An expansion board with two 8-bit ISA slots plugged into a Sharp laptop

New Expansion Module Brings Standard Slots To Ancient Laptop

Upgrading and repairing vintage laptops is often a challenge — even if their basic hardware is compatible with ordinary PCs, they often use nonstandard components and connectors due to space constraints. The Sharp PC-4600 series from the late 1980s is a case in point: although it comes with standard serial and parallel ports, the only other external interface is a mysterious connector labelled EXPBUS on the back of the case. [Steven George] has been diving into the details of this port and managed to design a module to turn it into a pair of standard ISA ports.

Apparently, no peripherals were ever released for the EXPBUS port, so reverse-engineering an existing module was out of the question. [Steven] did stumble upon a service manual for the PC-4600 however, and as it turned out, the connector carried all the signals present in an 8-bit ISA bus. Turning it into something useful was simply a matter of designing an adapter board with the EXPBUS connector on one side and regular ISA slots on the other.

An expansion board plugged into a laptop, carrying two ISA cardsThe board also has an external power connector, to avoid overloading the laptop’s internal power supply, as well as a couple of buffer capacitors to smooth out the power rails. [Steven] tested the expansion board with a network adapter and a sound card, and it appears to be functioning well. It should be noted that only the +5 V power rail is available by default, so if any cards need +12 V or any negative rail, those should be provided externally.

Gerber files for this project are available on [Steven]’s website, so if you’ve got one of these machines lying around, now might be the time to upgrade it. This isn’t the first expansion for the PC-4600 series that [Steven] developed, either: he also designed an external floppy drive adapter that should ease data transfer with other PCs.

It’s great to see how the hacker community keeps classic portables like this one alive: one day it might also need a broken screen replaced or a dodgy power supply repaired.

A bench setup with a spectrum analyzer and a PCB under test

Clever Test Rig Clarifies Capacitor Rules-of-Thumb

If you’ve done any amount of electronic design work, you’ll be familiar with the need for decoupling capacitors. Sometimes a chip’s datasheet will tell you exactly what kind of caps to place where, but quite often you’ll have to rely on experience and rules of thumb. For example, you might have heard that you should put 100 µF across the power supply pins and 100 nF close to each chip. But how close is “close”? And can that bigger cap really sit anywhere? [James Wilson] has been doing research to get some firm answers to those questions, and wrote down his findings in a fascinating blog post.

A PCB used to measure the effect of capacitor placement
The test board has two-layer and four-layer sections. The inter-layer capacitance greatly affects the PDN’s performance in each case.

[James] designed a set of circuit boards that enabled him to place different types of capacitors at various distances along a set of PCB traces. By measuring the impedance of such a power distribution network (PDN) across frequency, he could then calculate its performance under different circumstances.

The ideal tool for those measurements would have been a vector network analyzer (VNA), but because [James] didn’t have such an instrument, he made a slightly simpler setup using a spectrum analyzer with a tracking generator. This can only measure the impedance’s magnitude, without any phase information, but that should be good enough for basic PDN characterization.

The results of [James]’s tests are pretty interesting, if not too surprising. For example, those 100 nF capacitors really ought to be placed within 10 mm of your chip if it’s operating at 100 MHz, but you can get away with even 10 cm if no signals go much above 1 MHz. A bulk 100 µF cap can be placed at 10 cm without much penalty in either case. Combining several capacitors of increasing size to get a low impedance across frequency is a good idea in principle, but you need to design the network carefully to avoid resonances between the various components. This is where a not-too-low equivalent series resistance (ESR) is actually a good thing, because it helps to dampen those resonances.

Overall, [James]’s blog post is a good primer on the topic, and gives a bit of much-needed context to those rules of thumb. If you want to dive deeper into the details of PDN design or the inductance of PCB traces, our own [Bil Herd] has made some excellent videos on those topics.

Jac Goudsmit and Ralf Porankiewicz at Supercon 2022

2022 Supercon: Jac And Ralf Explore The Secrets Of The Digital Compact Cassette

During the 1990s, music was almost invariably stored on CDs or cassette tapes. When the new millennium came around, physical formats became obsolete as music moved first to MP3 files, and later to network streams. But a few years before that big transition, there were several attempts at replacing the aging cassette and CD formats with something more modern. You might remember the likes of MiniDisc and Super Audio CD, but there were a few other contenders around.

