Tiny Prisms Let You See What Lies Beneath A BGA Chip

May 1, 2024 by Dan Maloney 16 Comments

Compared to through-hole construction, inspecting SMD construction is a whole other game. Things you thought were small before are almost invisible now, and making sure solder got where it’s supposed to go can be a real chore. Add some ball grid array (BGA) chips into the mix, where the solder joints are not visible by design, and inspection is more a leap of faith than objective proof of results.

Unless, of course, you put the power of optics to work, as [Petteri Aimonen] does with this clever BGA inspection tool. It relies on a pair of tiny prisms to bounce light under one side of a BGA chip and back up the other. The prisms are made from thin sheets of acrylic; [Petteri] didn’t have any 1-mm acrylic sheet on hand, so he harvested material from a razor blade package. The edge of each piece was ground to a 45-degree angle and polished with successively finer grits until the surfaces were highly reflective. One prism was affixed to a small scrap of PCB with eleven SMD LEDs in a row, forming a light pipe that turns the light through 90 degrees. The light source is held along one edge of a BGA, shining light underneath to the other prism, bouncing light through the forest of solder balls and back toward the observer.

The results aren’t exactly crystal clear, which is understandable given the expedient nature of the materials and construction employed. But it’s certainly more than enough to see any gross problems lying below a BGA, like shorts or insufficiently melted solder. [Petteri] reports that flux can be a problem, too, as excess of the stuff can crystalize between pads under the BGA and obstruct the light. A little extra cleaning should help in such cases.

Haven’t tackled a BGA job yet? You might want to get up to speed on that.

Simplest Speaker Oscillator, Now Even Simpler

April 30, 2024 by Dan Maloney 21 Comments

It never fails. Lay down some kind of superlative — fastest, cheapest, smallest — around this place and someone out there says, “Hold my beer” and gets to work. In this case, it’s another, even simpler audio oscillator, this time with just a loudspeaker and a battery.

Attentive readers will recall the previous title holder was indeed pretty simple, consisting only of the mic and speaker from an old landline telephone handset wired in series with a battery. Seeing this reminded [Hydrogen Time] of a lucky childhood accident while experimenting with a loudspeaker, which he recreates in the video below. The BOM for this one is even smaller than the previous one — just a small speaker and a battery, plus a small scrap of solid hookup wire. The wire is the key; rather than connecting directly to the speaker terminal, it connects to the speaker frame on one end while the other is carefully adjusted to just barely touch the flexible wire penetrating the speaker cone on its way to the voice coil.

When power is applied with the correct polarity, current flows through the wire into the voice coil, which moves the cone and breaks the circuit. The speaker’s diaphragm resets the cone, completing the circuit and repeating the whole process. The loudspeaker makes a little click with each cycle, leading to a very rough-sounding oscillator. [Hydrogen Time] doesn’t put a scope on it, but we suspect the waveform would be a ragged square wave whose frequency depends on the voltage, the spring constant of the diaphragm, and the spacing between the fixed wire and the voice coil lead.

Yes, we realize this is stretching the definition of an audio oscillator somewhat, but you’ve got to admit it’s simple. Can you get it even simpler?

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Hackaday Links: April 28, 2024

April 28, 2024 by Dan Maloney 24 Comments

Well, it’s official — AI is ruining everything. That’s not exactly news, but learning that LLMs are apparently being used to write scientific papers is a bit alarming, and Andrew Gray, a librarian at University College London, has the receipts. He looked at a cross-section of scholarly papers from 2023 in search of certain words known to show up more often in LLM-generated text, like “commendable”, “intricate”, or “meticulous”. Most of the words seem to have a generally positive tone and feel a little fancier than everyday speech; one rarely uses “lucidly” or “noteworthy” unless you’re trying to sound smart, after all. He found increases in the frequency of appearance of these and other keywords in 2023 compared to 2022, when ChatGPT wasn’t widely available.

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Hackaday Podcast Episode 268: RF Burns, Wireless Charging Sucks, And Barnacles Grow On Flaperons

April 26, 2024 by Dan Maloney 4 Comments

Not necessarily the easy way to program an EPROM

Elliot and Dan got together to enshrine the week’s hacks in podcast form, and to commiserate about their respective moms, each of whom recently fell victim to phishing attacks. It’s not easy being ad hoc tech support sometimes, and as Elliot says, when someone is on the phone telling you that you’ve been hacked, he’s the hacker. Moving on to the hacks, we took a look at a hacking roadmap for a cheap ham radio, felt the burn of AM broadcasts, and learned how to program old-school EPROMs on the cheap.

We talked about why having a smart TV in your house might not be so smart, especially for Windows users, and were properly shocked by just how bad wireless charging really is. Also, cheap wind turbines turn out to be terrible, barnacles might give a clue to the whereabouts of MH370, and infosec can really make use of cheap microcontrollers.

