Author: Al Williams

4375 Articles

Deep Drawing With Ultrasonics

March 9, 2025 by 17 Comments

Small cylindrical parts are often formed through deep drawing — a process by which a punch forms the finished piece from a flat sheet of metal using a forming die. If it sounds like that stresses the metal, it does. But researchers at Fraunhofer have found a way to reduce friction protecting both the material and the tools that do the forming. The process — known as VibroDraw — uses ultrasonic vibrations at around 500 Hz.

Researchers claim a 20% reduction in friction now, and it may be possible to go even further. With less friction, it is possible to do a deeper draw in a single stage. It also creates less heat which is good for tool life and prevents overheating lubricant. The process has a patent if you want more details. You might need to brush up on your German, though. Unsurprisingly, the vibrations are from a piezoelectric transducer.

Copper is soft enough to use 3D printed dies. We don’t know if this technique would help with that or not. Then there’s hydroforming. If you have any results using ultrasonics with these or any other techniques, be sure to let us know.

Fictional Computers: EMERAC Was The Chatbot Of 1957

March 8, 2025 by 17 Comments

Movies mirror the time they were made. [ErnieTech] asserts that we can see what people thought about computers back in 1957 by watching the classic Spencer Tracy/Katharine Hepburn movie “Desk Set.” What’s more, he thinks this might be the first movie appearance of a human-like computer. On a side note, in the UK this movie was known as “The Other Woman.”

The story is about an MIT computer expert computerizing a broadcasting company who, of course, finds romance and, at least towards the end, comedy.

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Transceiver Reveals Unusual Components

March 8, 2025 by 22 Comments

[MSylvain59] likes to tear down old surplus, and in the video below, he takes apart a German transceiver known as a U-600M. From the outside, it looks like an unremarkable gray box, especially since it is supposed to work with a remote unit, so there’s very little on the outside other than connectors. Inside, though, there’s plenty to see and even a few surprises.

Inside is a neatly built RF circuit with obviously shielded compartments. In addition to a configurable power supply, the radio has modules that allow configuration to different frequencies. One of the odder components is a large metal cylinder marked MF450-1900. This appears to be a mechanical filter. There are also a number of unusual parts like dogbone capacitors and tons of trimmer capacitors.

The plug-in modules are especially dense and interesting. In particular, some of the boards are different from some of the others. It is an interesting design from a time predating broadband digital synthesis techniques.

While this transceiver is stuffed with parts, it probably performs quite well. However, transceivers can be simple. Even more so if you throw in an SDR chip.

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This Laser Knows About Gasses

March 7, 2025 by 5 Comments

What’s that smell? If you can’t tell, maybe a new laser system from CU Bolder and NIST can help. The device is simple and sensitive enough to detect gasses at concentrations down to parts per trillion.

The laser at the system’s heart is a frequency comb laser, originally made for optical atomic clocks. The laser has multiple optical frequencies in its output. The gas molecules absorb light of different wavelengths differently, giving each type of molecule a unique fingerprint.

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Tearing Down A Vintage Word Processor

March 7, 2025 by 3 Comments

There was a time when the line between typewriters and word processing software was a bit fuzzy. [Poking Technology] found a Xerox 6040 which can’t decide what it is. It looks like a typewriter but has a monitor and a floppy drive, along with some extra buttons. You can watch him tear it down in the video below.

The old device uses a daisywheel type element, which, back then, was state of the art. A wheel had many spokes with letters and the printer would spin the wheel and then strike the plastic spoke.

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Repairing A 1955 Classic Radio

March 6, 2025 by 8 Comments

We used to say that fixing something was easier than bringing up a design for the first time. After all, the thing you are fixing, presumably, worked at one time or another. These days, that’s not always true as fixing modern gear can be quite a challenge. Watching [Ken’s] repair of an old 1955 Silvertone radio reminded us of a simpler time. You can watch the action on the video below.

If you’ve never had the pleasure of working on an AM radio, you should definitely try it. Some people would use an amplifier to find where the signal dies out. Others will inject a signal into the radio to find where it stops. A good strategy is to start at the volume control and decide if it is before or after that. Then split the apparently bad section roughly in half and test that portion—sort of a hardware binary search. Of course, your first step should probably be to verify power, but after that, the hunt is on.

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Combined Crypto, Anglo-American Style

March 6, 2025 by 8 Comments

If you think about military crypto machines, you probably think about the infamous Enigma machine. However, as [Christos T.] reminds us, there were many others and, in particular, the production of a “combined cipher” machine for the US and the UK to use for a variety of purposes.

The story opens in 1941 when ships from the United States and the United Kingdom were crossing the Atlantic together in convoys. The US wanted to use the M-138A and M-209 machines, but the British were unimpressed. They were interested in the M-134C, but it was too secret to share, so they reached a compromise.

Starting with a British Typex, a US Navy officer developed an attachment with additional rotors and converted the Typex into a CCM or Combined Cipher Machine. Two earlier verisons of the attachment worked with the M-134C. However the CSP 1800 (or CCM Mark III) was essentially the same unit made to attach to the Typex. Development cost about $6 million — a huge sum for the middle of last century.

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