Take A Deep Dive Into A Commodity Automotive Radar Chip

January 17, 2023 by Dan Maloney 24 Comments

When the automobile industry really began to take off in the 1930s, radar was barely in its infancy, and there was no reason to think something that complicated would ever make its way into the typical car. Yet here we stand less than 100 years later, and radar has been perfected and streamlined so much that an entire radar set can be built on a single chip, and commodity radar modules can be sprinkled all around the average vehicle.

Looking inside these modules is always fascinating, especially when your tour guide is [Shahriar Shahramian] of The Signal Path, as it is for this deep dive into an Infineon 24-GHz automotive radar module. The interesting bit here is the BGT24LTR11 Doppler radar ASIC that Infineon uses in the module, because, well, there’s really not much else on the board. The degree of integration is astonishing here, and [Shahriar]’s walk-through of the datasheet is excellent, as always.

Things get interesting once he gets the module under the microscope and into the X-ray machine, but really interesting once the RF ASIC is uncapped, at the 15:18 mark. The die shots of the silicon germanium chip are impressively clear, and the analysis of all the main circuit blocks — voltage-controlled oscillator, power amps, mixer, LNAs — is clear and understandable. For our money, though, the best part is the look at the VCO circuit, which appears to use a bank of fuses to tune the tank inductor and keep the radar within a tight 250-Mz bandwidth, for regulatory reasons. We’d love to know more about the process used in the factory to do that bit.

This isn’t [Shahriar]’s first foray into automotive radar, of course — he looked at a 77-GHz FMCW car radar a while back. That one was bizarrely complicated, though, so there’s something more approachable about a commodity product like this.

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It’s Not Easy Counting Transistors In The 8086 Processor

January 16, 2023 by Maya Posch 15 Comments

For any given processor it’s generally easy to find a statistic on the number of transistors used to construct it, with the famous Intel 8086 CPU generally said to contain 29,000 transistors. This is where [Ken Shirriff] ran into an issue when he sat down one day and started counting individual transistors in die shots of this processor. To his dismay, he came to a total of 19,618, meaning that 9,382 transistors are somehow unaccounted for. What is going on here?

The first point here is that the given number includes so-called ‘potential transistors’. Within a section of read-only memory (ROM), a ‘0’ would be a missing transistor, but depending on the programming of the mask ROM (e.g. for microcode as with a CISC x86 CPU), there can be a transistor there. When adding up the potential but vacant transistor locations in ROM and PLA (programmable logic array) sections, the final count came to 29,277 potential transistors. This is much closer to the no doubt nicely rounded number of 29,000 that is generally used.

[Ken] also notes that further complications here are features such as driver transistors that are commonly found near bond wire pads. In order to increase the current that can be provided or sunk by a pad, multiple transistors can be grouped together to form a singular driver as in the above image. Meanwhile yet other transistors are used as (input protection) diodes or even resistors. All of which makes the transistor count along with the process node used useful primarily as indication for the physical size and complexity of a processor.

Is It A Game? Or A Calculator?

January 6, 2023 by Al Williams 27 Comments

If you are a certain age, you probably remember the Mattel Football game. No LCD screen or fancy cartridges. Just some LEDs and a way to play football when you should be in class. While these might seem primitive to today’s kids, they were marvels of technology in the 1970s when they came out. [Sean Riddle] looks, well, not exactly at the games, but more like in them. As it turns out, they used chips derived from those made for calculators.

[Sean’s] post is a glimpse into this world of over four decades past. Football was actually the second electronic game from Mattel. The first one was Auto Race. There were also games called Space Alert, Baseball, and Gravity. Inside each are quad in-line packages with 42 pins, a Rockwell logo, and a custom part number.

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Showing the same thumbdrive plugged into the same USB-C port in two different orientations, enumerating as two different USB ports

Dirty USB-C Tricks: One Port For The Price Of Two

December 31, 2022 by Arya Voronova 48 Comments

[RichardG] has noticed a weird discrepancy – his Ryzen mainboard ought to have had fourteen USB3 ports, but somehow, only exposed thirteen of them. Unlike other mainboards in this lineup, it also happens to have a USB-C port among these thirteen ports. These two things wouldn’t be related in any way, would they? Turns out, they are, and [RichardG] shows us a dirty USB-C trick that manufacturers pull on us for an unknown reason.

On a USB-C port using USB3, the USB3 TX and RX signals have to be routed to two different pin groups, depending on the plugged-in cable orientation. In a proper design, you would have a multiplexer chip detecting cable orientation, and routing the pins to one or the other. Turns out, quite a few manufacturers are choosing to wire up two separate ports to the USB-C connector instead.

In the extensive writeup on this problem, [Richard] explains how the USB-C port ought to be wired, how it’s wired instead, shows telltale signs of such a trick, and how to check if a USB-C port on your PC is miswired in the same way. He also ponders on whether this is compliant with the USB-C specification, but can’t quite find an answer. There’s a surprising amount of products and adapters doing this exact thing, too, all of them desktop PC accessories – perhaps, you bought a device with such a USB-C port and don’t know it.

