Author: Dan Maloney

3139 Articles

A Wobble Disk Air Motor With One Moving Part

October 22, 2024 by 17 Comments

In general, the simpler a thing is, the better. That doesn’t appear to apply to engines, though, at least not how we’ve been building them. Pistons, cranks, valves, and seals, all operating in a synchronized mechanical ballet to extract useful work out of some fossilized plankton.

It doesn’t have to be that way, though, if the clever engineering behind this wobbling disk air engine is any indication. [Retsetman] built the engine as a proof-of-concept, and the design seems well suited to 3D printing. The driven element of the engine is a disk attached to the equator of a sphere — think of a model of Saturn — with a shaft running through its axis. The shaft is tilted from the vertical by 20° and attached to arms at the top and bottom, forming a Z shape. The whole assembly lives inside a block with intake and exhaust ports. In operation, compressed air enters the block and pushes down on the upper surface of the disk. This rotates the disc and shaft until the disc moves above the inlet port, at which point the compressed air pushes on the underside of the disc to continue rotation.

[Resetman] went through several iterations before getting everything to work. The main problems were getting proper seals between the disc and the block, and overcoming the friction of all-plastic construction. In addition to the FDM block he also had one printed from clear resin; as you can see in the video below, this gives a nice look at the engine’s innards in motion. We’d imagine a version made from aluminum or steel would work even better.

If [Resetman]’s style seems familiar, it’s with good reason. We’ve featured plenty of his clever mechanisms, like this pericyclic gearbox and his toothless magnetic gearboxes.

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Hackaday Links: October 20, 2024

October 20, 2024 by 44 Comments

When all else fails, there’s radio. Hurricane Helene’s path of destruction through Appalachia stripped away every shred of modern infrastructure in some areas, leaving millions of residents with no ability to reach out to family members or call for assistance, and depriving them of any news from the outside world. But radio seems to be carrying the day, with amateur radio operators and commercial broadcasters alike stepping up to the challenge.

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DIY Air Bearings, No Machining Required

October 20, 2024 by 26 Comments

Seeing a heavy load slide around on nearly frictionless air bearings is pretty cool; it’s a little like how the puck levitates on an air hockey table. Commercial air bearings are available, of course, but when you can build these open-source air bearings, why bother buying?

One of the nice things about [Diffraction Limited]’s design is that these bearings can be built using only simple tools. No machining is needed past what can be easily accomplished with a hand drill, thanks to some clever 3D-printed jigs that allow you to drill holes with precision into stainless steel discs you can buy on the cheap. An extremely flat surface is added to the underside of these discs thanks to another jig, some JB Weld epoxy, and a sheet of float glass to serve as an ultra-flat reference. Yet more jigs make it easy to scribe air channels into the flat surface and connect them to the air holes through a bit of plaster of Paris, which acts as a flow restriction. The video below shows the whole process and a demo of the bearings in action.

[Diffraction Limited] mentions a few applications for these air bearings, but the one that interests us most is their potential use in linear bearings; a big CNC cutter using these air bearings would be pretty cool. We seen similar budget-friendly DIY air bearings before, including a set made from used graphite EDM electrodes.

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Fundamentals Of FMCW Radar Help You Understand Your Car’s Point Of View

October 19, 2024 by 3 Comments

Pretty much every modern car has some driver assistance feature, such as lane departure and blind-spot warnings, or adaptive cruise control. They’re all pretty cool, and they all depend on the car knowing where it is in space relative to other vehicles, obstacles, and even pedestrians. And they all have another thing in common: tiny radar sensors sprinkled around the car. But how in the world do they work?

If you’ve pondered that question, perhaps after nearly avoiding rear-ending another car, you’ll want to check out [Marshall Bruner]’s excellent series on the fundamentals of FMCW radar. The linked videos below are the first two installments. The first covers the basic concepts of frequency-modulated continuous wave systems, including the advantages they offer over pulsed radar systems. These advantages make them a great choice for compact sensors for the often chaotic automotive environment, as well as tasks like presence sensing and factory automation. The take-home for us was the steep penalty in terms of average output power on traditional pulsed radar systems thanks to the brief time the radar is transmitting. FMCW radars, which transmit and receive simultaneously, don’t suffer from this problem and can therefore be much more compact.

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Overcomplicating The Magnetic Compass For A Reason

October 18, 2024 by 17 Comments

Some inventions are so simple that it’s hard to improve them. The magnetic compass is a great example — a magnetized needle, a bit of cork, and a bowl of water are all you need to start navigating the globe. So why in the world would you want to over-complicate things with something like this Earth inductor compass? Just because it’s cool, of course.

