Why Some Chips Have Inconvenient Pinouts

February 17, 2020 by Donald Papp 29 Comments

If you’ve ever handled a chip with a really strange or highly inconvenient pinout and suspected that the reason had something to do with the inner workings, you may be interested to see [electronupdate]’s analysis of why the 4017 Decade Counter IC has such a weirdly nonintuitive pinout. It peeks into an IC design dating from the 1970s to see an example of the kind of design issues that can affect physical layout.

Inside the 4017. Want to make sense of how lines and shapes on a silicon wafer make an IC work? With the right teachers, it’s simple.

In the case of the 4017, once decapped and the inner workings exposed, things became more clear. Inside the chip are a bunch of flip-flops and NAND gates, laid out in a single layer. Some of the outputs (outputs 5 and 1 for example, physically on pins 1 and 2 respectively) share the same flip-flop.

The original design placed the elements in a way that made the most logical sense for routing and layout, which resulted in nice and tidy inner workings but an apparently illogical pinout. A lot of this is probably feeling familiar to anyone who has designed and routed a single-layer PCB, where being limited to one layer makes it important to get the most connections as directly near one another as possible.

Chip design has of course come a long way since the 70s, but there is forever some level of trade-off to be made between outward tidiness and inner design harmony. The next time you’re looking at a part with an apparently illogical pinout, there’s a fair chance it makes far more sense on the inside.

If any of you are interested in decapping ICs yourselves to see what’s inside, we saw that it’s possible with commonly available chemicals, not just nasty ones.

Continue reading “Why Some Chips Have Inconvenient Pinouts” →

Have LED Bulbs Reached Their Final (and Cheapest) Form?

February 16, 2020 by Donald Papp 129 Comments

[electronupdate] has done a lot of LED light bulb teardowns over the years, witnessing a drive towards ever-cheaper and ever-simpler implementations, and suspects that LED light bulb design has finally reached its ultimate goal. This teardown of a recent dollar store example shows that cost-cutting has managed to shave even more off what was already looking like a market saturated with bottom-dollar design.

The electrical components inside this glowing model of cost-cutting consists of one PCB (previously-seen dollar store LED bulb examples had two), eleven LEDs, one bridge rectifier, two resistors, and a controller IC. A wirewound resistor apparently also serves as a fuse, just in case.

Inside the unmarked controller IC. The design is as cheap as it is clever in its cost-cutting.

That’s not all. [electronupdate] goes beyond a simple teardown and has decapped the controller IC to see what lurks inside, and the result is shown here. This controller is responsible for driving the LEDs from the ~100 Volts DC that the bridge rectifier and large electrolytic cap present to it, and it’s both cheap and clever in its own way.

The top half is a big transistor for chopping the voltage and the bottom half is the simple control logic; operation is fast enough that no flicker is perceived in the LEDs, and no output smoothing cap is needed. The result, of course, is fewer components and lower cost.

Some of you may recall that back in the early days of LED lighting, bulbs that could last 100,000 hours were a hot promise. That didn’t happen for a variety of reasons and the march towards being an everyday consumable where cost was paramount continued. [electronupdate] feels they have probably reached that ultimate goal, at least until something else changes. They work, they’re cheap, and just about everything else has been successfully pried up and tossed out the door.

Cheap Strain Relief By Casting Hot Glue In A 3D Print

February 11, 2020 by Donald Papp 53 Comments

[Daniel Roibert] found a way to add cheap strain relief to JST-XH connectors, better known to hobby aircraft folks as the charging and balance connectors on lithium-polymer battery packs. His solution is to cast them in hot glue, with the help of 3D printed molds. His project provides molds fitted for connectors with anywhere from two to eight conductors, so just pick the appropriate one and get printing. [Daniel] says to print the mold pieces in PETG, so that they can hold up to the temperature of melted glue.