The Digital Compact Cassette, or DCC, was one such format. Released by Philips in 1992 as a replacement for the analog audio cassette, it failed to gain traction in the market and disappeared before most people had even heard of it. Not so for [Jac Goudsmit] and [Ralf Porankiewicz] however, who have spent years researching all aspects of the DCC system and shared some of the results in their 2022 Supercon talk.

[Ralf] is the curator of the DCC Museum in Cathedral City, California, which owns examples of all DCC equipment ever released, as well as several devices that never made it to market. He also aims to document the history of audio recording and DCC’s contribution to it, which goes further than you might think. For example, the audio compression format used in the DCC system, called PASC, was an early version of what would later become MP3 – though most histories of audio compression ignore this fact.

[Jac], for his part, made an extensive study of all the technical features of the DCC format. He has written numerous articles about his findings, first in the DCC FAQ and later by maintaining the relevant Wikipedia articles. He is running several projects aimed at keeping the format alive, often in collaboration with the DCC Museum.

[Jac] and [Ralf] begin their talk with a brief introduction to the system and its media. DCC players were designed to be compatible with analog audio cassettes, so DCC cartridges are the same basic size, though with a different type of tape inside. Playback devices contain a complex set of magnetic heads to read either the analog signals from classic tapes, or the digital data stored on DCCs.

One unique feature of DCC is Interactive Text Transfer Service, or ITTS, which is a separate data area on the tape that can hold additional information like song lyrics or even simple animations. It was intended to be displayed on players that supported it, but no such devices were ever released. Luckily, [Jac] and [Ralf] managed to find a rare ITTS decoder system used in a tape mastering facility, and were able to reveal the contents of this “secret track”, which is present on all prerecorded tapes, for the first time.

User-recorded tapes never had any ITTS data, and differed from prerecorded ones in several other ways, too. The most obvious difference was that professionally-made tapes could be indexed by song title, while home-made ones could only jump to track numbers. [Jac] and [Ralf] are however working to enable all the professional features on home-made tapes as well, through a number of software and hardware projects.

The most basic software needed is an encoder and decoder for the PASC format, which [Jac] developed from existing MP1 sofware. But to explore some of the more obscure hardware features, he had to reverse-engineer several different DCC players. This led him to discover many interesting half-finished features: the ITTS data sector is one example, but he also found out that some players send ready-to-use VU meter data to their front panel, even though they are unable to display that information.

[Jac] was also one of the first people to buy the DCC-175 portable DCC player when it was released in 1995. This was the only DCC player ever sold with a computer interface, allowing direct transfer of digital audio between a computer and a DCC tape. The parallel port interface and its accompanying Windows 9x software are completely obsolete and unusable with modern PCs, so [Jac] is working on directly accessing the data from the DCC-175 through a custom cable. He’s making good progress: he already figured out the electrical interface and wrote some software that enables him to control the tape recorder directly.

We can’t help but be impressed by the amount of effort both [Jac] and [Ralf] have put into understanding and documenting all the intricacies of a long-obsolete audio format. Thanks to their efforts, we can still appreciate the impressive technology behind DCC – even if it never came close to replacing its analog cousin.

Continue reading “2022 Supercon: Jac And Ralf Explore The Secrets Of The Digital Compact Cassette”

A ChatGPT client running on an IBM Portable PC

MS-DOS Client Brings ChatGPT To The IBM PC

AI-powered chatbots are clearly the future of computing, and it’s only a matter of time before you’ll see them appear on every internet-connected gadget. If you thought you were safe from this by sticking to an ancient MS-DOS PC though, think again: [Yeo Kheng Meng] has recently written a ChatGPT client that runs on DOS.

[Yeo Kheng Meng] didn’t cheat by simply running MS-DOS on a modern PC, either: he tested the client on a real 1984 vintage IBM 5155 Portable PC. This semi-portable PC/XT model sports a 4.77 MHz 8088 CPU, 640 kB of RAM and a CGA video card with a built-in monochrome monitor. An NE2000 ISA network card, running in 8-bit mode, enables the Portable to connect to the internet.

Running the client couldn’t be simpler: just run doschgpt.exe and type in your question. [Yeo Kheng Meng] developed this program using the Open Watcom C/C++ compiler, which was the compiler of choice for most DOS game developers back in the day. Networking support was provided by an era-appropriate packet driver together with MTCP, a TCP/IP stack developed by [Michael Brutman] for DOS-based internet applications.

