Upgrading the Batteries In A BMW i3

The BMW i3 debuted on the market in late 2013, one of the brand’s first electric cars. Also available with an optional range-extending engine, early models featured a 60 Ah battery providing up to 130km range on a full charge. However, times have changed, and over the years, BMW have updated the model with larger capacity batteries over the years. So what does it take to retrofit an older model with the newer, fatter, juicer 120 Ah pack?

It’s all helpfully laid out in a video by [Daniel], who notes that it’s not a job for the faint of heart or poorly equipped. The good news is that, mechanically, the newer batteries have the same external dimensions as the older packs, meaning they can be bolted in without requiring any cutting, welding or, adapters. But that’s about it for the good news. The batteries are cooled by the air conditioning system, meaning that removal and replacement means draining the system of refrigerant using highly expensive specialised hardware. Additionally, many batteries in crashed cars are disabled when the airbags are triggered for safety reasons, requiring unlocking through BMW’s proprietary software or replacement of the internal battery controller. Then there’s the usual laundry list of gradual changes that happen across any automotive line, meaning that certain model years and trim packages can have incompatible plugs and connectors or other features.

Overall, it can be quite a bit of work to do, and with the tools required, something that needs the services of a dedicated mechanic’s workshop. However, find an experienced shop that regularly works with EVs, and you might find they can facilitate the upgrade for you without too much fuss. We’ve seen [Daniel] tackle upgrades before, such as a much easier swap on the Nissan Leaf. Video after the break.

 

source https://hackaday.com/2021/02/01/upgrading-the-batteries-in-a-bmw-i3/

This Isn’t Your Father’s Yellow Card

As the global vaccination effort rolls out in many countries, people will increasingly be required to provide evidence for various reasons, especially travelers. Earlier this month a coalition which includes Microsoft, the Mayo Clinic, Oracle, MITRE, and others announced an effort to establish digital vaccination records called the Vaccination Credential Initiative (VCI). This isn’t going to be a brand new thing, but rather an initiative to provide digital proof-of-vaccination to people who want it, using existing open standards:

  • Verifiable Credentials, per World Wide Web Consortium Recommendation (VC Data Model 1.0)
  • Industry standard format and security, per the Health Level Seven International (HL7) FHIR standard

In addition, the World Health Organization formed the Smart Vaccination Certificate Working Group in December. Various other countries and organizations also have technical solutions in the works or already deployed. If a consensus doesn’t form soon, we can see this quickly becoming a can of worms. Imagine having to obtain multiple certifications of your vaccination because of non-uniform requirements between countries, organizations, and/or purposes.

Older readers and international travelers may be wondering, “don’t we already have a vaccination card system?” Indeed we do: the Carte Jaune or Yellow Card. The concept of a “vaccination passport” was conceived and agreed upon at the International Sanitary Convention for Aerial Navigation in 1933. Over the years the names and diseases of interest have changed, but since 2007 it has been formally called the International Certificate of Vaccination or Prophylaxis (ICVP). In recent times, yellow fever was the only vaccination of interest to travelers, but other vaccinations or booster shots can be recorded as well. One problem with the paper Yellow Card is that it is ridiculously easy to forge. Nefarious or lazy travelers could download it from the WHO site, print it on appropriate yellow card stock, and forge a doctor’s signature. The push for a more secure ICVP is not completely unreasonable.

Reading the instructions on the Yellow Card brings up a couple of interesting points:

  • This certificate is valid only if the vaccine or prophylaxis used has been approved by the World Health Organization — Currently the Pfizer vaccine is the only one to be approved by WHO, and even that is only an emergency approval. If you receive a non-Pfizer vaccination, what then?
  • The only disease specifically designated in the International Health Regulations (2005) for which proof of vaccination or prophylaxis may be required as a condition of entry to a State Party, is yellow fever — This one is interesting, and suggests that member states cannot require proof of Covid19 vaccination as an entry requirement, a situation that will no doubt be quickly revised or ignored.

Note: This writeup is about vaccinations, not about immunity. While immunity certificates have been used from time to time throughout modern history, the concept of an international immunity passport is not well established like the ICVP.

source https://hackaday.com/2021/02/01/this-isnt-your-fathers-yellow-card/

Upgrading An Old Mig Welder Wire Feeder With Arduino

Older industrial equipment is often a great option if you’re on a budget, and you might even be able to add some premium features yourself. [Brett] from [Theoretically Practical] has done with his old MIG welder, adding premium control features with the help of an Arduino.

The main features [Brett] were after is pre-flow, post-flow, and a spot welding timer. Pre-flow starts the flow of shielding gas a moment before energizing the filler wire, while post-flow keeps the gas after the weld is complete. This reduces the chances of oxygen contaminating the welds. A spot welding timer automatically limits welding time, enabling consistent and repeatable spot welds.

The Miller S-22A wire feeder can have these features, but it requires an expensive and difficult to find control unit. All it does is time the activation of the relays that control the gas flow, power, and wire feeder, so [Brett] decided to use an Arduino instead. The welders control circuit runs and 24V, so an optoisolator receives the trigger signal, and relays are used for outputs. Potentiometers were added to the original control panel, and all the wiring was neatly fitted behind it. The upgrade worked perfectly and allowed [Brett] to increase the quality of his welds. See the video after the break for the full details.