Grab a copy for yourself if you want to listen offline.

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AI System Drops A Dime On Noisy Neighbors

April 25, 2024 by Dan Maloney 4 Comments

“There goes the neighborhood” isn’t a phrase to be thrown about lightly, but when they build a police station next door to your house, you know things are about to get noisy. Just how bad it’ll be is perhaps a bit subjective, with pleas for relief likely to fall on deaf ears unless you’ve got firm documentation like that provided by this automated noise detection system.

OK, let’s face it — even with objective proof there’s likely nothing that [Christopher Cooper] is going to do about the new crop of sirens going off in his neighborhood. Emergencies require a speedy response, after all, and sirens are perhaps just the price that we pay to live close to each other. That doesn’t mean there’s no reason to monitor the neighborhood noise, though, so [Christopher] got to work. The system uses an Arduino BLE Sense module to detect neighborhood noises and Edge Impulse to classify the sounds. An ESP32 does most of the heavy lifting, including running the UI on a nice little TFT touchscreen.

When a siren-like sound is detected, the sensor records the event and tries to classify the type of siren — fire, police, or ambulance. You can also manually classify sounds the system fails to understand, and export a summary of events to an SD card. If your neighborhood noise problems tend more to barking dogs or early-morning leaf blowers, no problem — you can easily train different models.

While we can’t say that this will help keep the peace in his neighborhood, we really like the way this one came out. We’ve seen the BLE Sense and Edge Impulse team up before, too, for everything from tuning a bike suspension to calming a nervous dog. Continue reading “AI System Drops A Dime On Noisy Neighbors” →

Chip Mystery: The Case Of The Purloined Pin

April 25, 2024 by Dan Maloney 29 Comments

Let’s face it — electronics are hard. Difficult concepts, tiny parts, inscrutable datasheets, and a hundred other factors make it easy to screw up in new and exciting ways. Sometimes the Magic Smoke is released, but more often things just don’t work even though they absolutely should, and no amount of banging your head on the bench seems to change things.

It’s at times like this that one questions their sanity, as [Gili Yankovitch] probably did when he discovered that not all CH32V003s are created equal. In an attempt to recreate the Linux-on-a-microcontroller project, [Gili] decided to go with the A4M6 variant of the dirt-cheap RISC-V microcontroller. This variant lives in a SOP16 package, which makes soldering a bit easier than either of the 20-pin versions, which come in either QFN or TSSOP packages.

Wisely checking the datasheet before proceeding, [Gili] was surprised and alarmed that the clock line for the SPI interface didn’t appear to be bonded out to a pin. Not believing his eyes, he turned to the ultimate source of truth and knowledge, where pretty much everyone came to the same conclusion: the vendor done screwed up.

Now, is this a bug, or is this a feature? Opinions will vary, of course. We assume that the company will claim it’s intentional to provide only two of the three pins needed to support a critical interface, while every end user who gets tripped up by this will certainly consider it a mistake. But forewarned is forearmed, as they say, and hats off to [Gili] for taking one for the team and letting the community know.

More Mirrors (and A Little Audio) Mean More Laser Power

April 24, 2024 by Dan Maloney 10 Comments

Lasers are pretty much magic — it’s all done with mirrors. Not every laser, of course, but in the 1980s, the most common lasers in commercial applications were probably the helium-neon laser, which used a couple of mirrors on the end of a chamber filled with gas and a high-voltage discharge to produce a wonderful red-orange beam.

The trouble is, most of the optical power gets left in the tube, with only about 1% breaking free. Luckily, there are ways around this, as [Les Wright] demonstrates with this external passive cavity laser. The guts of the demo below come from [Les]’ earlier teardown of an 80s-era laser particle counter, a well-made instrument powered by a He-Ne laser that was still in fine fettle if a bit anemic in terms of optical power.

[Les] dives into the physics of the problem as well as the original patents from the particle counter manufacturer, which describe a “stabilized external passive cavity.” That’s a pretty fancy name for something remarkably simple: a third mirror mounted to a loudspeaker and placed in the output path of the He-Ne laser. When the speaker is driven by an audio frequency signal, the mirror moves in and out along the axis of the beam, creating a Doppler shift in the beam reflected back into the He-Ne laser and preventing it from interfering with the lasing in the active cavity. This forms a passive cavity that greatly increases the energy density of the beam compared to the bare He-Ne’s output.

The effect of the passive cavity is plain to see in the video. With the oscillator on, the beam in the passive cavity visibly brightens, and can be easily undone with just the slightest change to the optical path. We’d never have guessed something so simple could make such a difference, but there it is.

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