As a conclusion, he debates making an adapter to break the stolen USB3 port out. This wouldn’t be the first time we’re cheated when it comes to USB ports – the USB2 devices with blue connectors come to mind.

Reverse Engineering Saves Weller With A Wonky LCD From The Trash Pile

December 25, 2022 by Dan Maloney 15 Comments

There’s nothing more satisfying than finding a broken piece of gear in the trash and bringing it back to life. Satisfying, but also potentially more time-consuming — someone tossed it for a reason, after all. Figuring out what that reason is and finding a way to back it better is where the fun — and the peril — are.

Luckily, some pieces of equipment have a relatively short list of well-known failure modes, a fact that [Lauri Pirttiaho] relied on for this fix of an old Weller WD1 soldering station. The unit, sporting the familiar light blue Weller livery and more than a few scratches and dings, had an LCD that was DOA. Typically it’s the driver that’s the problem here, but [Lauri]’s diagnosis revealed it was the LCD module itself that was bad.

With OEM replacements being basically unobtainium at this point, the fix was to intercept the data heading from the driver to the old LCD and send it to a new, easily sourced 16×2 character LCD display. This began with an inspection of the display controller’s datasheet, and a bit of probing of the old display to find out which segments and backplanes map to which pins. A little bit of case modding allowed the new display to fit, the old controller chip was removed, and a PIC16 went into its place, in a tidy nest of Kapton tape and bodge wires. The PIC does the job of translating the original display, which had a fair number of custom icons and symbols, into sensible text-based equivalents and sending them to the 16×2 via I2C. The video below shows the hack in action; it honestly looks like it could have come from the factory like that.

The nice thing here is that [Lauri]’s fix applies to a whole range of Weller stations, so if you find one in the trash, you might be able to resuscitate it. Failing that, you could always roll your own Weller from (more-or-less) scratch.

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Old Robotic Vacuum Gets A New RC Lease On Life

December 22, 2022 by Dan Maloney 8 Comments

To our way of thinking, the whole purpose behind robotic vacuum cleaners is their autonomy. They’re not particularly good at vacuuming, but they are persistent about it, and eventually get the job done with as little human intervention as possible. So why in the world would you want to convert a robotic vacuum to radio control?

For [Lucas], the answer was simple: it was a $20 yard sale find, so why not? Plus, he’s got some secret evil plan to repurpose the suckbot for autonomous room mapping, which sounds like a cool project that would benefit from a thorough knowledge of this little fellow’s anatomy and physiology. The bot in question is a Hoover Quest. Like [Lucas] we didn’t know that Hoover made robotic vacuums (Narrator: they probably don’t) but despite generally negative online reviews by users, he found it to be a sturdily built and very modular and repairable unit.

After an initial valiant attempt at reverse engineering the bot’s main board — a project we encourage [Lucas] to return to eventually — he settled for just characterizing the bot’s motors and sensors and building his own controller. The Raspberry Pi Zero he chose may seem like overkill, but he already had it set up to talk to a PS4 game controller, so it made sense — right up until he released the Magic Smoke within it. A backup Pi took the sting out of that, and as the brief video below shows, he was finally able to get the bot under his command.

[Lucas] has more plans for his new little buddy, including integrating the original sensors and adding new ones. Given its intended mission, we’d say a lidar sensor would be a good addition, but that’s just a guess. Whatever he’s got in store for this, we’re keen to hear what happens.

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The Story Behind The TVGuardian Curse Catcher

December 14, 2022 by Chris Lott 23 Comments

The recent flurry of videos and posts about the TVGuardian foul language filter brought back some fond memories. I was the chief engineer on this project for most of its lifespan. You’ve watched the teardowns, you’ve seen the reverse engineering, now here’s the inside scoop.

Gumby is Born

TVG Model 101 Gumby (Technology Connections)

Back in 1999, my company took on a redesign project for the TVG product, a box that replaced curse words in closed-captioning with sanitized equivalents. Our first task was to take an existing design that had been produced in limited volumes and improve it to be more easily manufactured.

The original PCB used all thru-hole components and didn’t scale well to large quantity production. Replacing the parts with their surface mount equivalents resulted in Model 101, internally named Gumby for reasons long lost. If you have a sharp eye, you will have noticed something odd about two parts on the board as shown in [Ben Eater]’s video. The Microchip PIC and the Zilog OSD chip had two overlapping footprints, one for thru-hole and one for SMD. Even though we preferred SMD parts, sometimes there were supply issues. This was a technique we used on several designs in our company to hedge our bets. It also allowed us to use a socketed ICs for testing and development. Continue reading “The Story Behind The TVGuardian Curse Catcher” →