Inverter welders can be picked up for ridiculously cheap prices, if you’re willing to live with the trade-offs. We’ve also seen some other DIY welder upgrades, on small and large machines.

source https://hackaday.com/2021/02/01/upgrading-an-old-mig-welder-wire-feeder-with-arduino/

Handy Tool Drains 18650 Cells So You Don’t Have To

Draining a battery is easy. Just put a load across the terminals, maybe an incandescent bulb or a beefy power resistor, and wait. What’s quite a bit trickier is doing so safely. Put too large a load on, or leave it connected for longer than necessary, and you can end up doing damage to the cell. Not convinced he’d always remember to pull the battery out of his jury-rigged discharger at the opportune moment, [Jasper Sikken] decided to come up with a simple tool that could automatically handle the process with the cold and calculating precision of silicon.

V4 used the protection module from a pouch battery.

At a glance we can see the major components you’d expect in a discharger: a fairly simple PCB, four ceramic power resistors, a holder for a single 18650 cell, and a rocker switch to connect it all together. But wait, what’s that a TP4056 charging module doing in there?

While its presence technically makes this device a battery charger, [Jasper] is actually using it for the onboard protection IC. With the charging module between the cell and the power resistors, it will cut the connection when the voltage drops to 2.4 V. Oh yeah, and it can charge the battery back up if you connect up a USB cable.

[Jasper] says his little tool works great, with the resistor array putting just enough load on the battery to pull it down quickly without getting so hot that they’re dangerous to have exposed. He estimates the BOM for this gadget runs around $2 USD, and is considering offering it as a kit on Tindie in the near future.

If you’re looking for something a bit more advanced, [Jasper] built a programmable load a few years back that can discharge batteries and test power supplies all while logging the data to your computer for later analysis.

source https://hackaday.com/2021/02/01/handy-tool-drains-18650-cells-so-you-dont-have-to/

Mechanical Timekeeping Hack Chat with Clickspring

Join us on Wednesday, February 3 at noon Pacific for the Mechanical Timekeeping Hack Chat with Clickspring!

The reckoning of the passage of time has been of vital importance to humans pretty much for all our history, but for most of that time we were stuck looking at the movements of heavenly bodies or noting the changing of the seasons to answer questions of time. The search for mechanical aids to mark the passage of time began surprisingly early, though, pretty much from the time our ancestors first learned to work with metals.

Timekeeping devices were often created to please a potentate or to satisfy a religious imperative, but whatever the reason for their invention, these early clocks and calendars were key to a ton of discoveries. Timekeeping devices were among the first precision mechanisms, and as such formed the basis of much of our mechanical world. A mechanical representation of the passage of time also gave us some of the first precise observations of the physical world, which led to an enormous number of discoveries about the nature of the universe, not to mention practical skills such as navigation, which allowed us to explore the world with greater confidence.

In our era, precision timekeeping has moved beyond the mechanical realm into the subatomic world, and mechanisms built to please a prince are relegated to museums and collectors. That’s not to say there isn’t plenty to learn from the building of mechanical timepieces, as anyone who has watched any of the videos on Clickspring’s YouTube channel can attest. Clickspring not only makes some magnificent modern timepieces, like his famous open-frame clock, but recently he’s also branched out into the timekeeping mechanisms of the ancients. He built a reproduction Byzantine sundial-calendar, and tackled a reproduction of the famous Antikythera mechanism. The latter was undertaken using only the tools and materials that would have been available to the original maker. That led to an unexpected discovery and a detour into the world of scholarly publishing.

Clickspring has been busy lately, but he made some time to stop by the Hack Chat and talk about mechanical timepieces. We’ll talk about his modern builds, his forays into the mechanisms of antiquity, and his serendipitous discovery. On the way we’re likely to talk about what it takes to build precision mechanisms in a small shop, and whatever else that crops up.

join-hack-chatOur Hack Chats are live community events in the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Wednesday, February 3 at 12:00 PM Pacific time. If time zones have you tied up, we have a handy time zone converter.

Click that speech bubble to the right, and you’ll be taken directly to the Hack Chat group on Hackaday.io. You don’t have to wait until Wednesday; join whenever you want and you can see what the community is talking about.

 

source https://hackaday.com/2021/02/01/mechanical-timekeeping-hack-chat-with-clickspring/

Mechanical Timekeeping Hack Chat with Clickspring

Join us on Wednesday, February 3 at noon Pacific for the Mechanical Timekeeping Hack Chat with Clickspring!

The reckoning of the passage of time has been of vital importance to humans pretty much for all our history, but for most of that time we were stuck looking at the movements of heavenly bodies or noting the changing of the seasons to answer questions of time. The search for mechanical aids to mark the passage of time began surprisingly early, though, pretty much from the time our ancestors first learned to work with metals.

Timekeeping devices were often created to please a potentate or to satisfy a religious imperative, but whatever the reason for their invention, these early clocks and calendars were key to a ton of discoveries. Timekeeping devices were among the first precision mechanisms, and as such formed the basis of much of our mechanical world. A mechanical representation of the passage of time also gave us some of the first precise observations of the physical world, which led to an enormous number of discoveries about the nature of the universe, not to mention practical skills such as navigation, which allowed us to explore the world with greater confidence.