The 3D models aren’t particularly intuitive to look at, but an instructional video makes everything clear. First coat the inside surfaces of the mold with a release agent (something like silicone oil should do the trick) and then a small amount of hot glue goes in the bottom. Next the connector is laid down on top of the glue, more glue is applied, and the top of the mold is pressed in. The small hole in the top isn’t for filling with glue, it’s to let excess escape as the mold is closed. After things cool completely, just pop apart the mold (little cutouts for a screwdriver tip make this easy) and trim any excess. That’s all there is to it.

One last thing: among the downloads you may notice one additional model. That one is provided in split parts, so that one can make a mold of an arbitrary width just by stretching the middle parts as needed, then merging them together. After all, sometimes the STL file is just not quite right and if sharing CAD files is not an option for whatever reason, providing STLs that can be more easily tweaked is a welcome courtesy. You can watch a short video showing how the whole thing works, below.

Continue reading “Cheap Strain Relief By Casting Hot Glue In A 3D Print” →

New Part Day: The Wi-Fi Stepper Gets Ideas Working Faster

February 10, 2020 by Donald Papp 38 Comments

Like most of us, I sometimes indulge in buying a part for its potential or anticipated utility rather than for a specific project or purpose. That’s exactly how I ended up with the WSX100 Wi-Fi Stepper, a single board device intended to be one of the fastest and easiest ways to get a stepper motor integrated into a project. Mine came from their Crowd Supply campaign, which raised money for production and continues to accept orders.

What’s It For?

The WSX100 Wi-Fi Stepper Driver (with motor), by Good Robotics

The main reason the Wi-Fi Stepper exists is to make getting a stepper motor up and running fast and simple, in a way that doesn’t paint a design into a corner. The device can certainly be used outside of prototyping, but I think one of its best features is the ability to help quickly turn an idea into something physical. When prototyping, it’s always better to spend less time on basic bits like driving motors.

In a way, stepper motors are a bit like RGB LEDs or LCD displays were before integrated drivers and easy interfaces became common for them. Steppers require work (and suitable power supplies) to get up and running, and that effort can be a barrier to getting an idea off the ground. With the Wi-Fi Stepper, a motor can be fired up and given positional commands (or set to a speed and direction) in no time at all. By sending commands over WiFi, there isn’t even the need to wire up any control logic.

Continue reading “New Part Day: The Wi-Fi Stepper Gets Ideas Working Faster” →

Rollbot Crams Ten Arms Onto One Wheel

February 6, 2020 by Donald Papp 9 Comments

It’s not every day that we see someone trying something new with robot locomotion, but [kong]’s robot Rollyboi was made to do exactly that by mixing up the usual robot-wheel-motor layout. Instead of the robot using motors to drive wheels, Rollyboi is itself the wheel, and uses multiple simple arms (legs?) attached to hobby servo motors to propel itself. The idea is that the arms swivel out one at a time to roll the robot along as needed.

It’s a novel idea, but how well does it work in practice? The first version was blind and mechanically unstable, with no idea which way was up and therefore no way to effectively control which arm needed to be extended, but was nevertheless able to roll along. The next version implemented a simple control system: buttons installed along the outside rim let the robot know how it is moving and which arm to extend next. With two sets of arms (one on each side) the robot becomes capable of executing simple turns by extending one arm more than the other.

In the end, Rollyboi could move but still lacks a means to perceive and navigate its environment. This is made more challenging by the fact that the robot’s body (and therefore any sensors mounted to it) would be in constant motion as the robot moves. Still, it’s interesting to see how far the idea went using only simple hardware, and its motion gives off a certain radial solenoid engine vibe. You can watch a brief video below.

Continue reading “Rollbot Crams Ten Arms Onto One Wheel” →

Tricking The Brain Into Seeing Boosted Contrast In Stereo Imagery

February 1, 2020 by Donald Papp 20 Comments

Last year a team of researchers published a paper detailing a method of boosting visual contrast and image quality in stereoscopic displays. The method is called Dichoptic Contrast Enhancement (DiCE) and works by showing each eye a slightly different version of an image, tricking the brain into fusing the two views together in a way that boosts perceived image quality. This only works on stereoscopic displays like VR headsets, but it’s computationally simple and easily implemented. This trick could be used to offset some of the limitations of displays used in headsets, for example making them appear capable of deeper contrast levels than they can physically deliver. This is good, because higher contrasts are generally perceived as being more realistic and three-dimensional; important factors in VR headsets and other stereoscopic displays.

