Advanced PCB Graphics With KiCAD 6 And Inkscape

January 8, 2022 by Dave Rowntree 16 Comments

There are many, many video tutorials about designing the functional side of PCBs, giving you tips on schematic construction, and layout tips. What is a little harder to find are tutorials on the graphical aspects, covering the process from creating artworks and how you can drive the tools to get them looking good on a PCB, leveraging the silkscreen, solder and copper layers to maximum effect. [Stuart Patterson] presents his guide for Advanced PCB Graphics in KiCAD 6.0 and Inkscape, (Video, embedded below) to help you on your way to that cool looking PCB build.

Silkscreen layers in yellow, solder mask opening in red

The first step is to get your bitmap, whether you create it yourself, or download it, and trace it into a set of vectors using the Inkscape ‘trace bitmap’ tool. If you started with an SVG or similar vector shape, then you can skip that stage.

Next simply create a PCB outline shape by deleting all the details that aren’t part of the outline. A little scaling here and there to get the dimensions correct and you’re done with the first part. [Stuart] has an earlier video showing that process.

The usability improvements in KiCAD 6.0 are many, but one greatly demanded feature is the ability to group objects, just like you do in Inkscape and any other vector graphics tool for that matter. That means you can simply import that SVG outline into the Edge.Cuts PCB layer and all the curves will be nicely tied together. Next you select the details you want for the silkscreen layer, solder mask removal layers and any non-circuit copper. In Inkscape it would be wise to use the layers feature to assign the different material types to a uniquely named layer, so they can be hidden for exporting. This allows you to handle silk, mask and copper PNG exports from a single master file, in addition to any vector details for outline, slots and holes.

Once you have PNG bitmap exports for the silk, mask etc. you need to create a footprint inside a board-specific library, using the KiCAD image converter tool. It was interesting to note that you can export a new image footprint from the tool and paste it straight into the footprint editor, and tweak all the visibility details at the same time. That will save some time and effort for sure. Anyway, we hope this little tutorial from [Stuart] helps, and we will be sure to bring you plenty more in the coming months.

Need some more help with KiCAD? Checkout this tutorial, and if you want a bit more power from the tool, you need some action plugins!

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The Year Of Owning It

January 8, 2022 by Elliot Williams 41 Comments

Talking over the year in review on the Podcast, Tom Nardi and I were brainstorming what we thought was the single overarching trend in 2021, and we came up with many different topics: victories in the right to repair, increasingly dystopian service contracts, a flourishing of cyberdecks, and even greater prevalence of reverse engineering style hacks. And then we realized: they are all different faces of the same beast — people just want to own the devices that they own.

Like Dr. Jekyll and Mr. Hyde, our modern Internet-connected-everythings have two sides. On one side, we get so much additional functionality from having everything on the net. But on the other, if your car is always connected, it gives Toyota a means to make you pay a monthly fee to use a car fob, and if you have to use Cricut’s free online service to upload designs to the cutter, they can suddenly decide to start charging you. It allows Samsung to not only spy on whatever you’re currently watching on your smart TV, but to also brick it if they want to. More and more, we don’t actually own (in the sense of control) the devices that we own (in the sense of having purchased).

We don’t have to take it lying down. On the one hand, consumer protest made Cricut walk back their plans, and may do the same with Toyota. We can achieve a lot, collectively, by just talking about our grievances, and letting the firms in question know how we feel — naturally also with our wallets. But as hackers and all-around techie types, we can do even more. When something is broken because of a bad service, we can often fix it with firmware or by standing up our own version of the service. We can pwn them.

But there’s even more to the cyberdeck and the extreme DIY movements of the last few years than just the defense against lock-in or the liberating of hardware. There’s also the pride of truly owning something because you made it. Not just owning it because you bought it, or owning it because you control it, but owning it because you understand it and because you gave birth to it.

Whichever way you’re into owning your own, I think that’s the single overarching trend of 2021 — both on the positive and proactive side and the negative and reactive. Talking about it, reverse engineering it, or building it yourself, 2021 was the year of owning it.