In our era, precision timekeeping has moved beyond the mechanical realm into the subatomic world, and mechanisms built to please a prince are relegated to museums and collectors. That’s not to say there isn’t plenty to learn from the building of mechanical timepieces, as anyone who has watched any of the videos on Clickspring’s YouTube channel can attest. Clickspring not only makes some magnificent modern timepieces, like his famous open-frame clock, but recently he’s also branched out into the timekeeping mechanisms of the ancients. He built a reproduction Byzantine sundial-calendar, and tackled a reproduction of the famous Antikythera mechanism. The latter was undertaken using only the tools and materials that would have been available to the original maker. That led to an unexpected discovery and a detour into the world of scholarly publishing.

Clickspring has been busy lately, but he made some time to stop by the Hack Chat and talk about mechanical timepieces. We’ll talk about his modern builds, his forays into the mechanisms of antiquity, and his serendipitous discovery. On the way we’re likely to talk about what it takes to build precision mechanisms in a small shop, and whatever else that crops up.

join-hack-chatOur Hack Chats are live community events in the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Wednesday, February 3 at 12:00 PM Pacific time. If time zones have you tied up, we have a handy time zone converter.

Click that speech bubble to the right, and you’ll be taken directly to the Hack Chat group on Hackaday.io. You don’t have to wait until Wednesday; join whenever you want and you can see what the community is talking about.

 

source https://hackaday.com/2021/02/01/mechanical-timekeeping-hack-chat-with-clickspring/

Electric Candle Replaces Flame with Plasma

Ah, the charm of candlelight! Nothing says “romance” — or “extended power outage” — like the warm, soft glow of a real candle. But if you’re not a fan of burning wax for whatever reason, this electric plasma candle may be just the thing to build for your next dinner for two.

This re-imagining of the humble candle comes to us by way of plasma super-fan [Jay Bowles], who has a lot of experience with plasmas and the high-voltage circuits that often go along with them. Even so, he had to enlist help with the circuit, with is essentially a 10-MHz Class-E oscillator, from [Leon] at the Teslaundmehr channel on YouTube. The most prominent feature of the build is the big resonator coil, surrounded by the shorter primary coil and sitting atop the heatsink for the MOSFET driver. [Jay]’s usual acrylic-rich style is well represented here, and the resulting build is quite lovely.

The tuning process, though, sounds like it was pure torture. It took a lot of tweaking — and a lot of MOSFETs — to get the candle to produce a stable flame. But once it did, the results were striking. The plasma coming off the breakout point on the resonator coil is pretty much the same size, shape, and — occasionally — the color as a candle flame. It’s also hot enough to do some damage, so do be careful if you build this. We’ve included both [Jay]’s and [Leon]’s videos below; [Leon]’s has great step-by-step build instructions.

We’ve been following [Jay]’s journey through the plasmaverse for a while now, from his cheap and simple Tesla coils to using corona discharge to clean his hands. He even hosted a Hack Chat on the subject last year.

source https://hackaday.com/2021/02/01/electric-candle-replaces-flame-with-plasma/

Electronic Embroidery Birthday Card is a Celebration of Skills

Hackers and makers can sometimes feel like they’re getting the short end of the stick when it comes to gift giving. You’re out there making thoughtful, intricate circuit sculptures, helpful software, or face masks for people, and what do you get in return? Okay, yes, usually gift cards or tools or other things that feed your creativity in the first place. But darn it, it would be nice to receive a handmade gift once in a while, right?

So here’s what you do: make friends with enough other makers that you find your birthday twin, or close enough that you both feel the warmth of the personal holiday you share. Then you get them to agree to trade handmade birthday presents with you. That’s more or less what happened between [Becky Stern] and [Estefannie], who seem to have found each other through the magic of sharing projects on YouTube.

[Becky]’s gift to [Estefannie] is a busy intersection of maker elements including graphic design, embroidery, electronics, and 3D printing. [Becky] started with the embroidery, which was made possible thanks to a new open-source library for Processing called PEmbroider. Once that was done, she 3D printed the frame and added the electronics — candle flicker LEDs for the birthday cake, and a handful of songs that are accessible via touch contacts screwed into the side of the frame. [Becky] added a real-time clock module so it plays a few extra songs on [Estefannie]’s actual birthday.

The most thoughtful element here is personalization, and it’s amazing what can happen when you put 100% of yourself into something that is 100% about someone else. Every bit of the art is personal to [Estefannie], and every atom of the build is pure [Becky]. Check out the demo and build video and see what [Estefannie] made for [Becky] after the break.

[Becky]’s varied creativity has graced these pages many times before. See how she bid adieu to 2020, built a daily affirmation mirror, and gave a mask-making masterclass in the early stages of the pandemic.

source https://hackaday.com/2021/02/01/electronic-embroidery-birthday-card-is-a-celebration-of-skills/

13,000 Regular Expressions Make An Editor’s Life Easier

Being an editor is a job that seems deceptively easy until you are hauled over the coals for letting a textual howler go to print (or website). Most publications have style guides to ensure that their individual voice is preserved, but even the most eagle-eyed will sometimes slip up in their application. At the Guardian newspaper in the UK they have been struggling with this against an ever-evolving style guide that must adapt to fast-moving world events, to the extent that they had a set of regular expressions to deal with commonly-occurring problems. A lot of regular expressions, in fact around 13,000 of them.

Clearly some form of management was required, and  a team of developers set about taming this monster. The result is Typerighter, their server-side document-checker, which can be found in a GitHub repository. Surprisingly for rule management they started with a Google Sheet, a choice which proved unexpectedly robust when working with such a long list even though they later replaced it. The back end doing the job of text matching was written in Scala, and for the front end a plugin was created for their Prosemirror text editor.

