Author: Danie Conradie

420 Articles

Fix That Old Remote With Graphite

November 1, 2024 by 45 Comments

A button that stopped working has probably led to more than a few smashed remotes over the years. Fortunately [pescado99] has shared a beautifully simple cure for dead or dying remote buttons: graphite dry lubricant.

Most remotes operate by pushing a conductive carbon coating on the back of the button onto a pair of contacts on the PCB. Unfortunately, that conductive coating can wear off, leaving you with a dead or dying button. The video after the break [pescado99] demonstrates how to use a cotton swab to apply powdered graphite to the rear of the buttons to make them conductive again. A soft pencil can also be used, but the graphite works better.

This beautifully simple hack is too good not to share and could save many remotes from landfills. If you’re more interested in upgrading remote, you can build your own universal remote or replace it with a web browser.

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Combining Gyro Stabilisation With Weight Shift Balancing

November 1, 2024 by 4 Comments

Gyroscopes are perfect to damper short impulses of external forces but will eventually succumb if a constant force, like gravity, is applied. Once the axis of rotation of the mass aligns with the axis of the external torque, it goes into the gimbal lock and loses the ability to compensate for the roll on that axis. [Hyperspace Pirate] tackled this challenge on a gyroscopically stabilized RC bike by shifting a weight around to help keep the bike upright.

[Hyperspace Pirate] had previously stabilized a little monorail train with a pair of control moment gyroscopes. They work by actively adjusting the tilt of gyroscopes with a servo to apply a stabilizing torque. On this bike, he decided to use the gyro as a passive roll damper, allowing it to rotate freely on the pitch axis. The bike will still fall over but at a much slower rate, and it buys time for a mass on the end of the servo-actuated arm to shift to the side. This provides a corrective torque and prevents gimbal lock.

[Hyperspace Pirate] does an excellent job of explaining the math and control theory behind the system. He implemented a PD-controller (PID without the integral) on an Arduino, which receives the roll angle (proportional) from the accelerometer on an MPU6050 MEMS sensor and the roll rate (Derivative) from a potentiometer that measures the gyro’s tilt angle. He could have just used the gyroscope output from the MPU6050, but we applaud him for using the actual gyro as a sensor.

Like [Hyperspace Pirate]’s other projects, aesthetics were not a consideration. Instead, he wants to experiment with the idea and learn a few things in the process, which we can support.

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Bogey Six O’clock!: The AN/APS-13 Tail Warning Radar

October 31, 2024 by 20 Comments

Although we think of air-to-air radar as a relatively modern invention, it first made its appearance in WWII. Some late war fighters featured the AN/APS-13 Tail Warning Radar to alert the pilot when an enemy fighter was on his tail. In [WWII US Bombers]’ fascinating video we get a deep dive into this fascinating piece of tech that likely saved many allied pilots’ lives.

Fitted to aircraft like the P-51 Mustang and P-47 Thunderbolt, the AN/APS-13 warns the pilot with a light or bell if the aircraft comes within 800 yards from his rear. The system consisted of a 3-element Yagi antenna on the vertical stabilizer, a 410 Mhz transceiver in the fuselage, and a simple control panel with a warning light and bell in the cockpit.

In a dogfight, this allows the pilot to focus on what’s in front of him, as well as helping him determine if he has gotten rid of a pursuer. Since it could not identify the source of the reflection, it would also trigger on friendly aircraft, jettisoned wing tanks, passing flak, and the ground. This last part ended up being useful for safely descending through low-altitude clouds.

This little side effect turned out to have very significant consequences. The nuclear bombs used on Hiroshima and Nagasaki each carried four radar altimeters derived from the AN/APS-13 system.

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Portable Solder Paste Station Prevents Smears With Suction

October 30, 2024 by 28 Comments

Applying solder paste to a new custom PCB is always a little nerve-racking. One slip of the hand, and you have a smeared mess to clean up. To make this task a little easier, [Max Scheffler] built the Stencil Fix Portable, a compact self-contained vacuum table to hold your stencil firmly in place and pop it off cleanly every time.

The Stencil Fix V1 used a shop vac for suction, just like another stencil holder we’ve seen. The vacuum can take up precious space, makes the jig a little tricky to move, and bumping the hose can lead to the dreaded smear and colorful language. To get around this [Max] added a brushless drone motor with a 3D printed impeller, with a LiPo battery for power. The speed controller gets its PWM signal from a little RP2040 dev board connected to a potentiometer. [Max] could have used a servo tester, but he found the motor could be a little too responsive and would move the entire unit due to inertia from the impeller. The RP2040 allowed him to add a low pass filter to eliminate the issue. The adjustable speed also means the suction force can be reduced a little for easy alignment of the stencil before locking it down completely.