Now, the thing with complication is that it’s often instructive. The simplicity of the magnetic compass masks the theory behind its operation to some degree and completely fails to deliver any quantitative data on the Earth’s magnetic field. [tsbrownie]’s gadget is built from a pair of electric motors, one intact and one stripped of its permanent magnet stators. The two are mounted on a 3D printed frame and coupled by a long shaft made of brass, to magnetically isolate them as much as possible. The motor is powered by a DC supply while a digital ammeter is attached to the terminals on the stator.

When the motor spins, the stator at the other end of the shaft cuts the Earth’s magnetic lines of force and generates a current, which is displayed on the ammeter. How much current is generated depends on how the assembly is oriented. In the video below, [tsbrownie] shows that the current nulls out when oriented along the east-west axis, and reaches a maximum along north-south. It’s not much current — about 35 microamps — but it’s enough to get a solid reading.

Is this a practical substitute for a magnetic compass? Perhaps not for most use cases, but a wind-powered version of this guided [Charles Lindbergh]’s Spirit of St. Louis across the Atlantic in 1927 with an error of only about 10 miles over the trip, so there’s that. Other aircraft compasses take different approaches to the problem of nulling out the magnetic field of the plane.

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Mining And Refining: Mine Dewatering

October 17, 2024 by 8 Comments

From space, the most striking feature of our Pale Blue Dot is exactly what makes it blue: all that water. About three-quarters of the globe is covered with liquid water, and our atmosphere is a thick gaseous soup laden with water vapor. Almost everywhere you look there’s water, and even where there’s no obvious surface water, chances are good that more water than you could use in a lifetime lies just below your feet, and accessing it could be as easy as an afternoon’s work with a shovel.

And therein lies the rub for those who delve into the Earth’s depths for the minerals and other resources we need to function as a society — if you dig deep enough, water is going to become a problem. The Earth’s crust holds something like 44 million cubic kilometers of largely hidden water, and it doesn’t take much to release it from the geological structures holding it back and restricting its flow. One simple mineshaft chasing a coal seam or a shaft dug in the wrong place, and suddenly all the hard-won workings are nothing but flooded holes in the ground. Add to that the enormous open-pit mines dotting the surface of the planet that resemble nothing so much as empty lakes waiting to fill back up with water if given a chance, and the scale of the problem water presents to mining operations becomes clear.

Dewatering mines is a complex engineering problem, one that intersects and overlaps multiple fields of expertise. Geotechnical engineers work alongside mining engineers, hydrogeologists, and environmental engineers to devise cost-effective ways to control the flow of water into mines, redirect it when they can, and remove it when there’s no alternative.

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New Study Looks At The Potential Carcinogenicity Of 3D Printing

October 14, 2024 by 39 Comments

We’ve all heard stories of the dangers of 3D printing, with fires from runaway hot ends or dodgy heated build plates being the main hazards. But what about the particulates? Can they actually cause health problems in the long run? Maybe, if new research into the carcinogenicity of common 3D printing plastics pans out.

According to authors [CheolHong Lim] and [ and that PLA was less likely to be hazardous than ABS. The study was designed to assess the potential carcinogenicity of both ABS and PLA particulates under conditions similar to what could be expected in an educational setting.

To do this, they generated particulates by heating ABS and PLA to extruder temperatures, collected and characterized them electrostatically, and dissolved them in the solvent DMSO. They used a cell line known as Balb/c, derived from fibroblasts of an albino laboratory mouse, to assess the cytotoxic concentration of each plastic, then conducted a comet assay, which uses cell shape as a proxy for DNA damage; damaged cells often take on a characteristically tailed shape that resembles a comet. This showed no significant DNA damage for either plastic.

But just because a substance doesn’t cause DNA damage doesn’t mean it can’t mess with the cell’s working in other ways. To assess this, they performed a series of cell transformation assays, which look for morphological changes as a result of treatment with a potential carcinogen. Neither ABS nor PLA were found to be carcinogenic in this assay. They also looked at the RNA of the treated cells, to assess the expression of genes related to carcinogenic pathways. They found that of 147 cancer-related genes, 113 were either turned up or turned down relative to controls. Finally, they looked at glucose metabolism as a proxy for the metabolic changes a malignant cell generally experiences, finding that both plastics increased metabolism in vitro.

Does this mean that 3D printing causes cancer? No, not by a long shot. But, it’s clear that under lab conditions, exposure to either PLA or ABS particulates seems to be related to some of the cell changes associated with carcinogenesis. What exactly this means in the real world remains to be seen, but the work described here at least sets the stage for further examination.

What does this all mean to the home gamer? For now, maybe you should at least crack a window while you’re printing.