For a publication of course this is extremely interesting, but where’s the interest for hackers? The answer lies in any text-processing engine that uses a lot of regular expressions; those of you who have dabbled in this space will know how unwieldy this work can become. Any user of computational linguistic techniques in the pursuit of language processing could probably find much of interest here.

If you’re a bit hazy on regular expressions, how about the episode on them from our long-running Linux-fu series?

source https://hackaday.com/2021/02/01/13000-regular-expressions-make-an-editors-life-easier/

Bugatti Concept Car Shows 3D Printed Strength

We doubt you’ll be driving a Bugatti Bolide anytime soon. It’s a bit of a showy concept car, and it really is pushing some limits on what you can 3D print in an automobile. As you can imagine, they aren’t printing car parts out of ABS or PLA. According to The Drive, the prints use selective laser melting with titanium to make some impressively strong and light parts.

It isn’t just the material that makes the 3D prints strong. Bugatti actually patented the internal structure of some parts which are almost bone-like. By having the parts largely hollow, the weight is cut. But fine internal structure creates very strong parts. How strong? A 3.52 ounce pushrod can handle up to 3.85 tons. The printed titanium is apparently heat-treated to increase its resistance to fracture strains.

In addition to titanium, some of the concept car’s parts are printed ceramic which insulates some components from heat. The printing process can apparently get resolutions down to 0.1 mm. Many parts are quite lightweight including a 0.48 mm wheel that with supports weighs in at about 100 grams.

If you want to get into having a project car, we’d suggest something more modest. Even if you want to 3D print a titanium part for your ride, we’d still start a little smaller.

source https://hackaday.com/2021/01/31/bugatti-concept-car-shows-3d-printed-strength/

Hackaday Links: January 31, 2021

There are an awful lot of machines on the market these days that fall under the broad category of “cheap Chinese laser cutters”. You know the type — the K40s, the no-name benchtop CO2 cutters, the bigger floor-mount units. If you’ve recently purchased one of these machines from one of the usual vendors, or even if you’re just thinking about doing so, you’ll likely have some questions. In which case, this “Chinese Laser Cutters 101” online class might be right up your alley. We got wind of this though its organizer, Jonathan Schwartz of American Laser Cutter in Los Angeles, who says he’s been installing, repairing, and using laser cutters for a decade now. The free class will be on February 8 at 5:00 PM PST, and while it’s open to all, it does require registration.

We got an interesting tip the other day that had to do with Benford’s Law. We’d never heard of this one, so we assumed was a “joke law” like Murphy’s Law or Betteridge’s Rule of Headlines. But it turns out that Benford’s Law describes the distribution of leading digits in large sets of numbers. Specifically, it says that the leading digit in any given number is more likely to be one of the smaller numbers. Measurements show that rather than each of the nine base 10 digits showing up about 11% of the time, a 1 will appear in the leading digit 30% of the time, while a 9 will appear about 5% of the time. It’s an interesting phenomenon, and the tip we got pointed to an article that attempted to apply Benford’s Law to image files. This technique was used in a TV show to prove an image had been tampered with, but as it turns out, Hollywood doesn’t always get technical material right. Shocking, we know, but the technique was still interesting and the code developed to Benford-ize image files might be useful in other ways.

Everyone knew it was coming, and for a long time in advance, but it still seems that the once-and-for-all, we’re not kidding this time, it’s for realsies shutdown of Adobe Flash has had some real world consequences. To wit, a railroad system in the northern Chinese city of Dalian ground to a halt earlier this month thanks to Flash going away. No, they weren’t using Flash to control the railroad, but rather it was buried deep inside software used to schedule and route trains. It threw the system into chaos for a while, but never fear — they got back up and running by installing a pirated version of Flash. Here’s hoping that they’re working on a more permanent solution to the problem.

First it was toilet paper and hand sanitizer, now it’s…STM32 chips? Maybe, if the chatter on Twitter and other channels is to be believed. Seems like people are having a hard time sourcing the microcontroller lately. It’s all anecdotal so far, of course, but the prevailing theory is that COVID-19 and worker strikes have lead to a pinch in production. Plus, you know, the whole 2020 thing. We’re wondering if our readers have noticed anything on this — if so, let us know in the comments below.

And finally, just because it’s cool, here’s a video of what rockets would look like if they were transparent. Well, obviously, they’d look like twisted heaps of burning wreckage on the ground is they were really made with clear plastic panels and fuel tanks, but you get the idea. The video launches a virtual fleet — a Saturn V, a Space Shuttle, a Falcon Heavy, and the hypothetical SLS rocket — and flies them in tight formation while we get to watch their consumables be consumed. If the burn rates are accurate, it’s surprising how little fuel and oxidizer the Shuttle used compared to the Saturn. We were also surprised how long the SLS holds onto its escape tower, and were pleased by the Falcon Heavy payload reveal.

source https://hackaday.com/2021/01/31/hackaday-links-january-31-2021/

Serial Studio: Easily Visualise And Log Serial Data

Outputting data from a microcontroller over a serial port is convenient and easy, but formatting, visualizing, and analyzing the data can be tedious and frustrating. [Alex Spataru] knows this all too well, having spent too many hours building and debugging custom dashboards. To save himself and others the same frustration in the future, he created Serial Studio, a tool for quickly building dashboards for serial data.

