Tearing Apart Pulse Transformer Switches

June 3, 2019 by Brian Benchoff 29 Comments

If you like mechanical keyboards, you like switches. Historically, switches were weird, with strange capacitive rubber dome switches in Topre boards, buckling springs in the IBM Model M, and beamsprings in earlier IBM keyboards. This teardown of an HP signal generator has the weirdest keyboard switches ever. They’re being called pulse transformer switches, but they are the strangest, weirdest, and most complicated keyboard switch we’ve ever seen

Mechanically, these keys are mounted on a 1×5 plastic frame with a plunger that presses down on a (brass?) photoetched plate. Mechanically, this is effectively a metal dome keyboard that simply presses a springy bit of metal against a contact on a printed circuit board. That’s the mechanical explanation, the electrical theory of operation is much, much weirder.

Electrically, this keyboard consists of a printed circuit board with two coils underneath each key. The circuit is wired up so two keys are ‘read’ at the same time with a pulse from a multiplexer. This pulse induces a current in the ‘sense’ coil of two individual keys which is sent to a comparator. If both keys are not pressed, the comparator sees a positive and a negative voltage which cancels out, meaning no keys are pressed. If one key is pressed, the metal dome shorts out the transformer underneath the keyboard, meaning only one voltage is seen by the comparator, and that key is registered as being pressed.

This is some crazy keyboard circuitry, and I do not say that lightly. There are ‘acoustic’ keyboards out there which consist of a row of keys striking a metal bar with an acoustic transducer on each end. By measuring the time it takes for the sound of a keypress to reach either end of the metal bar, a keypress can be registered. This is weird and expensive to build, and it’s still simpler than a pulse transformer switch. Check out the video below.

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How Hard Can It Be To Buy A Computer In Germany And Get It Back Home To The UK?

May 21, 2019 by Jenny List 40 Comments

Some of the best adventures in the world of hardware hacking start in the pub. For three volunteers at the National Museum Of Computing in the UK, [Adam Bradley], [Chris Blackburn], and [Peter Vaughan], theirs started over a pint with an eBay listing for an old computer in Germany. No problem you might think, we’re well used to international parcel shipping. This computer wasn’t a crusty old Commodore 64 though, instead it was a room-sized IBM System/360 Model 20 from the 1960s, complete with the full array of peripherals and what seemed to be a lot of documentation and software media. It would need a Mercedes Sprinter, a large van, to shift it, but that seemed feasible. With a bit of frantic bidding they secured the auction, and set off for Germany to view their purchase.

Arriving at the machine’s location they found a little bit more than they had expected. In an abandoned building on a side street in Nuremburg there was an intact machine room full of the IBM computer cabinets over a false floor with all the machine cabling in place, and the only usable access was through a street door which hadn’t been opened in decades and which was obstructed by the false floor itself. To cap it all they found they’d bought not one but two System/360s, and also unexpectedly a 1970s System/370 Model 125. Clearly this was more than a job for a quick in-and-out with a Sprinter.

What followed became a lengthy saga of repeated trips, van hire, constructing ramps, and moving heavy computer parts to a hastily rented storage unit. Decabling a computer of this size is no easy task at the best of times, and these cables had spent many decades in a neglected machine room. It’s a fascinating read, and a very well-documented one with plenty of photos. The machines now sit in their storage units awaiting a return to the UK, and the trio are soliciting any help they can find to make that happen. So if you happen to own a European haulage company with spare capacity on your Germany — UK route or if you can help them in any way, donate or get in touch with them. We think this project has much more to offer, so we’ll be following their progress with interest.

These three intrepid computer hunters were brought together at The National Museum Of Computing at Bletchley, UK. If you find yourself within range it is an essential place to visit, we did so in 2016.