Baby Steps Toward DIY Autonomous Driving: VW Golf Edition

January 8, 2022 by Dave Rowntree 18 Comments

Nice thermal design, but conformal coating and no ID marks make this tough to reverse engineer

[Willem Melching] owns a 2010 Volkswagen Golf – a very common vehicle in Europe – and noticed that whilst the electronic steering rack supports the usual Lane Keep Assist (LKAS) system, and would be theoretically capable of operating in a far more advanced configuration using openpilot, there were some shortcomings in VW’s implementation which means that it would not function for long enough to make it viable. Being very interested in and clearly extremely capable at reverse engineering car ECUs and hacking them into submission, [Willem] set about documenting his journey to unlocking openpilot support for his own vehicle.

And what a journey it was! The four-part blog series is beautifully written, showing every gory detail and all tools used along the way. The first part shows the Electronic Power Steering (EPS) ECU from a 2010 Volkswagen Golf Mk6 module (which rides on the back of the three-phase steering rack motor) being cracked open to reveal an interesting multi-chip module approach, with bare die directly bonded to a pair of substrate PCBs, that are in turn, bonded to the back of the motor casing, presumably for heat dissipation reasons. Clever design, but frustrating at the same time as this makes part identification somewhat tricker!

Entropy less the 1.0, and zero sections indicate no encryption applied

[Willem] uses a variety of tools and tricks to power up and sniff the ECU traffic on the CAN bus, when hooked up to a SAE J2534-compliant debug tool, eventually determining it speaks the VW-specific TP2.0 CAN bus protocol, and managed to grab enough traffic to check that it was possible to use the standard KWP2000 diagnostic protocol to access some interesting data. Next was a very deep dive into reverse engineering update images found online, by first making some trivial XOR operations, then looking at an entropy plot of the file using Binwalk to determine if he really did have code, and if it was encrypted or not, After running cpu_rec, it was determined the CPU was a Renesas V850. Then the real work started – loading the image into Ghidra to start making some guesses of the architecture of the code, to work out what needed patching to make the desired changes. In the final part of the series, [Willem] extracts and uses the bootloader procedure to partially patch the code configuration area of his vehicle and unlocks the goal he was aiming at – remote control of his steering. (OK, the real goal was running openpilot.)

In our opinion, this is a very interesting, if long, read showing a fascinating subject expertly executed. But we do want to stress, that the vehicular EPS module is an ASIL-D safety tested device, so any hacks you do to a road-going vehicle will most definitely void your insurance (not to mention your warranty) if discovered in the event of a claim.

Older ECUs are a bit easier to hack, if you can pull the EPROM, and people out there are producing modules for allsorts of vehicular hacking. So plenty to tinker with!

555 Timer On Its Own In Electronic Dice

January 8, 2022 by Bryan Cockfield 18 Comments

One of the most common clichés around here is that a piece of equipment chosen for a project is always too advanced. If a Raspberry Pi was used, someone will say they should have used an Arduino. If they use an Arduino, it should have been an ATtiny. And of course, if an ATtiny was used, there should have simply been a 555 timer. This time, however, [Tim] decided to actually show how this can be done by removing some of the integrated circuits from an electronic dice and relying entirely on the 555 timer for his build.

The electronic dice that [Tim] has on hand makes use of two main ICs: a NE555 and a CD4017 which is a decade counter/divider used for cycling through states. In order to bring the 555 to the forefront of this build, he scraps the CD4017 and adds an array of 555 timers. These are used to generate the clock signals necessary for this build but can also be arranged to form logic circuits. This comes at a great cost, however. The 555 chips take up an unnecessarily large area on the PCB (even though these are small surface-mount chips), consume an incredible amount of power, and are very slow. That’s fine for an electronic dice-rolling machine like this one, but that’s probably where [Tim] will leave this idea.

The 555 timer is a surprisingly versatile chip, and this project shows that there is some element of truth to the folks claiming that projects need naught but a few 555s. We’ve seen entire CPUs built using nothing but 555s, and even a classic project that uses a 555 timer to balance a robot.

playing Super Hang-On with Paw Patroller

Playing Super Hang-On With Hacked Controller Gives Reason For Paws

January 7, 2022 by Ryan Flowers 4 Comments

There’s a thing that happens when you’re shopping at a second hand store. You know how it goes: You see an item that strikes your fancy, your mind immediately locks in, and the item just has to be yours. [Tom Tilley] experienced this when he saw a Paw Patrol kids toy at a local thrift store, and you can see the results of his holiday hacking sessions in the video below the break.