The only input required for Serial Studio to create a dashboard is a simple JSON structure specifying the data’s format, and how it should be grouped and displayed. Originally Serial Studio required all the JSON data to be sent over serial, which is fine for simple data but quickly becomes cumbersome for more complex applications. To solve this, [Alex] added a feature allowing the JSON document with the format information loaded from the computer, while only the data is sent over serial.

Serial Studio includes several visualization options, including raw line graphs, bar/level indicator, dial indicator, the artificial horizon for IMU data, or a map widget. It can also output the formatted data to a CSV file for further analysis in other software. A console window is also included for viewing raw data or debugging purposes. See the usage demo after the break.

We like Serial Studio’s ease of use and adaptability, and we’ll likely use it for our own projects in the future. It is compatible with Linux, Windows, and Mac thanks to the Qt framework, and the code is open-source and available on GitHub.

If you’ve ever watched one of the BPS.Space model rocket launch videos, you’ll know how critical data logging, visualization and analysis is for [Joe Barnard]’s work. Serial Studio is perfect for such applications, and [Alex] used it extensively for simulated satellite competitions at his university.

source https://hackaday.com/2021/01/31/serial-studio-easily-visualise-and-log-serial-data/

OpenCV And Depth Camera Spots Weeds

Using vision technology to identify weeds in agriculture is an area of active development, and a team of researchers recently shared their method of using a combination of machine vision plus depth information to identify and map weeds with the help of OpenCV, the open-source computer vision library. Agriculture is how people get fed, and improving weed management is one of its most important challenges.

Many current efforts at weed detection and classification use fancy (and expensive) multispectral cameras, but PhenoCV-WeedCam relies primarily on an OAK-D stereo depth camera. The system is still being developed, but is somewhat further along than a proof of concept. The portable setups use a Raspberry Pi, stereo camera unit, power banks, an Android tablet for interfacing, and currently require an obedient human to move and point them.

It’s an interesting peek at the kind of hands-on work that goes into data gathering for development. Armed with loads of field data from many different environments, the system can use the data to identify grasses, broad leaf plants, and soil in every image. This alone is useful, but depth information also allows the system to estimate overall plant density as well as try to determine the growth center of any particular plant. Knowing that a weed is present is one thing, but to eliminate it with precision — for example with a laser or mini weed whacker on a robot arm — knowing where the weed is actually growing from is an important detail.

PhenoCV-WeedCam (GitHub repository) is not yet capable of real-time analysis, but the results are promising and that’s the next step. The system currently must be carried by people, but could ultimately be attached to a robotic platform made specifically to traverse fields.

source https://hackaday.com/2021/01/31/opencv-and-depth-camera-spots-weeds/

Old Gas Meter gets Smart with the ESP8266

Measuring the usage of domestic utilities such as water, gas or electricity usually boils down to measuring a repetitive pulse signal with respect to time. To make things easy, most modern utility meters have a pulsed LED output, which can be used to monitor the consumption by using an external optical sensor. But what do you do if your meter isn’t so cooperative?

That’s exactly what [Francesco] had to figure out while developing the non-invasive gas tracking system he calls ESPmeter. His meter might not have an LED, but it did have a magnet attached to the counter disk which activated an internal hall sensor. With some hacking, he was able to attach an external Hall-effect sensor to pick up this magnet and use the signal to monitor his daily gas consumption.


A big stumbling block in such projects is the issue of powering the device for an extended period, and remembering when it’s time to change the batteries. With the clever use of commonly available parts, he was able to reduce power consumption allowing three AA batteries to last about a year between changes. For one thing, he uses an ATtiny13 to actually read the sensor values. The chip doesn’t run continuously, its watchdog is set at 1 Hz, ensuring that the device is woken up often enough so that it has time to power up the sensor and detect the presence of the magnet. Battery voltage is also measured via a voltage divider connected to the chip’s ADC pin.

At regular intervals throughout the day, the ESP8266 polls the ATtiny13 to pull the stored sensor pulses and voltage measurement. Then at midnight, the ESP transmits all the collected data to a remote server. Overall, this whole scheme allows [Francesco] to reliably gather his gas consumption data while not having to worry about batteries until he gets the low voltage notification. Since the data visualization requirements are pretty basic, he is keeping things simple by using Plotly to display his time series data.

If you are unfortunate enough to have an even older meter which doesn’t use optical or magnetic rotation sensing, you can use a disassembled mouse to keep track of the Gas Meter.

source https://hackaday.com/2021/01/31/old-gas-meter-gets-smart-with-the-esp8266/

Old Gas Meter gets Smart with the ESP8266

Measuring the usage of domestic utilities such as water, gas or electricity usually boils down to measuring a repetitive pulse signal with respect to time. To make things easy, most modern utility meters have a pulsed LED output, which can be used to monitor the consumption by using an external optical sensor. But what do you do if your meter isn’t so cooperative?

That’s exactly what [Francesco] had to figure out while developing the non-invasive gas tracking system he calls ESPmeter. His meter might not have an LED, but it did have a magnet attached to the counter disk which activated an internal hall sensor. With some hacking, he was able to attach an external Hall-effect sensor to pick up this magnet and use the signal to monitor his daily gas consumption.


