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5162 Articles

Fail Of The Week: A Candle Caused Browns Ferry Nuclear Incident

December 6, 2018 by 122 Comments

A colleague of mine used to say he juggled a lot of balls; steel balls, plastic balls, glass balls, and paper balls. The trick was not to drop the glass balls. How do you know which is which? For example, suppose you were tasked with making sure a nuclear power plant was safe. What would be important? A fail-safe way to drop the control rods into the pile, maybe? A thick containment wall? Two loops of cooling so that only the inner loop gets radioactive? I’m not a nuclear engineer, so I don’t know, but ensuring electricians at a nuclear plant aren’t using open flames wouldn’t be high on my list of concerns. You might think that’s really obvious, but it turns out if you look at history that was a glass ball that got dropped.

In the 1960s and 70s, there was a lot of optimism in the United States about nuclear power. Browns Ferry — a Tennessee Valley Authority (TVA) nuclear plant — broke ground in 1966 on two plants. Unit 1 began operations in 1974, and Unit 2 the following year. By 1975, the two units were producing about 2,200 megawatts of electricity.

That same year, an electrical inspector and an electrician were checking for air leaks in the spreading room — a space where control cables split to go to the two different units from a single control room.  To find the air drafts they used a lit candle and would observe the flame as it was sucked in with the draft. In the process, they accidentally started a fire that nearly led to a massive nuclear disaster.

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Your BOM Is Not Your COGS

December 6, 2018 by 83 Comments

“The prototype was $12 in parts, so I’ll sell it for $15.” That is your recipe for disaster, and why so many Kickstarter projects fail. The Bill of Materials (BOM) is just a subset of the Cost of Goods Sold (COGS), and if you aren’t selling your product for more than your COGS, you will lose money and go out of business.

We’ve all been there; we throw together a project using parts we have laying around, and in our writeup we list the major components and their price. We ignore all the little bits of wire and screws and hot glue and time, and we aren’t shipping it, so there’s no packaging to consider. Someone asks how much it cost, and you throw out a ballpark number. They say “hey, that’s pretty reasonable” and now you’re imagining making it in volume and selling it for slightly higher than your BOM. Stop right there. Here’s how pricing really works, and how to avoid sinking time into an untenable business.

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Ken Shirriff Explains His Techniques For Reverse Engineering Silicon

December 5, 2018 by 8 Comments

When it comes to reverse engineering silicon, there’s no better person to ask than Ken Shirriff. He’s the expert at teasing the meaning out of layers of polysilicon and metal. He’s reverse engineered the ubiquitous 555 timer, he’s taken a look at the inside of old-school audio chips, and he’s found butterflies in his op-amp. Where there’s a crazy jumble of microscopic wires and layers of silicon, Ken’s there, ready to do the teardown.

For this year’s talk at the Hackaday Superconference, Ken walked everyone through the techniques for reverse engineering silicon. Surprisingly, this isn’t as hard as it sounds. Yes, you’ll still need to drop acid to get to the guts of an IC (of course, you could always find a 555 stuck in a metal can, but then you can’t say ‘dropping acid’), but even the most complex devices on the planet are still made of a few basic components. You’ve got n-doped silicon, p-doped silicon, and some metal. That’s it, and if you know what you’re looking for — like Ken does — you have all the tools you need to figure out how these integrated circuits are made.

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Daphne Oram And The Birth Of Electronic Music

December 4, 2018 by 10 Comments

For most of human history, musical instruments were strictly mechanical devices. The musician either plucked something, blew into or across something, or banged on something to produce the sounds the occasion called for. All musical instruments, the human voice included, worked by vibrating air more or less directly as a result of these mechanical manipulations.

But if one thing can be said of musicians at any point in history, it’s that they’ll use anything and everything to create just the right sound. The dawn of the electronic age presented opportunities galore for musicians by giving them new tools to create sounds that nobody had ever dreamed of before. No longer would musicians be constrained by the limitations of traditional instruments; sounds could now be synthesized, recorded, modified, filtered, and amplified to create something completely new.

Few composers took to the new opportunities offered by electronics like Daphne Oram. From earliest days, Daphne lived at the intersection of music and electronics, and her passion for pursuing “the sound” lead to one of the earliest and hackiest synthesizers, and a totally unique way of making music.

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Why Is Continuous Glucose Monitoring So Hard?

December 3, 2018 by 99 Comments

Everyone starts their day with a routine, and like most people these days, mine starts by checking my phone. But where most people look for the weather update, local traffic, or even check Twitter or Facebook, I use my phone to peer an inch inside my daughter’s abdomen. There, a tiny electrochemical sensor continuously samples the fluid between her cells, measuring the concentration of glucose so that we can control the amount of insulin she’s receiving through her insulin pump.

Type 1 diabetes is a nasty disease, usually sprung on the victim early in life and making every day a series of medical procedures – calculating the correct amount of insulin to use for each morsel of food consumed, dealing with the inevitable high and low blood glucose readings, and pinprick after pinprick to test the blood. Continuous glucose monitoring (CGM) has been a godsend to us and millions of diabetic families, as it gives us the freedom to let our kids be kids and go on sleepovers and have one more slice of pizza without turning it into a major project. Plus, good control of blood glucose means less chance of the dire consequences of diabetes later in life, like blindness, heart disease, and amputations. And I have to say I think it’s pretty neat that I have telemetry on my child; we like to call her our “cyborg kid.”

But for all the benefits of CGM, it’s not without its downsides. It’s wickedly expensive in terms of consumables and electronics, it requires an invasive procedure to place sensors, and even in this age of tiny electronics, it’s still comparatively bulky. It seems like we should be a lot further along with the technology than we are, but as it turns out, CGM is actually pretty hard to do, and there are some pretty solid reasons why the technology seems stuck.

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Linux Fu: Controlling The Terminal

November 28, 2018 by 17 Comments

A Linux terminal has a lot more features than the TeleType of yore. On a TeleType, text spews out and scrolls up and is gone forever. A real terminal can use escape characters to do navigate around and emulate most of what you like about GUIs. However, doing this at the lowest level is a chore and limits portability. Luckily, all the hard work has already been done.

First, there’s a large database of terminal capabilities available for you to use: terminfo.  And in addition, there’s a high-level library called curses or ncurses that simplifies writing programs to control the terminal display. Digging deep into every nook and cranny of ncurses could take years. Instead, I’m going to talk about using a program that comes with ncurses to control the terminal, called tput. Using these two commands, you can figure out what kind of terminal you’re dealing with, and then manipulate it nearly to your heart’s content. Let’s get started!

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Collecting, Repairing, And Wearing Vintage Digital Watches

November 28, 2018 by 91 Comments

Electronics enthusiasts have the opportunity to be on the very cusp of a trend with vintage digital watches (VDW). Vintage digital watches are those watches that from the late 70’s and throughout the 80’s. They’re unlike any watch style today, and for anyone around when they made their debut these deliver a healthy dose of nostalgia.

Monetarily speaking, it is not worth the money to pay a watch maker to restore a digital watch but for those of us with basic electronics skills we can put the time and effort into making them run again and be one of the few in possession of functioning VDW. It’s a statement as well as a sign of your own aptitude.

Earlier this year, Steven Dufresne walked us through the history of the digital watch. In this article we will dive into the world of vintage digital watch repair.

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