Retrotechtacular: Making Chains

We take the everyday materials of engineering for granted, as ubiquitous components rather than as complex items in their own right. Sure, we know that an integrated circuit represents the pinnacle of a hundred years’ development in the field of electronics, but to us it’s simply a black box with some wires. Even with more basic materials it’s easy to forget the work that goes into their manufacture, as for example with the two videos below the break. They both take a look from a very different angle at the creation of the same product: metal chain. However, the approaches couldn’t be more different as the two examples are separated by about a century and with vastly different techniques and material.

The first film follows the manufacture of the chain and anchor that would have been found on a ship around the turn of the twentieth century. One of the text frames mentions Netherton Works, allowing us to identify it as being filmed at N. Hingley & Sons, a specialist anchor and chain manufacturer based in the area to the west of the English city of Birmingham known as the Black Country. It’s a window on a manufacturing world that has entirely disappeared, as large gangs of men do almost every task in the process by hand, with very few automated steps. There is scant regard for health and safety in handling the huge pieces of red-hot metal, and the material in question is not the steel we’d be used to today but wrought iron. The skill required to perform some of the steps such as forge-welding large anchor parts under a steam hammer is very significant, and the film alone can not convey it. More recent videos of similar scenes in Chinese factories do a better job.

The other video is contemporary, a How It’s Made look at chain manufacture. Here the chains involved are much smaller, everything is done by automated machinery, and once we have got over marveling at the intricacy of the process we can see that there is far more emphasis on the metallurgy. The wire is hard drawn before the chain is formed, and then hardened and annealed in a continuous process by a pair of induction heaters and water baths. I’m trying really hard to avoid a minor rant about the propensity of mass-market entertainment such as this for glossing over parts of the process. A keen eye notices that each link has become welded but we are not shown the machine that performs the task.

Most of us will never have the chance of a peek into a chain factory, so the medium of YouTube industrial films and videos is compulsive viewing. These two views of what is essentially the same process could not be more different, however it would be wrong to assume that one has replaced the other. There would have been mechanised production of small chains when the first film was made, and large chains will still be made today with fewer workers and from arc-welded steel rather than wrought iron. Plants like the Hingley one in Netherton may have closed in the 1980s, but there is still a demand for chains and anchors.

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Retrotechtacular: History Of Sony Mini Doc Bursts With 1970s Style

The 1970s, it was a time when cameras needed film, phones had cords, and televisions masqueraded as furniture. A time where hi-fi systems were judged by the volume knob feel, and thanks to YouTube user [nefesh22] we have a behind-the-scenes glimpse of what the era was like from the Sony corporate perspective in this mini documentary of the company’s history below. The film was originally created for internal use at Sony’s US manufacturing facilities in San Diego, however, now it now can be watched by anyone with an internet connection.

Sony CRT Testing Rig 1970s

Sony’s corporate ethos of allowing its engineers to drive business innovation is on full display here. For instance how in 1950 Sony introduced the first magnetic tape recorder, the G-Type, in Japan and followed that up with the first portable television, the TV8-301, a decade later. Throughout the 1970s Sony became an innovator in the video space. In fact, the Sony Trinitron brand of color TVs garnered so much notoriety in the television industry that the company was awarded an Emmy in 1973. Though the most telling feature is the documentary’s focus on the 3/4-inch U-Matic videocassette format, a precursor to VHS and Sony’s own Betamax videotapes. Highlighting the “superiority” of those VTR systems of the day really does date the film as those hulking decks failed to penetrate the market beyond early adopters and media companies.

It’s interesting to see how hands-on quality assurance testing used to be. Whether it’s glancing at NPN transistors under a microscope, dialing in the focus on a Super 8 camera, or a quick wave of the degaussing wand before a tube leaves the line, each of the QA tasks were carried out by individual employees rather than the automated methods of today. On an unrelated note, the brief overview of the Sony’s on-site “fiefdom” for its young workforce is a reminder that some ideas may be better left in the past… Google’s Mountain View campus anyone? If anything is to be gleaned from this retrotechtacular retrospective is that we could all use a little more wood-grain in our electronics these days.

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Retrotechtacular: Balloons Go To War

To the average person, the application of balloon technology pretty much begins and ends with birthday parties. The Hackaday reader might be able to expand on that a bit, as we’ve covered several projects that have lofted various bits of equipment into the stratosphere courtesy of a high-altitude balloons. But even that is a relatively minor distinction. They might be bigger than their multicolored brethren, but it’s still easy for a modern observer to write them off as trivial.

But during the 1940’s, they were important pieces of wartime technology. While powered aircraft such as fighters and bombers were obviously more vital to the larger war effort, balloons still had numerous defensive and reconnaissance applications. They were useful enough that the United States Navy produced a training film entitled History of Balloons which takes viewers through the early days of manned ballooning. Examples of how the core technology developed and matured over time is intermixed with footage of balloons being used in both the First and Second World Wars, and parallels are drawn to show how those early pioneers influenced contemporary designs.