Fun With Negative Resistance II: Unobtanium Russian Tunnel Diodes

May 16, 2019 by Ted Yapo 24 Comments

In the first part of this series, we took a look at a “toy” negative-differential-resistance circuit made from two ordinary transistors. Although this circuit allows experimentation with negative-resistance devices without the need to source rare parts, its performance is severely limited. This is not the case for actual tunnel diodes, which exploit quantum tunneling effects to create a negative differential resistance characteristic. While these two-terminal devices once ruled the fastest electronic designs, their use has fallen off dramatically with the rise of other technologies. As a result, the average electronics hacker probably has never encountered one. That ends today.

Due to the efficiencies of the modern on-line marketplace, these rare beasts of the diode world are not completely unobtainable. Although new-production diodes are difficult for individuals to get their hands on, a wide range of surplus tunnel diodes can still be found on eBay for as little as $1 each in lots of ten. While you’d be better off with any number of modern technologies for new designs, exploring the properties of these odd devices can be an interesting learning experience.

For this installment, I dug deep into my collection of semiconductor exotica for some Russian 3И306M gallium arsenide tunnel diodes that I purchased a few years ago. Let’s have a look at what you can do with just a diode — if it’s the right kind, that is.

[Note: the images are all small in the article; click them to get a full-sized version]

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A Full-Stack Web Browser

May 14, 2019 by Brian Benchoff 13 Comments

Interviewing to be a full-stack engineer is hard. It’s a lot harder than applying for a junior dev job where you’re asked to traverse a red-black tree on a whiteboard. For the full-stack job, they just give you a pile of 2N2222 transistors. (The first company wasn’t a great fit, and I eventually found a place that gave me some 2N2907s for the interview.) That said, there’s a certain challenge in seeing how far you can push some doped silicon. Case in point, [Alastair Hewitt]. He’s building a computer to browse the world wide web from the gate level up.

The goal of this project is to browse the web using only TTL logic. This presents problems that aren’t readily apparent at first glance. First up is being able to display text on a screen. The easiest way to do this now is to get a whole bunch of modern memories that are astonishingly fast for a 1970s vintage computer. This allows for VGA output, and yes, we’ve seen plenty of builds that output VGA using some big honkin’ memories. It turns out these RAM and ROM chips are a little better than the specs say they are, and this computer is overclocked from the very beginning.

A bigger problem is how to interface with a network. This is a problem for very old computers, but PPP still exists and if you have the software stack you can read something from a server over a serial connection. [Alistar] actually found the UART frequency was more important than the dot clock frequency of VGA, and the system clock must therefore be built around the serial port, not the display interface. This means the text mode interface is actually 96 columns instead of the usual 80 columns.

It’s very easy to say that you’re building a computer on a bread board. It’s another thing entirely to actually do it. This is actually a surprisingly well-though out sketch of a computer system that will, theoretically, be able to connect to the Internet. Of course, the reality of the situation is that this computer will be connecting over serial to a computer that’s connected to the Internet, but there’s no shame in that. You can check out the progress on the GitHub for this project.

Analog Failures On RF Product Cause Production Surprise

May 13, 2019 by Kerry Scharfglass 15 Comments

A factory is a machine. It takes a fixed set of inputs – circuit boards, plastic enclosures, optimism – and produces a fixed set of outputs in the form of assembled products. Sometimes it is comprised of real machines (see any recent video of a Tesla assembly line) but more often it’s a mixture of mechanical machines and meaty humans working together. Regardless of the exact balance the factory machine is conceived of by a production engineer and goes through the same design, iteration, polish cycle that the rest of the product does (in this sense product development is somewhat fractal). Last year [Michael Ossmann] had a surprise production problem which is both a chilling tale of a nasty hardware bug and a great reminder of how fragile manufacturing can be. It’s a natural fit for this year’s theme of going to production.

Surprise VCC glitching causing CPU reset

The saga begins with [Michael] receiving an urgent message from the factory that an existing product which had been in production for years was failing at such a high rate that they had stopped the production line. There are few worse notes to get from a factory! The issue was apparently “failure to program” and Great Scott Gadgets immediately requested samples from their manufacturer to debug. What follows is a carefully described and very educational debug session from hell, involving reverse engineering ROMs, probing errant voltage rails, and large sample sizes. [Michael] doesn’t give us a sense for how long it took to isolate but given how minute the root cause was we’d bet that it was a long, long time.

