Tools of the Trade – Through Hole Assembly

In our last installment of Tools of the Trade, we had just finished doing the inspection of the surface mount part of the PCB. Next in the process is the through hole components. Depending on the PCB, the order may change slightly, but generally it makes more sense to get all the SMT work done before moving to the through hole work.

Through hole used to be the standard, but as the need for size reduction and automation increased, SMT gained favor. However, there are still a lot of reasons to use through hole components, so they aren’t going away entirely (at least not any time soon). One of the biggest advantages of THT is mechanical strength, which makes it better suited for connectors than SMT. If you’ve ever popped a microusb connector off a PCB by breathing on it heavily, you’ll understand. So, how do we most efficiently get through hole components on a PCB, and how do the big boys do it?

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Books You Should Read: Instruments Of Amplification

Psst… Wanna make a canning jar diode? A tennis ball triode? How about a semiconductor transistor? Or do you just enjoy sitting back and following along an interesting narrative of something being made, while picking up a wealth of background, tips and sparking all sorts of ideas? In my case I wanted to make a cuprous oxide semiconductor diode and that lead me to H.P. Friedrichs’ wonderful book Instruments of Amplification. It includes such a huge collection of amplifier knowledge and is a delight to read thanks to a narrative style and frequent hands-on experiments.

Friedrichs first authored another very popular book, The Voice of the Crystal, about making crystal radios, and wanted to write a second one. For those not familiar with crystal radios, they’re fun to make radios that are powered solely by the incoming radio waves; there are no batteries. But that also means the volume is low.

Readers of that book suggested a good follow-up would be one about amplifier circuits, to amplify the crystal radio’s volume. However, there were already an abundance of such books. Friedrichs realized the best follow-up would be one on how to make the amplifying components from scratch, the “instruments of amplification”.  It would be unique and in the made-from-scratch spirit of crystal radios. The book, Instruments of Amplification was born.

The Experiments

Microphonic relays
Microphonic relays, via H.P. Friedrichs Homepage

The book includes just the right amount of a history, giving background on what an amplifier is and how they first came in the electrical world. Telegraph operators wanted to send signals over greater and greater distances and the solution was to use the mix of electronics and mechanics found in the telegraph relay. This is the springboard for his first project and narrative: the microphonic relay.

The microphonic relay example shown on the right places a speaker facing a microphone; the speaker is the input with the microphone amplifying the output. He uses a carbon microphone salvaged from an old telephone headset, housing everything in an enclosure of copper pipe caps, steel bar stock, nuts and bolts mounted on an elegant looking wood base. All the projects are made with simple parts, with care, and they end up looking great.

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Retrotechtacular: The Incredibly Difficult Task of Copying a Document

It seems hard to imagine, but in the early part of the 20th century, there weren’t a lot of great options for creating copies of documents. The most common method was to use carbon paper to create multiple copies at once from a typewriter or a line printer. All that changed with a company called Haloid. Never heard of them? They later became the Xerox company.

The underlying technology dates back to 1938 (invented by a physicist who was also a lawyer). In 1944, they produced a practical copier and shortly thereafter sold the rights to Haloid. The Haloid company originally made photographic copy machines that used wet chemistry.

In 1959, the Xerox 914 (so called because it could copy a 9″ x 14″ document) came on the scene (that’s it, below). The 650 pound copier could make seven copies per minute and came with a fire extinguisher because it had a tendency to burst into flames. If you didn’t want to spend the $27,500 price tag, you could rent for only $25/month (keep in mind that in 1959, $25 would buy about 25 pounds of T-bone steaks). You can see a commercial for the 914 in the video below.


In the commercial, you’ll see them make a big deal out of the fact that the print was dry. That’s because a lot of previous machines used actual photographic processes with wet chemistry. Obviously, that also took special paper.

Even Further Back

If the copier didn’t exist until recently, how did people make copies before? Turns out there were lots of ways to make copies of varying degrees of bad quality or extreme trouble. In some sense, the best copies were made by scribes just writing down a second copy of things. There were a variety of machines that would capture what you wrote and make a copy by mechanical or other means. A polygraph (not the lie detecting kind) allowed Thomas Jefferson to write letters and make a copy. The machine moved a pen to match the movements of the author’s pen, thus making a near perfect copy. With a few adjustments, this became the pantograph which not only does the same job, but also can shrink or enlarge the copy. Carbon paper was widely used to make multiple copies of handwritten and typewritten documents.

