A very good question came up on The EEVBlog forum that I thought deserved an in depth answer. The poster asked why would amplifier companies in the heyday of tube technology operate tubes in mass produced circuits well in excess of their published manufacturers recommended limits. The simple answer is: because the could get away with it. So the real question worth exploring is how did they get away with operating outside of their own published limitations? Let’s jump in and take a look at the collection of reasons.
To a lot of people, radio-frequency (RF) design is black magic. Even if you’ve built a number of RF projects, and worked your way through the low-lying gotchas, you’ve probably still got a healthy respect for the gremlins lying in wait around every dimly-lit corner. Well, [Michael Ossmann] gave a super workshop at the Hackaday Superconference to give you a guided tour of the better-illuminated spaces in RF design.
[Michael] is a hacker-designer, and his insights into RF circuit design are hard-won, by making stuff. The HackRF One is probably his most famous (and complex) project, but he’s also designed and built a number of simpler RF devices. And the main point of his talk is that there’s a large range of interesting projects that are possible without getting yourself into the fringes of RF design (which require expensive test equipment, serious modelling, or a Ph.D. in electro-wavey-things).
You should watch [Mike]’s workshop which is embedded below. That said, here’s the spoilers. [Mike] suggests five rules that’ll keep your RF design on the green, rather than off in the rough.
If you want a stable oscillator, you usually think of using a crystal. The piezoelectric qualities of quartz means that it can be cut in a particular way that it will oscillate at a very precise frequency. If you present a constant load and keep the temperature stable, a crystal oscillator will maintain its frequency better than most other options.
There are downsides to crystals, though. As you might expect, because crystals are so stable it’s hard to change the frequency much when you want a different one. You can use a trimming capacitor to pull the frequency a little, but to really change frequency, you have to change crystals.
There are other kinds of oscillators that are more frequency agile. However, they aren’t usually as stable. To combine flexibility with crystal-like stability, you can use a Phase Locked Loop (PLL). Many modern systems use direct digital synthesis, but the PLL is a venerable and time-tested technique.
Our bodies rely on DNA to function, it’s often described as “the secret of life”. A computer program that describes how to make a man. However inaccurate these analogies might be, DNA is fundamental to life. In order for organisms to grown and replicate they therefore need to copy their DNA.
Since the discovery of its structure in 1953, the approximate method used to copy DNA has been obvious. The information in DNA is encoded in 4 nucleotides (which in their short form we call A,T,G, and C). These couple with each other in pairs, forming 2 complimentary strands that mirror each other. This structure naturally lends itself to replication. The two strands can dissociate (under heat we call this melting), and new strands form around each single stranded template.
However, this replication process can’t happen all by itself, it requires assistance. And it wasn’t until we discovered an enzyme called the DNA polymerase that we understood how this worked. In conjunction with other enzymes, double stranded DNA is unwound into 2 single strands which are replicated by the polymerase.
While “writing it down” might seem like common sense, it wasn’t always the case. From the times of Ancient Greece, Plato tells a story of a worried Egyptian King, who, upon witnessing the invention of writing, remarks,
“If men learn this, it will implant forgetfulness in their souls; they will cease to exercise memory because they rely on that which is written, calling things to remembrance no longer from within themselves, but by means of external marks. [1]”
To some, the notebook was a dangerous device, a thief that would rob us of our memories [2]. Fortunately, these days, there’s plenty of evidence from our Psych texts that say we humans are pretty shabby at keeping the facts straight. In fact, each time we recall a memory, we change it! Here lies the beauty of the notebook. Have an idea for a new project? Why not log it somewhere for future reference? With diligence, the notebook can become our own personal hub for spurring on new project ideas.
As a fresh-faced electronic engineering student while the first Gulf War was raging in a far-off desert, I learned my way through the different families of 74 logic at a university in the North of England. 74LS was the one to use, the story went, because it’s quick and doesn’t use much power. At the time, there was an upstart on the scene: 74HC. Now that’s really quick. New. Exotic, even.
Thus an association was formed, when you want a quick logic function then 74HC is the modern one to go for. It could have been a lifelong love affair, but over twenty years, after many factors of speed increases and some RF tricks with gates we wouldn’t have dreamed of back then, it’s over. There is a whole world of newer logic families to choose from, and while HC is still good at what it does, it’s well past time to admit that it may just have been superseded.
40673s, probably now worth more by weight than anything else on four legs. (Thanks are due to [Brandon Dunson] and Tanner Electronics) A tendency to cling to the past with logic families is pretty harmless. Like [Adam Fabio]’s TIP power transistors they’re pretty cheap, still very much in production, and still do most jobs demanded of them excellently. But what prompted this piece was a far more egregious example of an old component still being specified: the RCA 40673 dual-gate MOSFET. Launched in the mists of time when dinosaurs probably still roamed the earth, this static-sensitive four-pin TO72 found a home in a huge variety of RF amplifiers, oscillators, and mixers. It worked well, but as you might expect better devices came along, and the 40673 was withdrawn some time in the 1980s.