The post stands alone as an exemplar for debugging nasty hardware glitches, but we’d like to call attention to the second root cause buried near the end of the post. What stopped the manufacturer wasn’t the hardware problem so much as a process issue which had been exposed. It turned out the bug had always been reproducible in about 3% of units but the factory had never mentioned it. Why? We’d suspect that [Michael]’s guess is correct. The operators who happened to perform the failing step had discovered a workaround years ago and transparently smoothed the failure over. Then there was a staff change and the new operator started flagging the failure instead of fixing it. Arguably this is what should have been happening the entire time, but in this one tiny corner of the process the manufacturing process had been slightly deviated from. For a little more color check out episode #440.2 of the Amp Hour to hear [Chris Gammell] talk about it with [Michael]. It’s a good reminder that a product is only as reliable as the process that builds it, and that process isn’t always as reliable as it seems.

Open Hardware E-Ink Display Just Needs An Idea

May 12, 2019 by Tom Nardi 25 Comments

Its taken awhile, but thanks to devices like the Amazon Kindle, the cost of e-ink displays are finally at the point where mere mortals such as us can actually start using them in our projects. Now we’ve just got to figure out how to utilize them properly. Sure you can just hook up an e-ink display to a Raspberry Pi to get started, but to truly realize the potential of the technology, you need hardware designed with it in mind.

To that end, [Mahesh Venkitachalam] has created Papyr, an open hardware wireless display built with the energy efficiency of e-ink in mind. This means not only offering support for low-energy communication protocols like BLE and Zigbee, but keeping the firmware as concise as possible. According to the documentation, the end result is that Papyr only draws 22 uA in its idle state.

So what do you do with this energy-sipping Bluetooth e-ink gadget? Well, that part is up to you. The obvious application is signage, but unless you’re operating a particularly well organized hackerspace, you probably don’t need wireless dynamic labels on your part bins (though please let us know if you actually do). More likely, you’d use Papyr as a general purpose display, showing sensor data or the status of your 3D printer.

The 1.54 inch 200×200 resolution e-ink panel is capable of showing red in addition to the standard grayscale, and the whole thing is powered by a Nordic nRF52840 SoC. Everything’s provided for you to build your own, but if you’d rather jump right in and get experimenting, you can buy the assembled version for $39 USD on Tindie.

Battle Tested Current Limiter For Cheap DC Motor Controllers

May 11, 2019 by Jenny List 1 Comment

Running a brushed motor in muddy or dusty environments takes a toll on controllers, with both heavy back EMF and high stall currents. This explains one of the challenge in Europe’s Hacky Racer series, which is decidedly more off-road than America’s Power Racing Series.

In pushing these little electric vehicles to the limits, many builders use brushless Chinese scooter motors since they’re both available and inexpensive. Others take the brushed DC route if they’re lucky enough to score a motor — and then the challenge becomes getting the most performance without burning up your controller. To fix this, [MechanicalCat] has come up with a current limiter for cheap DC motor controllers.

The full write-up is in the included PDF file, and describes the set-up of an Arduino Nano sitting between throttle and controller, and taking feedback from a current sensor. The controller in question is a 4QD Porter 10 so an extra component is a DC-to-DC converter to provide a floating ground for the Arduino. However, there is also the intriguing possibility of the same set-up being used with absurdly cheap Chinese motor controllers. There is also advice on fitting flyback diodes, something which might have saved one controller in the Hackaday pits last year.

It’s yet to be seen what effect this will have on Hacky Racer competitiveness, however its applications go far beyond that field into anywhere a reliable small DC motor drive on the cheap is required. Meanwhile, if you’re unsure where this Hacky Racer stuff came from, you could start here.