hardware

1674 Articles

Journey Through The Inner Workings Of A PCB

December 10, 2019 by 20 Comments

Most electronics we deal with day to day are comprised of circuit boards. No surprise there, right? But how do they work? This might seem like a simple question but we’ve all been in the place where those weird green or black sheets are little slices of magic. [Teddy Tablante] at Branch Eduction put together a lovingly crafted walkthrough flythrough video of how PCB(A)s work that’s definitely worth your time.

[Teddy]’s video focuses on unraveling the mysteries of the PCBA by peeling back the layers of a smartphone. Starting from the full assembly he separates components from circuit board and descends from there, highlighting the manufacturing methods and purpose behind what you see.

What really stands out here is the animation; at each step [Teddy] has modeled the relevant components and rendered them on the PCBA in 3D. Instead of relying solely on hard to understand blurry X-ray images and 2D scans of PCBAs he illustrates their relationships in space, an especially important element in understanding what’s going on underneath the solder mask. Even if you think you know it all we bet there’s a pearl of knowledge to discover; this writer learned that VIA is an acronym!

If you don’t like clicking links you can find the video embedded after the break. Credit to friend of the Hackaday [Mike Harrison] for acting as the best recommendation algorithm and finding this gem.

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Antique Pocket Watch Project Updates Antique Pocket Watch

December 8, 2019 by 54 Comments

Here at Hackaday we have a bit of a preoccupation with timepieces. Maybe it’s the deeply personal connection to an object you wear on your body, or the need for ultimate reliability. Perhaps it’s just a fascination with the notion of time itself. Whatever the case, we don’t seem to be alone as there is a constant stream of time-related projects coming through our virtual doors. For this article we’ve unearthed the LED Pocketwatch 1.0 by [Dr. Pauline Pounds] from way back in 2009 (ironically via a post about a wristwatch from last year!). Fortunately for us the Internet Archive has saved this heirloom nouveau from the internet dustbin so we can appreciate the craftsmanship involved in [Dr. Pounds]’ work.

Check out the wonderful, spiral routing!

My how far we’ve come; a decade after this project was posted a hacker might choose to 3d print a case for a new wearable, but in 2009 that would have been an entire project by itself! [Dr. Pounds] chose to use the casing from an antique Elgin pocket watch. Even through the mists of a grainy demo video we can imagine how soft the well-worn casing must be from heavy use. This particular unit was chosen because it was a hefty 50mm in diameter, leaving plenty of room inside for a 44mm double sided PCBA with 133 0603 LEDs (60 seconds, 60 minutes, 12 hours), a PIC 16F946, an ERM, and a 110mAh LiPo. But what really sets the LED Pocketwatch 1.0 apart is the user interface.

The ERM is attached directly to the rear of the case in order to best conduct vibration to the outside world. For maximum authenticity it blips on the second, to give a sense that the digital watch is mechanically ticking like the original. The original pocket watch was designed with a closing lid which is released when the stem is pressed. [Dr. Pounds] integrated a button and encoder with the end of the stem (on the PCBA) so the device can be aware of this interaction; on lid open it wakes the device to display the time on the LEDs. The real pièce de résistance is that he also integrated a minuscule rotary encoder, so when the stem is pressed you can rotate it to set the time. It’s all quite elegantly integrated and imminently usable.

At this point we’d love to link to sources, detailed drawings, or CAD files, but unfortunately we haven’t found any. If this has you inspired check out some of the other pocket watches we’ve posted about in the past. If you’re interested in a live demo of the LED Pocketwatch 1.0, check out the original video after the break.

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David Williams Is “FPGA-Curious”

December 6, 2019 by 17 Comments

If you hadn’t noticed, we had a bit of an FPGA theme running at this year’s Superconference. Why? Because the open-source FPGA toolchain is ripening, and because many of the problems that hackers (and academics) are tackling these days have become complex enough to warrant using them. A case in point: David Williams is a university professor who just wanted to build a quadruped robotics project. Each leg has a complex set of motors, motor drivers, sensors, and other feedback mechanisms. Centralizing all of this data put real strains on the robot’s network, and with so many devices the microcontrollers were running out of GPIOs. This lead him to become, in his words, “FPGA-curious”.

If you’re looking for a gentle introduction to the state of the art in open-source FPGAs, this is your talk. David covers everything, from a bird’s eye view of hardware description languages, through the entire Yosys-based open-source toolchain, and even through to embedding soft-CPUs into the FPGA fabric. And that’s just the first 18 minutes. (Slides for your enjoyment, and you can watch the talk embedded below the break.)
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Creating Easy Glass Circuit Boards At Home

December 1, 2019 by 41 Comments

This tip for creating glass substrate circuit boards at home might hew a bit closer to arts and crafts than the traditional Hackaday post, but the final results of the method demonstrated by [Heliox] in her recent video are simply too gorgeous to ignore. The video is in French, but between YouTube’s attempted automatic translation and the formidable mental powers of our beloved readers, we don’t think it will be too hard for you to follow along after the break.