Connecting to the ChatGPT API and parsing the results was pretty straightforward, but implementing the required TLS encryption was not. Even if there was a library available for MS-DOS, the 5155 wouldn’t have enough CPU power to run it in real time, so [Yeo Kheng Meng] decided to run that bit of the networking stack on a modern PC and send an unencrypted HTTP stream to the DOS client.

The end result is a delightful retro-futuristic setup that seems to have come straight out of a 1980s science fiction movie. We can already picture it together with a Commodore 64 reporting the news and an IRC server running on an IBM PC. Continue reading “MS-DOS Client Brings ChatGPT To The IBM PC”

A 1960s Copal flip clock

Classic 1960s Flip Clock Gets NTP Makeover

Many of the clocks we feature here on Hackaday are entirely built from scratch, or perhaps reuse an unusual display type. But sometimes, an old clock is just perfect as it is, and only needs a bit of an upgrade to help it fit into the modern world. One such example is the lovely 1960s Copal flip clock (in German, Google Translate link) that [Wolfgang Jung] has been working with — he managed to bring it squarely into the 21st century without changing its appearance one bit.

Like most flip clocks from the 60s and 70s, the Copal clock uses a small synchronous AC motor to advance the digits. Because this motor runs in step with the mains frequency, it also acts as the clock’s timing reference. However the original motor had died, and a direct replacement was impossible to find. So [Wolfgang] decided to replace it with a modern stepper motor. He designed a small PCB that fit the original housing, on which he placed a Trinamic TMC2225 stepper motor driver, a Wemos D1 Mini and a small 5 V power supply.

A flip clock mechanism with a PCB attached to itThanks to its WiFi connection, the D1 can find out the correct time by contacting a Network Time Protocol (NTP) server. Displaying that time would be tricky with the original hardware though, because there is no indication of which numbers are displayed at any time. [Wolfgang] cleverly solved this problem by placing an IR proximity sensor near the lowest digit, allowing the D1 to count the number of digits that have flipped over and thereby deduce the current state of the display.

There’s plenty of fun to be had with classic flip clocks like this, and with a bit of hacking any old split-flap display should be usable for your own clock project. If none are available at your local thrift store or yard sales, you can always roll your own.

A freshly reballed BGA chip next to a clean PCB footprint

Working With BGAs: Soldering, Reballing, And Rework

In our previous article on Ball Grid Arrays (BGAs), we explored how to design circuit boards and how to route the signals coming out of a BGA package. But designing a board is one thing – soldering those chips onto the board is quite another. If you’ve got some experience with SMD soldering, you’ll find that any SOIC, TQFP or even QFN package can be soldered with a fine-tipped iron and a bit of practice. Not so for BGAs: we’ll need to bring out some specialized tools to solder them correctly. Today, we’ll explore how to get those chips on our board, and how to take them off again, without spending a fortune on equipment.

Tools of the Trade

For large-scale production, whether for BGA-based designs or any other kind of SMD work, reflow ovens are the tool of choice. While you can buy reflow ovens small enough to place in your workshop (or even build them yourself), they will always take up quite a bit of space. Reflow ovens are great for small-scale series production, but not so much for repairs or rework. Continue reading “Working With BGAs: Soldering, Reballing, And Rework”

A cardboard wind tunnel

Optimize Your Paper Planes With This Cardboard Wind Tunnel

We at Hackaday are great fans of hands-on classroom projects promoting science, technology, engineering and math (STEM) subjects – after all, inspiring kids with technology at a young age will help ensure a new generation of hardware hackers in the future. If you’re looking for an interesting project to keep a full classroom busy, have a look at [drdonh]’s latest project: a fully-functional wind tunnel made from simple materials.

A styrofoam car model in a cardboard wind tunnelBuilt from cardboard, it has all the same components you’d find in a full-size aerodynamics lab: a fan to generate a decent stream of air, an inlet with channels to stabilize the flow, and a platform to mount experiments on. There’s even some basic instrumentation included that can be used to measure drag and lift, allowing the students to evaluate the drag coefficients of different car designs or the lift-generating properties of various airfoils. Continue reading “Optimize Your Paper Planes With This Cardboard Wind Tunnel”