Disassembly Required

If you really want to hack software, you are going to face a time when you have to take apart someone’s machine code. If you aren’t very organized, it might even be your own — source code does get lost. If you want to impress everyone, you’ll just read through the hex code (well, the really tough old birds will read it in binary). That was hard to do even when CPUs only had a handful of instructions.

A more practical approach is to use a tool called a disassembler. This is nothing more than a program that converts numeric machine code into symbolic instructions. The devil, of course, is in the details. Real programs are messy. The disassembler can’t always figure out the difference between code and data, for example. The transition points between data and code can also be tricky.

When Not to Use

If you are coding your own program in assembly,  a disassembler isn’t usually necessary. The disassembly can’t recover things like variable names, some function names, and — of course — comments. If you use a high-level language and you want to check your compiler output, you can easily have the compiler provide assembly language output (see below).

The real value of a disassembler is when you don’t have the source code. But it isn’t easy, especially for anything nontrivial. Be prepared to do a lot of detective work in most cases.

Continue reading “Disassembly Required”

Tools Of The Trade – Thermoforming

Chances are good that you’ve already lost some blood to thermoforming, the plastics manufacturing process that turns a flat sheet of material into an unopenable clamshell package, tray inside a box, plastic cup, or leftover food container.  Besides being a source of unboxing danger, it’s actually a useful technique to have in your fabrication toolchest. In this issue of Tools of the Trade, we look at how thermoforming is used in products, and how you can hack it yourself.

The process is simple; take a sheet of plastic material, usually really thin stuff, but it can get as thick as 1/8″, heat it up so that it is soft and pliable, put it over a mold, convince it to take all the contours of the mold, let it cool, remove it from the mold, and then cut it out of the sheet. Needless to say, there will be details.

https://commons.wikimedia.org/wiki/File:Thermoforming_animation.gif
https://commons.wikimedia.org/wiki/File:Thermoforming_animation.gif

Continue reading “Tools Of The Trade – Thermoforming”

Millennium Tower Is Sinking; And Waiting Is The Hardest Part

San Francisco’s Millennium Tower is sinking. Since its completion in 2009, the 58-story, 645-foot tall residential building has settled 16 inches and tilted perhaps 2 inches to the northwest. Since the foundation issues came to light in August 2016, the vertiginous ultra-luxury highrise has become the subject of outrage, ridicule, and at least two pieces of pending litigation.

Nothing that we build is static. Our office towers, apartment complexes, and single family homes move in response to loads applied by the environment. Buildings sway in the wind, expand and contract in response to temperature changes, and shift with the land upon which they rest. In most scenarios, these deflections are so minuscule that the occupants never even notice. Millennium Tower happens to be a large enough project with a severe enough problem that the whole world can’t help but gawk.

Millenium Tower located in San Francisco's SOMA, near the Financial District
Millenium Tower located in San Francisco’s SOMA, near the Financial District.

In foundation design, not all terra is firma. While a one or two story wood-framed building can be built safely with a shallow foundation on crummy soil, a major skyscraper requires a foundation that can transfer extremely high loads into the earth. But the strata below our city streets can consist of anything from sand to clay to solid rock, and many cities, including San Francisco, have infilled former marshes and bays with soil in order to expand their coastlines and generate valuable real estate. Millennium Tower was built in South of Market, a neighborhood that mostly used to belong to San Francisco Bay.

Continue reading “Millennium Tower Is Sinking; And Waiting Is The Hardest Part”

I Think I Failed. Yes, I Failed.

Down the rabbit hole you go.

In my particular case I am testing a new output matching transformer design for an audio preamplifier and using one of my go to driver circuit designs. Very stable, and very reliable. Wack it together and off you go to test and measurement land without a care in the world. This particular transformer is designed to be driven with a  class A amplifier operating at 48 volts in a pro audio setting where you turn the knobs with your pinky in the air sort of thing. Extra points if you can find some sort of long out of production parts to throw in there for audiophile cred, and I want some of that.

img_2857-2Lets use some cool retro transistors! I merrily go along for hours designing away. Carefully balancing the current of the long tailed pair input. Picking just the right collector power resistor and capacitor value to drive the transformer. Calculating the negative feedback circuit for proper low frequency cutoff and high frequency stability, and into the breadboard the parts go — jumper clips, meter probes, and test leads abound — a truly joyful event.