The short version is that [Heliox] loads her Silhouette Cameo, a computer-controlled cutting machine generally used for paper and vinyl, with a thin sheet of copper adhered to a backing sheet to give it some mechanical strength. With the cutting pressure of the Cameo dialed back, the circuit is cut out of the copper but not the sheet underneath, and the excess can be carefully peeled away.

Using transfer paper, [Heliox] then lifts the copper traces off the sheet and sticks them down to a cut piece of glass. Once it’s been smoothed out and pushed down, she pulls the transfer paper off and the copper is left behind.

From there, it’s just a matter of soldering on the SMD components. To make it a little safer to handle she wet sands the edges of the glass to round them off, but it’s still glass, so we wouldn’t recommend this construction for anything heavy duty. While it might not be the ideal choice for your next build, it certainly does looks fantastic when mounted in a stand and blinking away like [Heliox] shows off at the end.

Ironically, when compared to some of the other methods of making professional looking PCBs at home that we’ve seen over the years, this one might actually be one of the easiest. Who knew?

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An Efficient Homemade Wood Furnace

November 30, 2019 by 17 Comments

For poor [workshop from scratch], winter brings the joy of a cold workshop. Since the building is structurally made from tin, warming up the room is difficult.

Naturally, the solution was to construct a homemade wood furnace. The build starts off with an angle grinder being taken to a compressed air tank. After sawing off the top and sanding down the edges, the builder slices out an opening and welds together some rods into a stand for the center. He then proceeds to weld some external frames for the furnace, as well as a chimney stack, some nifty covers joined by hinges, and a fan/temperature regulator to keep the fire going.

Most of the pieces seem to come from scrap metal lying around the workshop, although the degree to which the entire project comes together is quite smooth. Some filter and spray paint do the trick for cleaning up the furnace and making it look less scrappy. The last step? A stack of wooden logs and a blow torch to start the fun. Outside of the furnace, an LCD screen keeps track of the temperature, giving some feedback and control.

The result is perhaps a too effective at warming up the workshop, but the problem sure is solved!

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Secret C64 Program Found On A Christian Rock Band’s Vinyl Record

November 24, 2019 by 29 Comments

How often do you find Easter eggs in old vinyl records?

It sure was a surprise for [Robin Harbron] when he learned about a Commodore 64 program hidden on one of the sides of a record from the 1985 album of Christian rock band Prodigal. The host of the YouTube channel 8-Bit Show and Tell shows the “C-64” etching on one side of the vinyl, which he picked up after finding out online that the record contained the hidden program.

The run-out groove on records is typically an endless groove that keeps the record player from running off the record (unless there is an auto-return feature, which just replays the record). On side one of the vinyl, the run-out groove looks normal, but on side two, it’s a little thicker and contains some hidden audio. Recording the audio onto a cassette and loading it onto a dataset reveals a short C64 program.

The process is a little more troublesome that that, but after a few tries [Harbron] reveals a secret message, courtesy of Albert Einstein and Jesus Christ. It’s not the most impressive program ever written, but it’s pretty cool that programmers 35 years ago were able to fit it into only a few seconds of audio.

Unfortunately, we won’t be hearing much actual music from the album – [Harbron] chose not to play the songs to avoid copyright issues on YouTube.

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Old Cisco WAN Card Turned FPGA Playground

November 20, 2019 by 33 Comments

Many of us think of FPGAs as some new cutting edge technology, but the fact of the matter is that they’ve been around for quite some time. They’ve just traditionally been used in hardware that’s too expensive for us lowly hackers. A case in point is the Cisco HWIC-3G-CDMA WAN card. A decade ago these would have been part of a router valued in the tens of thousands of dollars, but today they can be had for less than $10 USD on eBay. At that price, [Tom Verbeure] thought it would be worth finding out if they could be repurposed as generic FPGA experimentation devices.

So as not to keep you in suspense, the short answer is a resounding yes. In the end, all [Tom] had to do was figure out what voltages the HWIC-3G-CDMA was expecting on the edge connector, and solder a 2×5 connector onto the helpfully labeled JTAG header. Once powered up and connected to the computer, Intel’s Quartus Programmer software immediately picked up the board’s Cyclone II EP2C35F484C8 chip. The blinking LEDs seen in the video after the break serve as proof that these bargain bin gadgets are ripe for hacking.

Unfortunately, there’s a catch. After studying the rest of the components on the board, [Tom] eventually came to the conclusion that the HWIC-3G-CDMA has no means of actually storing the FPGA’s bitstream. Presumably it was provided by the router itself during startup. If you just want to keep the board tethered to your computer for experimenting, that’s not really a big deal. But if you want to use it in some kind of project, you’ll need to include a microcontroller capable of pushing the roughly 1 MB bitstream into the FPGA to kick things off.

It might not be as easy to get up and running as the 2019 Hackaday Superconference badge, but it’s certainly a lot easier to get your hands on.

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