Unfortunately, nobody seems to have told a section of the amateur radio community about the 40673’s demise. Or perhaps nobody’s told them that many scrap analogue TV tuners of a certain age will yield a perfectly good newer replacement for free. Because even today, thirty years after the 40673 shuffled off this mortal coil, you can still find people specifying it. If you have a stash of them in your junk box, they’re worth a small fortune, and yours could be the bench with the throng of people at the next ham radio convention.
A different but equally annoying manifestation of the phenomenon comes when the device everyone likes to specify is not very old and very much still in production, but the designer hasn’t taken the time required to check for a cheaper alternative. Nobody ever got fired for buying IBM, they say, but perhaps they should be fired for specifying an AD8307 logarithmic amplifier in an amateur radio power meter. Don’t take this the wrong way, it’s a beautiful chip and probably a lot of work at Analog Devices has gone into laser-trimming resistors to make it perform to an extremely demanding specification. But eleven dollars for a chip? When a cursory search will turn up Maxim’s MAX9933 which does a perfectly good job in this application at well under two dollars? Someone isn’t doing their homework.
Sometimes there are components for which there are no perfect replacements. Germanium point-contact diodes, for example. 1N34As and OA91s are becoming like hen’s teeth these days, and though Schottky diodes can replace them in many applications, there are still a few places if you’re a radio person you’ll hanker for the original. There are suppliers on Alibaba who claim to manufacture 1N34s, but the pictures always look suspiciously like 1N4148s, and anyway who can find a home for a hundred thousand diodes? (Hang on, this is Hackaday. There will be someone out there with a hundred-thousand-diode project, you can count on it.)
OK, maybe germanium diodes are an edge case and the examples above have a radio flavour, but you get the picture. What the full-blown rant in the previous paragraphs has been building up to is this: a plea for designers to do their homework. Please try to design every project for the next two decades, and as though any extras in the component price come from your company’s bottom line. (We’ll make exceptions for building something for which the whole point is a retro circuit. An Apple I replica like the Mimeo 1 needs old logic chips for artistic purposes.)
Is there a vital electronic engineering skill that’s being lost here perhaps? Back when the Internet was the sole preserve of boffins and Tim Berners-Lee hadn’t yet plugged his hypertext ideas into it, we relied on catalogs. Big paper-bound books the size of telephone directories were our only window into the exciting world of electronic components. If you’re an American yours was probably from Radio Shack, but for most UK-based hackers and makers who couldn’t get their hands on a commercial account from RS or Farnell that meant the Maplin catalogue. Before they moved in a consumer-electronics direction, they were a component specialist whose catalogue with its distinctive spaceships on the cover could be bought at large newsstands.
It’s difficult to describe the impact of electronics catalogues in the ’70s and ’80s to someone who has known only the abundance of information from the WWW. These publications were our only window into the world of electronic components. They contained significant excerpts from semiconductor data sheets, and we read their wealth of information from cover to cover. We knew by heart what each device was capable of, and we eagerly devoured each new tidbit of information as it arrived.
In short, when we specified a component, we did so with a pretty good knowledge of all the components that were available to us.
By comparison, nowadays we can quickly buy almost any device or component in production from a multitude of suppliers. There are millions more devices available, and if RS or Farnell don’t have the part then Mouser or Digi-Key are sure to provide. The WWW allows us to find what we need in short order, and the miracle of global distribution means that we can have it delivered within 48 hours almost wherever we live.
CPC’s very aptly-named Big Book
Which means that all the new devices are available to us, but we’ve lost the ability to keep on top of them. We’ve become information rich, but knowledge poor. Printed catalogs still exist, but the sheer volume of information they contain forces brevity upon their entries and expands the size of the publication to the point at which it becomes an unwieldy work of reference. We therefore tend to stick with the devices and components we know, regardless of their cost or of whether they have been superseded, and our work is poorer for it.
We need to relearn the skill of inquisitiveness when it comes to the parts we use, and to rediscover the joy of just browsing, even if the medium is now a huge suppliers’ web site rather than a paper catalog. Otherwise we’ll still be looking at circuit diagrams containing 74LS logic and 40673 MOSFETs in the 2030s, and that can’t be a good thing!
There is of course also a slightly macabre alternative scenario. The highest online price we found for 40673s was over $30 each, so if a producer can make that kind of silly money then there’s a danger that RCA’s successors will see a business model in exhuming the corpse and re-animating it, thus ensuring that we’ll never be free of the undead. We need to make sure that doesn’t happen!
For some reason, communications and power infrastructure fascinates me, especially the long-haul lines that move power and data over huge distances. There’s something about the scale of these projects that really gets to me, whether it’s a high-tension line marching across the countryside or a cell tower on some remote mountain peak. I recently wrote about infrastructure with a field guide that outlines some of the equipment you can spot on utility poles. But the poles and wires all have to end at the shore. Naturally we have to wonder about the history of the utilities you can’t see – the ones that run under the sea.