We love seeing tool projects like these that make future projects a little easier. Fortunately, [Max] made the designs available so you can build your own.

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Little Quadruped Has PCB Spine And No Wiring

October 29, 2024 by 10 Comments

Dealing with all the wiring can quickly become a challenge on robots, especially the walking variety which have actuators everywhere. [Eric Yufeng Wu] sidestepped the wiring issue by creating Q8bot, a little quadruped where all the components, including the actuators, are mounted directly on the PCB.

[Eric] uses a custom PCB as the spine of the robot, and the eight servos plug directly into connectors on the PCB. With their bottom covers removed, the servos screw neatly into a pair of 3D printed frames on either side of the PCB, which also have integrated 14500 battery holders. The PCB is minimalist, with just the XIAO ESP32C3 module, a boost converter circuit to drive the servos, and a battery fuel gauge. Each SCARA-style leg consists of four SLS 3D printed segments, with press-fit bearings in the joints.

The little one moves quickly, and can even do little jumps. For this prototype, most of the control processing is done on a laptop, which sends raw joint angles to the onboard ESP32 via the ESP-Now protocol. We think this little robot has a lot of development potential, and fortunately [Eric] has made all the hardware and software files available for others to build their own.

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Small Steam Generator Creates Educational Experience

October 27, 2024 by 13 Comments

Steam turbines have helped drive a large chunk of our technological development over the last century or so, and they’ll always make for interesting DIY. [Hyperspace Pirate] built a small turbine and boiler in his garage, turning fire into flowing electrons, and learning a bunch in the process.

[Hyperspace Pirate] based the turbine design on 3D printed Pelton-style turbines he had previously experimented with, but milled it from brass using a CNC router. A couple of holes had to be drilled in the side of the rotor to balance it. The shaft drives a brushless DC motor to convert the energy from the expanding steam into electricity.

To avoid the long heat times required for a conventional boiler, [Hyperspace Pirate] decided to use a flash boiler. This involves heating up high-pressure water in a thin coil of copper tube, causing the water to boil as it flows down the tube. To produce the high-pressure water feed the propane tank for the burner was also hooked up to the water tank to pressurize it, removing the need for a separate pump or compressed air source. This setup allows the turbine to start producing power within twelve seconds of lighting the burner — significantly faster than a conventional boiler.

Throughout the entire video [Hyperspace Pirate] shows his calculation for the design and tests, making for a very informative demonstration. By hooking up a variable load and Arduino to the rectified output of the motor, he was able to measure the output power and efficiency. It came out to less than 1% efficiency for turning propane into electricity, not accounting for the heat loss of the boiler. The wide gaps between the turbine and housing, as well as the lack of a converging/diverging nozzle on the input of the turbine are likely big contributing factors to the low efficiency.

Like many of his other projects, the goal was the challenge of the project, not practicality or efficiency. From a gyro-stabilized monorail, to copper ingots from algaecide and and a DIY cryocooler, he has sure done some interesting ones.

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Clockwork Rover For Venus

October 26, 2024 by 27 Comments

Venus hasn’t received nearly the same attention from space programs as Mars, largely due to its exceedingly hostile environment. Most electronics wouldn’t survive the 462 °C heat, never mind the intense atmospheric pressure and sulfuric acid clouds. With this in mind, NASA has been experimenting with the concept of a completely mechanical rover. The [Beardy Penguin] and a team of fellow students from the University of Southampton decided to try their hand at the concept—video after the break.

The project was divided into four subsystems: obstacle detection, mechanical computer, locomotion (tracks), and the drivetrain. The obstacle detection system consists of three (left, center, right) triple-rollers in front of the rover, which trigger inputs on the mechanical computer when it encounters an obstacle over a certain size. The inputs indicate the position of each roller (up/down) and the combination of inputs determines the appropriate maneuver to clear the obstacle. [Beardy Penguin] used Simulink to design the logic circuit, consisting of AND, OR, and NOT gates. The resulting 5-layer mechanical computer quickly ran into the limits of tolerances and friction, and the team eventually had trouble getting their design to work with the available input forces.

Due to the high-pressure atmosphere, an on-board wind turbine has long been proposed as a viable power source for a Venus rover. It wasn’t part of this project, so it was replaced with a comparable 40 W electric motor. The output from a logic circuit goes through a timing mechanism and into a planetary gearbox system. It changes output rotation direction by driving the planet gear carrier with the sun gear or locking it in a stationary position.

As with many undergraduate engineering projects, the physical results were mixed, but the educational value was immense. They got individual subsystems working, but not the fully integrated prototype. Even so, they received several awards for their project and even came third in an international Simulink challenge. It also allowed another team to continue their work and refine the subsystems. Continue reading “Clockwork Rover For Venus” →