve covered his suboptimal CPU handwarmer, and his 3D-printed BLDC motor stator was a flop too. It’s always nice to post mortem these things to avoid a similar fate.

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Farting Baseball; From The Makers Of Self-Solving Rubik’s Cube

July 19, 2019 by Mike Szczys 12 Comments

Some hackers have a style all their own that is immediately recognizable from one project to the next. For instance, you can tell a [Takashi Kaburagi] by its insides. The behavior of his Farting Baseball project (machine translation) is amusing, but the joke is only skin deep. Look inside and you’ll gain a huge appreciation for what has been done here. It’s not as mind-boggling as his work on the self-solving Rubiks cube robot, but the creativity and design constraints are similarly impressive.

Clever detail is the square of soft material used to cushion impact

This whimsical project is a curve ball no matter who throws it. While in flight, a jet of compressed gas can alter the trajectory at the press of a button. Inside is a small pressure vessel that is filled with HFC134A refrigerant commonly used on gas blowback pistols. It’s a non-combustible that lies in wait until a solenoid is activated to release the pressure in a powerful jet. The ball carries a CR2032 to power the wireless link for activation, but that solenoid needs more juice so capacitors are charged for this purpose.

It’s worth digging through the details on this one, including the article on measuring discharge time (machine translation). There are numerous nice touches, like the yellow Whoopee Cushion neck that directs the jet, the capacitor discharge materials so there is not an accidental activation when not in use, and clever and clean construction that make everything fit.

Another hacker with an equally iconic style is [Mohit Bhoite]’s work; make his flywire sculptures your next stop.

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