A big stumbling block in such projects is the issue of powering the device for an extended period, and remembering when it’s time to change the batteries. With the clever use of commonly available parts, he was able to reduce power consumption allowing three AA batteries to last about a year between changes. For one thing, he uses an ATtiny13 to actually read the sensor values. The chip doesn’t run continuously, its watchdog is set at 1 Hz, ensuring that the device is woken up often enough so that it has time to power up the sensor and detect the presence of the magnet. Battery voltage is also measured via a voltage divider connected to the chip’s ADC pin.

At regular intervals throughout the day, the ESP8266 polls the ATtiny13 to pull the stored sensor pulses and voltage measurement. Then at midnight, the ESP transmits all the collected data to a remote server. Overall, this whole scheme allows [Francesco] to reliably gather his gas consumption data while not having to worry about batteries until he gets the low voltage notification. Since the data visualization requirements are pretty basic, he is keeping things simple by using Plotly to display his time series data.

If you are unfortunate enough to have an even older meter which doesn’t use optical or magnetic rotation sensing, you can use a disassembled mouse to keep track of the Gas Meter.

source https://hackaday.com/2021/01/31/old-gas-meter-gets-smart-with-the-esp8266/

Old Gas Meter gets Smart with the ESP8266

Measuring the usage of domestic utilities such as water, gas or electricity usually boils down to measuring a repetitive pulse signal with respect to time. To make things easy, most modern utility meters have a pulsed LED output, which can be used to monitor the consumption by using an external optical sensor. But what do you do if your meter isn’t so cooperative?

That’s exactly what [Francesco] had to figure out while developing the non-invasive gas tracking system he calls ESPmeter. His meter might not have an LED, but it did have a magnet attached to the counter disk which activated an internal hall sensor. With some hacking, he was able to attach an external Hall-effect sensor to pick up this magnet and use the signal to monitor his daily gas consumption.


A big stumbling block in such projects is the issue of powering the device for an extended period, and remembering when it’s time to change the batteries. With the clever use of commonly available parts, he was able to reduce power consumption allowing three AA batteries to last about a year between changes. For one thing, he uses an ATtiny13 to actually read the sensor values. The chip doesn’t run continuously, its watchdog is set at 1 Hz, ensuring that the device is woken up often enough so that it has time to power up the sensor and detect the presence of the magnet. Battery voltage is also measured via a voltage divider connected to the chip’s ADC pin.

At regular intervals throughout the day, the ESP8266 polls the ATtiny13 to pull the stored sensor pulses and voltage measurement. Then at midnight, the ESP transmits all the collected data to a remote server. Overall, this whole scheme allows [Francesco] to reliably gather his gas consumption data while not having to worry about batteries until he gets the low voltage notification. Since the data visualization requirements are pretty basic, he is keeping things simple by using Plotly to display his time series data.

If you are unfortunate enough to have an even older meter which doesn’t use optical or magnetic rotation sensing, you can use a disassembled mouse to keep track of the Gas Meter.

source https://hackaday.com/2021/01/31/old-gas-meter-gets-smart-with-the-esp8266/

This Hot Air Gun Is Either A Work Of Genius Or Lethal, We Can’t Decide

One of the essentials on the bench is some form of hot air gun. Whether it’s a precision tool intended for reworking PCBs or the broad-stroke item used for paint stripping, we’ve all got one somewhere. The paint-stripping variety are pretty cheap, but not as cheap as [Porcas Pregos e Parafusos]’s home made hot air gun. This slightly hair-raising device is made from a variety of junk parts and delivers hot air, though we suspect the possibility for burning the operator remains high.

At its heart is one of those mains powered water boiler elements designed to be lowered into a cup or similar, and since such devices would burn out if not cooled in some way, there is a fan from a microwave oven passing air over it. The whole thing sits inside an aluminium cone cut from a circular cake tin, and is held together on a wooden chassis to which the handle and power switch from a defunct electric drill provide the operator with something to hold on to.

As you can see from the video below the break it makes for an effective hot air gun, but one that we’re guessing you’d soon learn to avoid touching on the metal cone. Still, as a community we’re used to this with our soldering irons, as the RevSpace T-shirt puts it: “If it smells like chicken, you’re holding it wrong“.

Strangely, this isn’t the first DIY heat gun we’ve seen.

Thanks [Danjovic] for the tip.

source https://hackaday.com/2021/01/31/this-hot-air-gun-is-either-a-work-of-genius-or-lethal-we-cant-decide/

Mystery Box Gives Up Its Patented Secrets

[CuriousMarc] likes to go to surplus stores even though there are fewer of them around. On a recent trip, he found a box that had some parts he thought would work for a temperature controller project. It was marked Dial-A-Level and proudly proclaimed that it had a patent pending. The box was from the 1970s and [Marc] was wondering what the device was meant to do.

The device was a bit of a puzzle since it had three oddly-marked probe inputs. A search through the patent database revealed the device was a “capacitance probe for detecting moisture with very long cables.” The idea was to create a capacitor at the end of the cable and use the liquid as a dielectric. The sensor creates a 10 kHz sine wave it uses to excite the probe and an op amp measures the relative capacitive reactance of the probe versus a reference capacitor. The rest of the circuit is a comparator that reacts when the level is at a threshold.

We love seeing the old hand-drawn boards from that era. Component designations are in copper and there’s no solder mask visible. There was a clever application of a silicon controlled rectifiers and a relay to create a type of flip flop, that [Marc] explains.

Interestingly, the company that made the device, Expo Instruments, is still around and [Marc] contacted them. The actual patent holder replied and was amazed that [Marc] had possession of this antique. You can only wonder if anything you build today will wind up on whatever passes for YouTube three or four decades from now.