Even when the film was produced in 1944, balloons were an old technology. The timeline in the video starts all the way back in 1783 with the first piloted hot air balloon created by the Montgolfier brothers in Paris, and then quickly covers iterative advancements to ballooning made into the 1800’s. As was common in training films from this era, the various “reenactments” are cartoons complete with comic narration in the style of W.C. Fields which were designed to be entertaining and memorable to the target audience of young men.

While the style might seem a little strange to modern audiences, there’s plenty of fascinating information packed within the film’s half-hour run time. The rapid advancements to ballooning between 1800 and the First World War are detailed, including the various instruments developed for determining important information such as altitude and rate of climb. The film also explains how some of the core aspects of manned ballooning, like the gradual release of ballast or the fact that a deflated balloon doubles as a rudimentary parachute in an emergency, were discovered quite by accident.

When the film works its way to the contemporary era, we are shown the process of filling Naval balloons with hydrogen and preparing them for flight. The film also talks at length about the so-called “barrage balloons” which were used in both World Wars. Including a rather dastardly advancement which added mines to the balloon’s tethers to destroy aircraft unlucky enough to get in their way.

This period in human history saw incredible technological advancements, and films such as these which were created during and immediately after the Second World War provide an invaluable look at cutting edge technology from a bygone era. One wonders what the alternative might be for future generations looking back on the technology of today.

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Retrotechtacular: Transputer

Back in 2016, Hackaday published a review of The National Museum of Computing, at Bletchley Park. It mentions among the fascinating array of computer artifacts on display a single box that could be found in the corner of a room alongside their Cray-1 supercomputer. This was a Transputer development system, and though its architecture is almost forgotten today there was a time when this British-developed microprocessor family had a real prospect of representing the future of computing. So what on earth was the Transputer, why was it special, and why don’t we have one on every desk in 2019?

An Inmos RAMDAC (the 28-pin DIP) on the motherboard of a 1989 IBM PS/55. Darklanlan [CC BY 4.0]
An Inmos RAMDAC (the 28-pin DIP) on the motherboard of a 1989 IBM PS/55. Darklanlan [CC BY 4.0]
Inmos, based in Bristol, were a — no, make that the — British semiconductor company, in the days when governments saw such things as a home-grown semiconductor manufacturing capability to be of strategic importance. They made microcomputer peripheral chips, RAM chips, and video chips (the workaday silicon of 1980s computing) but their exciting project was the Transputer.

This microprocessor family addressed the speed bottlenecks inherent to conventional processors of the day by being built from the ground up to be massively multiprocessor.  A network of Transputer processors would share a web of serial interconnects arranged in a crosspoint formation, allowing multiple of them to connect with each other independently and without collisions. It was the first to feature such an architecture, and at the time was seen as the Next Big Thing. All computers were going to use Transputers by the end of the 1990s, so electronic engineering students were taught all about them and encountered them in their group projects. I remember my year of third-year EE class would split into groups, each of tasked with a part of a greater project that would communicate through the crosspoint switch at the heart of one of the Transputer systems, though my recollection is that none of the groups went so far as to get anything to work. Still how this machine was designed is fun to look back on in modern times. Let’s dig in!

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Retrotechtacular: Nellie The School Computer

When did computers arrive in schools? That should be an easy question to answer, probably in the years around 1980. Maybe your school had the Commodore Pet, the Apple II, or if you are British, the Acorn BBC Micro in that period, all 8-bit microcomputers running a BASIC interpreter. That’s certainly the case for the majority of schools, but not all of them. In early 1969 the BBC’s Tomorrow’s World visited a school with a computer, and in both technology and culture it was a world away from those schools a decade later that would have received those BBC Micros.

The school in question was The Forrest Grammar School, Winnersh, about 35 miles west of London, and the computer in question was a by-then-obsolete National Elliott 405 mainframe that had been donated four years earlier by the British arm of the food giant Nestlé. The school referred to it as “Nellie” — a concatenation of the two brand names. It seems to have been the preserve of the older pupils, but the film below still shows the concepts of its operation being taught at all levels. We get a brief look at some of their software too — no operating systems here, everything’s machine code on paper tape — as a teacher plays a reaction timer game and the computer wins at noughts and crosses (tic-tac-toe). One of them has even written a high-level language interpreter on which younger children solve maths problems. Of course, a 1950s mainframe with hundreds or thousands of tubes was never a particularly reliable machine, and we see them enacting their failure routine, before finally replacing a faulty delay line.

This is a fascinating watch on so many levels, not least because of its squeaky-clean portrayal of adolescent boys. This is what teenagers were supposed to be like, but by the late 1960s they must in reality have been anything but that away from the cameras. It’s a contrast with fifteen or twenty years later, the computer is seen as an extremely important learning opportunity in sharp opposition to how 8-bit computers in the 1980s came to be seen as a corrupting influence that would rot young minds.