All of the voltages check out, frequency response is what you would expect, and a slight tweak to the feedback look brought everything right into happiness. Time to fire up the trusty old HP 334A Distortion Analyzer. Those old machines require you to calibrate the input circuit and the volt meter, tune a filter to the fundamental frequency you are applying to the device under test and step down to lower and lower orders of distortion levels until the meter happily sits somewhere in the middle of a range.

Most modern circuits in even cheap products just go right down to sub .1% total harmonic distortion levels without even a thought and I expected this to be much the same. The look of horror must have been pronounced on my face when the distortion level of my precious circuit was something more akin to a clock radio! A frantic search began. Was it a bad jumper, or a dirty lead in the breadboard, or an unseated component? Was my function generator in some state of disrepair? Is the Stephen King story Maximum Overdrive coming true and my bench is going to eat me alive? All distinct possibilities in this state of panic.

Continue reading “I Think I Failed. Yes, I Failed.”

Softer Side Of Robots Is Future Of Space

What will next generation space suits look like? Kari Love is making the case that new space suits will exhibit the best in soft robot technology. The problem is that most people don’t really understand much about soft robots, or about space for that matter. Her talk at the Hackaday SuperConference explores the research she has been doing into future generations of space suits. Check out the video below and then join us after the break for more on this topic.

Continue reading “Softer Side Of Robots Is Future Of Space”

Off-Grid Travel — Setting Up A Solar System

When you’re living out of a vehicle, or even just traveling out of one, power quickly becomes a big concern. You need it for lights, to charge your various devices, to run your coffee maker and other appliances, and possibly even to store your food if you’ve got an electric refrigerator. You could do what many RV owners do: rely on campgrounds with electrical hookups plus a couple of car batteries to get you from one campground to the next. But, those campgrounds are pricey and often amount to glorified parking lots. Wouldn’t it be better if you had the freedom to camp anywhere, without having to worry about finding somewhere to plug in?

That’s exactly what we’re going to be covering in this article: off-grid power on the road. There are two major methods for doing this: with a portable gas generator, or with solar. Gas generators have long been the preferred method, as they provide a large amount of power reliably. However, they’re also fairly expensive, cumbersome, noisy, and obviously require that you bring along fuel. Luckily, major advances in solar technology over the past decade have made it very practical to use solar energy as your sole source of electricity on the road.

Continue reading “Off-Grid Travel — Setting Up A Solar System”

Closing The Loop On An Artificial Pancreas

Life as a parent is never easy, but when you’ve got a kid with Type 1 diabetes it’s a little harder. Sometimes it feels like a full-time job in itself; there’s never a break. With carb counts and insulin ratios that change throughout the day, every meal is a medical procedure. A romp in the snow or a long bike ride can send her blood glucose plummeting. The overnights are the worst, though, because you never know if you overestimated the number of carbs at dinner and gave her too much insulin. Low blood glucose is easily treated with a few sips of juice, but if it goes unnoticed in the middle of the night, it could be fatal. That’s why parents of diabetics are always a little glassy eyed — we rarely sleep.

Why is all this necessary? It’s because Type 1 diabetes (T1D) is an autoimmune disease that attacks the insulin-producing beta cells in the pancreas. Once those cells are dead, insulin is no longer produced, and without insulin the rest of the cells in the body can’t take in the glucose that they need to live. Diabetics have to inject just the right amount of insulin at just the right time to coincide with the blood glucose spike that occurs after meals. Knowing how much to give and when is why we say we have to “learn to think like a pancreas.”

1-1-2-4_ping
Animas Ping insulin pump, partial teardown. The cylinder on the bottom is the battery, the motor and syringe compartment are on top. Source: Animas

Things are better than they used to be, for sure. Insulin pumps have been a game changer for T1Ds. An insulin pump is just a tiny syringe pump. A small motor moves the plunger on a disposable syringe filled with a few days worth of insulin. The hormone is delivered through a small catheter placed under the skin every few days — painful, but better than a needle stick with every meal and snack.  A computer keeps track of everything and provides safety against overdosing on insulin, so it’s terribly convenient, but we still need to “think like a pancreas” and calculate the amount to deliver.

Even with its shortcomings, my daughter’s pump has been a blessing, and I’ll do whatever it takes to keep her in the latest gear. Pumps generally cost about $5000 or so, and need to be replaced every three years. While I’m not looking forward to paying the bill when her current pump gives up the ghost, I am certainly keen to do a teardown on the old one. I suspect it’s dead simple in there — a tiny gear motor, some kind of limit switches, and a main board. It’ll be painful to see how little my money buys, but it’ll be cool to play around with it.

Continue reading “Closing The Loop On An Artificial Pancreas”