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3D Printering: G-Code Post Processing With Perl

Most of our beloved tools, such as Slic3r, Cura or KISSlicer, offer scripting interfaces that help a great deal if your existing 3D printing toolchain has yet to learn how to produce decent results with a five headed thermoplastic spitting hydra. Using scripts, it’s possible to tweak the little bits it takes to get great results, inserting wipe or prime towers and purge moves on the fly, and if your setup requires it, also control additional servos and solenoids for the flamethrowers.

This article gives you a short introduction in how to post-process G-code using Perl and Slic3r. Perl Ninja skills are not required. Slic3r plays well with pretty much any scripting language that produces executables, so if you’re reluctant to use Perl, you’ll probably be able to replicate most of the steps in your favorite language.

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What Could Go Wrong? I2C Edition

I should really like I2C more than I do. In principle, it’s a brilliant protocol, and in comparison to asynchronous serial and SPI, it’s very well defined and clearly standardized. On paper, up to 127 devices can be connected together using just two wires (and ground). There’s an allowance for multiple clock-masters on the same bus, and a way for slaves to signal that the master to wait. It sounds perfect.

In reality, the tradeoff for using only two wires is a significantly complicated signalling and addressing system that brings both pitfalls and opportunities for debugging. Although I2C does reduce the number of signal wires you need, it gets dangerous when you have more than a handful of devices on the same pair of wires, and you’re lucky when they all conform to the same standard. I’ve never seen twenty devices on a bus, much less 127.

But still, I2C has its place. I2C was designed to connect up a bunch of slower, cheaper devices without using a lot of copper real estate compared to its closest rival protocol: SPI. If you need to connect a few cheap temperature sensors to a microcontroller (and their bus addresses don’t clash) I2C is a great choice. So here’s a guide to making it work when it’s not working.

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New Part Day: ST’s 32-Bit 3D Printer Controller

There are a few 32-bit ARM-based 3D printer controller boards out there such as the Smoothieboard, the Azteeg X5 mini, [Traumflug]’s Gen5 electronics, whatever board is in the Monoprice MP Mini Select, and several others I will be criticized for not mentioning. All of these ARM boards provide smoother acceleration, better control, and ultimately better prints from whatever 3D printer they’re controlling. Now, out of the blue, there’s a new board. It’s an evaluation board from ST — much like those famous Discovery boards — that sells itself as a plug and play solution for 3D printers.

The heart of this board is an STM32F401 — not the king of the STM32 line or the fastest ARM microcontroller, but anything faster or more capable will add considerably more to the BOM for this board. This controller board features six of ST’s L6474 motor drivers with enough current for some beefy NEMA 23 stepper motors , a multi-zone heated bed, and connections for a WiFi module and external LCD and keypad. You can buy this board right now for $118. This board isn’t a game changer, but it is evidence the game has been changed.

As with all 3D printer controller boards, there are a few aspects that will leave users wanting more. This is a board meant for 12V heaters (except for the bed, which has a 24V, 20A output), and the stepper drivers can only go up to 16 microsteps. That said, there’s not much else to complain about. This offering comes with a 32-bit firmware called Marlin4ST. From a quick perusal, it looks like the familiar configuration.h is still there, and still does what it’s supposed to do.

This ST Discovery board is extremely capable, available now, and relatively cheap, but that’s not really the big story here. What this board represents is a reference design and working firmware for a 32-bit ARM-based printer controller. That’s the future, and with this board the future might come a little sooner.

Thanks [jagerboots] for sending this one in.

Uncertainty – The Key to Quantum Weirdness

All these fifty years of conscious brooding have brought me no nearer to the answer to the question, ‘What are light quanta?’ Nowadays every Tom, Dick and Harry thinks he knows it, but he is mistaken.

                       Albert Einstein, 1954

As 1926 was coming to a close, the physics world lauded Erwin Schrodinger and his wave mechanics. Schrodinger’s purely mathematical tool was being used to probe the internal structure of the atom and to provide predictable experimental outcomes. However, some deep questions still remained – primarily with the idea of discontinuous movements of the electron within a hydrogen atom. Niels Bohr, champion of and chief spokesperson for quantum theory, had developed a model of the atom that explained spectral lines. This model required an electron to move to a higher energy level when absorbing a photon, and releasing a photon when it moved to a lower energy level. The point of contention is how the electron was moving. This quantum jumping, as Bohr called it was said to be instantaneous. And this did not sit well with classical minded physicists, including Schrodinger.

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