How did [Tom] put the Paw Patrol game to use? Looking like a motorcycle cockpit left him with few choices. Before long he’d flipped the game over over, pulled the innards, and hacked together what just might be the most perfect toy based interface we’ve seen lately.

Using a Raspberry Pi Pico controller and some careful surgery, [Tom] turned the Paw Patrol game into a controller for the 1987 Sega motorcycle race arcade game Super Hang-On. Watching [Tom] play is a blast, but just in case the whole thing is a losing prospect, it’s completely reversible as well!

Of course we were a little disappointed that Super Hang-On couldn’t make use of the paws button.

On the other end of the spectrum, here’s an actual car turned into a game controller. Got a hot controller hack to share? Be sure to let the Tip Line know!

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Production PCB And Pogo Pins Produce A Clever Test Jig

January 7, 2022 by Dave Rowntree 13 Comments

[Hans Summers] runs a site qrp-labs.com, selling self-assembly kits mostly for radio gear and GPS applications, and had some production problems with his QCX-mini QRP transceiver kit. They were using an assembly house that had some problems with a sub-contractor going under during the pandemic, and the replacement service was somewhat below the expected level of quality, resulting in a significant number of SMT populated boards coming out non-functional. Obviously, not wanting to pass these on to customers as a debug problem, they set to work on an in-house QA test jig, to give them the confidence to ship kits again. The resulting functional test jig, (video, embedded below) takes a fairly interesting approach. Skip the video to 9:00 for the description of the test jig and detailed test descriptions.

By taking an existing known-good PCB, stripping off all the SMT parts, and moving the through hole components to the rear PCB side, pogo pins could be soldered to strategic locations. Building the assembly into a rudimentary enclosure made from sawn-up raw copper clad board, with the pogos facing upwards, and a simple clamp on top, allowed the PCB-under-test (let’s call it the UUT from hereon) to be located and clamped in place. This compressed the pogos in order to make a firm electrical contact. A piece of MDF that had been attacked with a dremel did duty as a pressure plate, with cutouts around the SMT component areas to achieve the required uniform board pressure and keeping the force away from the delicate soldered parts. All this means that with an UUT connected via pogo pins to a through-hole only test PCB, the full circuit would be completed, if and only if the UUT was completely functional, and that means defect-free soldering and defect-free components.

Next the firmware was rewritten to do duty as the test controller, which when powered up would step through a sequence of test scenarios and measurements, logging the results to an OLED display and a serial interface. This rig survived 1,000 SMT tests without failing, giving [Hans] the confidence to ship out new kits and providing a database of datalog results as a backup should a customer have an issue during final assembly. All-in-all a smart idea to solve a difficult problem, with nary a custom test jig PCB in sight!

These pages have been graced with many a pogo-based test rig over the years. Here’s one to start, and if you’ve got a handy laser cutter and some scrap wood, making an accurate test rig is no bother either.

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Segments light up as a person's step goal is achieved.

Slither: A Visual Pedometer That Sheds Light

January 7, 2022 by Kristina Panos No comments

Have you already broken that New Year’s resolution to get more exercise? Yeah, us too. Maybe the problem is simply that we didn’t gamify the goal. A simple visual aid that shows your progress can help make a goal more achievable and easier to stick to, day after January day. That’s the idea behind [skhackett]’s Slither, the visual pedometer.

Although Slither uses the Fit Bit app, no actual Fit Bit is required — great news for those of us who don’t like to wear accessories. But you will have to carry your phone everywhere if you want your steps to count. By tracking the steps taken each day, the sum of Slither’s segments signifies a weekly total goal of 50,000 steps.

Around back is a Feather Huzzah that receives step data from the phone and drives a strand of side-lit LED strips. There’s a Hall effect sensor in the tail, and Slither is powered on and off with a small, separate piece of wood and acrylic with a magnet embedded inside. Isn’t that a classy way to switch a snake?

We really like the look of the plywood here, though [skhackett] recommends using MDF instead because they experienced a fair amount of chipping. If you just want to watch the snake light up, it shouldn’t be too hard to cheat the pedometer.