Capacitive sensing is quite versatile. Of course, there are many other ways to sense liquid level, too.

source https://hackaday.com/2021/01/31/mystery-box-gives-up-its-patented-secrets/

3D Printing a Full Scale Fiberglass Speedboat

It’s an age-old problem. You draw up a nice 6.5-meter long motorboat and then discover the shape won’t allow for a fiberglass mold. What do you do? If you’re [Moi], you grab a few Kuka robots and 3D print it using thermoplastic with embedded glass fibers. A UV light cures the plastic and you wind up with printed fiberglass. That’s the story behind the MAMBO, a 3D printed powerboat.

Despite the color, the fiberglass isn’t blue out of the gate — the boat is painted. Still, it looks nice with lines inspired by [Sonny Levi]’s Arcidiavolo design from 1973. MAMBO stands for Motor Additive Manufacturing BOat. It has a dry weight of about 800 kg and is fitted with a cork floor, white leather seats, and an engine. We presume none of those things were 3D printed.

Although it wasn’t fiberglass, we’ve seen a 3D printed boat before. In particular, the University of Maine’s giant 22,000 square foot printer cranked one out. We’ve also seen boats printed in standard PLA filament, which then had fiberglass cloth and resin applied after printing. True that one was only RC, but there’s no reason the concept couldn’t be scaled up if you had the patience.

source https://hackaday.com/2021/01/30/3d-printing-a-full-scale-fiberglass-speedboat/

Master Video Call Control Panel is Made of PCBs

[memestra] is a teacher whose life has become a series of videoconferences over the last year or so. With all the classes and meetings, they spend the whole day switching between either Zoom, Teams, or Meet. If anyone needs a single piece of hardware to control them all, it’s [memestra]. Well, and every other teacher out there.

The hardware — an Arduino Pro Micro and some buttons — should come as no surprise, except for maybe [memstra]’s use of a resistor network for the LEDs. Still, there’s a lot to like about this little box, starting with the enclosure. That’s not milled or laser-cut metal — each side is a PCB, and they’re all soldered together into a box.

We especially like the top panel, which fits down over the PCB that all the components are soldered to. Each of the non-volume buttons has multiple functions that are accessed by pressing, long pressing, or double pressing. But even the volume buttons do double duty: press them together to mute and un-mute. If [memestra] ever forgets which button does what and how, there’s a handy reference table silkscreened on the bottom panel.

In true teacher fashion, [memestra] has written comprehensive instructions for anyone looking to build a similar device. The heavily-commented code should make it a cinch to drop in keyboard shortcuts for Discord or anything else you might be using, though it’s worth noting that this box is optimized for the desktop apps and not the browser-based versions.

Just looking for a fun way to end video calls? Pull chains are pretty fun.

source https://hackaday.com/2021/01/30/master-video-call-control-panel-is-made-of-pcbs/

Master Video Call Control Panel is Made of PCBs

[memestra] is a teacher whose life has become a series of videoconferences over the last year or so. With all the classes and meetings, they spend the whole day switching between either Zoom, Teams, or Meet. If anyone needs a single piece of hardware to control them all, it’s [memestra]. Well, and every other teacher out there.

The hardware — an Arduino Pro Micro and some buttons — should come as no surprise, except for maybe [memstra]’s use of a resistor network for the LEDs. Still, there’s a lot to like about this little box, starting with the enclosure. That’s not milled or laser-cut metal — each side is a PCB, and they’re all soldered together into a box.

We especially like the top panel, which fits down over the PCB that all the components are soldered to. Each of the non-volume buttons has multiple functions that are accessed by pressing, long pressing, or double pressing. But even the volume buttons do double duty: press them together to mute and un-mute. If [memestra] ever forgets which button does what and how, there’s a handy reference table silkscreened on the bottom panel.

In true teacher fashion, [memestra] has written comprehensive instructions for anyone looking to build a similar device. The heavily-commented code should make it a cinch to drop in keyboard shortcuts for Discord or anything else you might be using, though it’s worth noting that this box is optimized for the desktop apps and not the browser-based versions.

Just looking for a fun way to end video calls? Pull chains are pretty fun.

source https://hackaday.com/2021/01/30/master-video-call-control-panel-is-made-of-pcbs/

Master Video Call Control Panel is Made of PCBs

[memestra] is a teacher whose life has become a series of videoconferences over the last year or so. With all the classes and meetings, they spend the whole day switching between either Zoom, Teams, or Meet. If anyone needs a single piece of hardware to control them all, it’s [memestra]. Well, and every other teacher out there.

The hardware — an Arduino Pro Micro and some buttons — should come as no surprise, except for maybe [memstra]’s use of a resistor network for the LEDs. Still, there’s a lot to like about this little box, starting with the enclosure. That’s not milled or laser-cut metal — each side is a PCB, and they’re all soldered together into a box.

We especially like the top panel, which fits down over the PCB that all the components are soldered to. Each of the non-volume buttons has multiple functions that are accessed by pressing, long pressing, or double pressing. But even the volume buttons do double duty: press them together to mute and un-mute. If [memestra] ever forgets which button does what and how, there’s a handy reference table silkscreened on the bottom panel.

In true teacher fashion, [memestra] has written comprehensive instructions for anyone looking to build a similar device. The heavily-commented code should make it a cinch to drop in keyboard shortcuts for Discord or anything else you might be using, though it’s worth noting that this box is optimized for the desktop apps and not the browser-based versions.