Stereoscopic vision works by having the brain fuse together what both eyes see, and this process is called binocular fusion. The small differences between what each eye sees mostly conveys a sense of depth to us, but DiCE uses some of the quirks of binocular fusion to trick the brain into perceiving enhanced contrast in the visuals. This perceived higher contrast in turn leads to a stronger sense of depth and overall image quality.

Example of DiCE-processed images, showing each eye a different dynamic contrast range. The result is greater perceived contrast and image quality when the brain fuses the two together.

To pull off this trick, DiCE displays a different contrast level to both eyes in a way designed to encourage the brain to fuse them together in a positive way. In short, using a separate and different dynamic contrast range for each eye yields an overall greater perceived contrast range in the fused image. That’s simple in theory, but in practice there were a number of problems to solve. Chief among them was the fact that if the difference between what each eyes sees is too great, the result is discomfort due to binocular rivalry. The hard scientific work behind DiCE came from experimentally determining sweet spots, and pre-computing filters independent of viewer and content so that it could be applied in real-time for a consistent result.

Things like this are reminders that we experience the world only through the filter of our senses, and our perception of reality has quirks that can be demonstrated by things like this project and other “sensory fusion” edge cases like the Thermal Grill Illusion, which we saw used as the basis for a replica of the Pain Box from Dune.

A short video overview of the method is embedded below, and a PDF of the publication can be downloaded for further reading. Want a more hands-on approach? The team even made a DiCE plugin (freely) available from the Unity asset store.

Continue reading “Tricking The Brain Into Seeing Boosted Contrast In Stereo Imagery” →

Form 3 SLA Printer Teardown, Bunnie Style

January 21, 2020 by Donald Papp 15 Comments

[Bunnie Huang] has shared with all of us his utterly detailed teardown on the Form 3 SLA printer from Formlabs (on the left in the image above) and in it he says one of the first things he noticed when he opened it to look inside was a big empty space where he expected to see mirrors and optics. [Bunnie] had avoided any spoilers about the printer design and how it worked, so he was definitely intrigued.

Not only does the teardown reveal the kind of thoughtful design and construction that [Bunnie] has come to expect of Formlabs, but it reveals that the Form 3 has gone in an entirely new direction with how it works. Instead of a pair of galvanometers steering a laser beam across a build surface (as seen in the Form 1 and Form 2 printers) the new machine is now built around what Formlabs calls an LPU, or Light Processing Unit, which works in conjunction with a new build tank and flexible build surface. In short, the laser and optics are now housed in a skinny, enviromentally-sealed unit that slides left and right within the printer. A single galvo within steers the laser vertically, as the LPU itself moves horizontally. Payoffs from this method include things such as better laser resolution, the fact that the entire optical system is no longer required to sit directly underneath a vat of liquid resin, and that build sizes can be bigger. In addition, any peeling forces that a model is subjected to are lower thanks to the way the LPU works.

Details about exactly how the Form 3 works are available on Formlabs’ site and you can also see it in action from a practical perspective on Adam Savage’s Tested (video link), but the real joy here is the deeply interesting look at the components and assembly through the eyes of someone with [Bunnie]’s engineering experience. He offers insights from the perspective of function, supply, manufacture, and even points out a bit of NASA humor to be found inside the guts of the LPU.

[Bunnie] knows his hardware and he’s certainly no stranger to Formlabs’ work. His earlier Form 2 teardown was equally detailed as was his Form 1 teardown before that. His takeaway is that the Form 3 and how it works represents an evolutionary change from the earlier designs, one he admits he certainly didn’t see coming.