Of course, these youngsters are not entirely representative of British youth in 1969, because as a grammar school the Forrest was part of the top tier of the selective education system prevalent at the time. There would certainly have been no computers of any sort in the local Secondary Modern school, and probably the BBC’s portrayal of the pupils would have been completely different had there been. In 1974 the Government abolished the grammar school system to create new one-size-fits-all comprehensive schools, one of which the Forrest school duly became. Following the vagaries of educational policy it is now an Academy, and there is probably not a room within it that does not contain a computer.

So what of Nellie? Because of the film there are plenty of online references to it in 1969, but we could only find one relating to its fate. It was finally broken up in 1971, with the only surviving component being a delay line. More than one Elliott machine survives in museum collections though, and your best chance in the UK of seeing one is probably at the National Museum Of Computing, in Bletchley.

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Retrotechtacular: How Not To Design With Transistors

Consider the plight of a mid-career or even freshly minted electrical engineer in 1960. He or she was perched precariously between two worlds – the proven, practical, and well-supported world of vacuum tube electronics, and the exciting, new but as yet unproven world of the transistor. The solid-state devices had only started making inroads into electronic products relatively recently, and mass production techniques were starting to drive the cost per unit down enough to start including them in your designs. But, your company has a long history with hot glass and no experience with flecks of silicon. What to do?

To answer that question, you might have turned to this helpful guide, “Tubes and Transistors: A Comparative Guide” (PDF link). The fancy booklet, with a great graphic design that our own [Joe Kim] would absolutely love, was the product of the Electron Tube Information Council, an apparently defunct group representing the interests of the vacuum tube manufacturers. Just reading the introduction of this propaganda piece reveals just how worried companies like RCA, General Electric, and Westinghouse must have been as the 1950s turned into the 1960s. The booklet was clearly aimed directly at engineers and sought to persuade them of the vacuum tube’s continued relevance and long-term viability. They helpfully explain that tubes are a reliable, proven technology that had powered decades of designs, and that innovations such as heaterless cathodes and miniaturization were just around the corner. Transistors, we’re told, suffer from “spread of characteristics” that correctly describes the state of materials engineering of silicon and germanium at the time, a thornier problem than dealing with glass and wires but that they had to know would be solved within a few years.

With cherry-picked facts and figures, the booklet makes what was probably in 1960 a persuasive case for sticking with tubes. But the Electron Tube Information Council was fighting a losing battle, and within a decade of swamping engineers with this book, the industry had largely shifted to the transistor. Careers were disrupted, jobs disappeared, and fortunes were lost, but the industry pressed forward as it always does. Still, it’s understandable why they tried so hard to stem the tide with a book like this. The whole PDF is worth a look, and we’d love to have a hard copy just for nostalgia’s sake.

Thanks to [David Gustafik] for the tip.

Retrotechtacular: HGTV, The Place For Everything CES 1996

It’s January, and that means it’s time once again for the Consumer Electronics Show. CES is the place where electronic manufacturers from all across the globe to show off their future products and make promises they probably can’t keep. Of course there is no better indicator of a company’s future than looking at the past, and thanks to [Home & Garden Television] we have a comprehensive look at what CES was twenty three years ago. The cable channel aired a special, “Plugged In with Wil Shriner”, covering CES 1996 and it is certainly illuminating to see in hindsight. Plus it even comes complete with “cable money” tier mid 90s motion graphics.

Over on YouTube, user [videoholic] has uploaded the HGTV CES ’96 special into five separate segments (links provided below). Some of the highlights include:

Part 1 – Home Video

  • Canon introduces IR eye tracking (akin to the New 3DS) in their camcorder line
  • Dual recording VCR from Sharp on one VHS tape provided you can fix the tracking with the remote.
  • The term “I triple E 1394” may just have been said for the first (and last) time ever on cable television.

Part 2 – Audio

  • A digital alarm clock from Oregon Scientific (called the Time Machine) that will tell you the weather.
  • Magellan thought, “Who needs a cell phone when you can have a satellite phone for $8000”.
  • Soundtube, the fashionable beer cozy for your gigantic speakers as seen on MTV Beach House.

Part 3 – Games & Multimedia

  • Noise Cancellation Technologies INC wanted to turn your cars headliner into a big ol’ speaker.
  • Cyber Pong promised online multiplayer a full decade before Rockstar’s Table Tennis on Xbox 360.
  • The Simpsons Cartoon Studio helps create fan fiction on multimedia CD-ROM.

Part 4 – Home & Office

  • Compaq’s PC keyboard with an integrated fax machine.
  • Norris Communication’s handheld voice recorder full of flash memory to offload to your PDA.
  • Crestron’s idea of home automation involved a touchscreen to operate a light switch (some things never change).

Part 5 – Digital Video