Just looking for a fun way to end video calls? Pull chains are pretty fun.

source https://hackaday.com/2021/01/30/master-video-call-control-panel-is-made-of-pcbs/

Scrappy: Drag Racing Bush Plane

We like to feature hacks that are affordable and accessible to the average person, but from time to time it’s fun to dream about the projects we’ll tackle when we’re all grown up and stinking rich. [Mike Patey] appears to fall rather comfortably in the latter category, but thankfully he hasn’t lost his “excited kid with big plans” spirit. A talented and experienced experimental aircraft builder, he’s currently working on Scrappy, a small bush plane built to be a short take-off and landing drag racer.

Scrappy started life as a Carbon Cub, a modernized kit version of the venerable Piper Super Cub. The only thing left of the original plane is a part of the fuselage frame, with almost everything else being custom. The engine is a 780 cubic inch (13 liter) horizontally opposed 8-cylinder, scavenged from one of [Mike]’s racing planes, and fitting it required extensive structural changes to the fuselage. The paddle-like propeller was intended for an airboat, and is designed for high thrust at low speeds. The skin of the aircraft is all carbon fiber, and the suspension almost looks like it’s borrowed from an off-road racing truck. [Mike] also added (and test fired) a ballistic recovery parachute. The cockpit instruments are also over-the-top for an aircraft like this, with seven Garmin multi-function displays.

Scrappy is still missing its wings, which will also be heavily modified. From the oil-cooling system to the door latch and gust-lock for the stick, everything was designed and made by [Mike]. We’re enjoying the in-depth build videos that show how he tackles all the little challenges that pop-up in such an ambitious project.

[Mike] made a name for himself with his previous monster bush plane Draco, which was sadly destroyed during an ill-considered take-off last year. Fortunately nobody was harmed in the incident, and Draco became a part donor for Scrappy. If budget planes are more your style, check out [Peter Sripol]’s latest electric microlight.

source https://hackaday.com/2021/01/30/scrappy-drag-racing-bush-plane/

A Heat Reclaimer For Your Woodstove; The One Thing It’s Not Is Cool

It’s the middle of winter for those of us who live in the Northern Hemisphere, which naturally turns minds towards heating, or sometimes the lack of it. It’s particularly difficult for those who rely on a wood stove to escape the feeling that perhaps most of that hard-won heat may be whistling up the chimney rather than keeping them warm. It’s a problem [Lou] has addressed with his DIY chimney heat reclaimer.

As can be seen from the video below the break, his stove appears to be in a workshop, and has a long single-wall metal stove pipe. Over the outside of this he’s placed a pair of T pieces joined by a longer length of pipe all of a larger bore, and a mains-powered fan forces air through this air jacket. The result is a continuous flow of hot air that he claims delivers a 45% heat reclamation. We’re curious though whether the reduction in flue temperature might cause extra tar condensation and thus the build-up of flammable material further up the chimney. The stove itself is a double barrel affair with access for smoking, and the video describing it is worth a look in itself.

Whatever the stove, be sure to ensure a constant supply of fuel!

source https://hackaday.com/2021/01/30/a-heat-reclaimer-for-your-woodstove-the-one-thing-its-not-is-cool/

Nissan Gives Up root Shell Thanks to Hacked USB Drive

For the impatient Nissan owners who may be joining us from Google, a hacker by the name of [ea] has figured out how to get a root shell on the Bosch LCN2kai head unit of their 2015 Xterra, and it looks like the process should be the same for other vehicles in the Nissan family such as the Rogue, Sentra, Altima, and Frontier. If you want to play along at home, all you have to do is write the provided image to a USB flash drive and insert it.

Now for those of us who are a more interested in how this whole process works, [ea] was kind of enough to provide a very detailed account of how the exploit was discovered. Starting with getting a spare Linux-powered head unit out of a crashed Xterra to experiment with, the write-up takes the reader through each discovery and privilege escalation that ultimately leads to the development of a non-invasive hack that doesn’t require the user to pull their whole dashboard apart to run.

The early stages of the process will look familiar to anyone who’s messed with embedded Linux hacking. The first step was to locate the board’s serial port and connect it to the computer. From there, [ea] was able to change the kernel parameters in the bootloader to spawn an interactive shell. To make things a little easier, the boot scripts were then modified so the system would start up an SSH server accessible over a USB Ethernet adapter. With full access to the system, the search for exploits could begin.

A simple script on the flash drive enables the SSH server.

After some poking, [ea] discovered the script designed to mount USB storage devices had a potential flaw in it. The script was written in such a way that the filesystem label of the device would be used to create the mount point, but there were no checks in place to prevent a directory traversal attack. By crafting a label that read ../../usr/bin/ and placing a Bash script on the drive, it’s possible to run arbitrary commands on the head unit. The provided script permanently adds SSHd to the startup process, so when the system reboots, you’ll be able to log in and explore.

So what does [ea] want to do with this new-found exploit? It looks like the goal is to eventually come up with some custom programs that extend the functionality of the in-dash Linux system. As it seems like these “infotainment” systems are now an inescapable feature of modern automobiles, we’re certainly excited to see projects that aim to keep them under the consumer’s control.

source https://hackaday.com/2021/01/30/nissan-gives-up-root-shell-thanks-to-hacked-usb-drive/