Teardown

547 Articles

Teardown Shows Why Innovative Designs Sometimes Fail

January 7, 2019 by 28 Comments

Some ideas are real head-scratchers from a design standpoint: Why in the world would you do it that way? For many of us, answering that question often requires a teardown, which is what [Ben Katz] did when this PCB motor-powered weed whacker came across his bench. The results are instructive on what it takes to succeed in the marketplace, or in this case, how to fail.

The unit in question comes from an outfit called CORE Outdoor Power. The line trimmer was powered by a big lithium-ion battery pack, but [Ben] concentrated on the unique motor for his teardown. After a problematic entry into the very sturdy case at the far end of the trimmer’s shaft, he found what looks like a souped-up version of [Carl Bugeja]’s PCB brushless motors. The rotors, each with eight large magnets embedded, are sandwiched on either side of a very thick four-layer PCB with intricately etched heavy copper traces. The PCB forms the stator, with four flat coils. The designer pulled a neat trick with the Hall-effect sensors needed for feedback; rather than go with surface-mount sensors, which would add to the thickness of the board, they used through-hole packages soldered to surface pads, with the body of the sensor nestled in a hole in the board. The whole design is very innovative, but sadly, [Ben]’s analysis shows that it has poor performance for its size and weight.

Google around a bit and you’ll see that CORE was purchased some years back by MTD, a big player in the internal combustion engine outdoor power market. They don’t appear to be a going concern anymore, and it looks as though [Ben] has discovered why.

[Jozef] tipped us off to this one. Thanks!

1973: When Calculators Were Built Like Computers

January 2, 2019 by 55 Comments

Should you ever pick up [Steve Wozniak]’s autobiography, you will learn that in the early 1970s when his friend [Steve Jobs] was working for Atari, [Woz] was designing calculators for Hewlett Packard. It seems scarcely believable today, but he describes his excitement at the prospects for the calculator business, admitting that he almost missed out on the emerging microcomputer scene that would make him famous. Calculators in the very early 1970s were genuinely exciting, and were expensive and desirable consumer items.

[Amen] has a calculator from that period, a Prinztronic Micro, and he’s subjected it to an interesting teardown. Inside he finds an unusual modular design, with keyboard, processor, and display all having their own PCBs. Construction is typical of the period, with all through hole components, and PCBs that look hand laid rather than made using a CAD package. The chipset is a Toshiba one, with three devices covering logic, display driver and clock.

The Prinztronic is an interesting device in itself, being a rebadged 1972 Sharp model under a house brand name for the British retailer Dixons, and that Toshiba chipset is special because it is the first CMOS design to market. It was one of many very similar basic calculators on the market at the time, but at the equivalent of over 100 dollars in today’s money it would still have been a significant purchase.

Long-tern Hackaday readers will remember we’ve shown you at least one classic calculator rebuild in the past, the venerable 1975 Sinclair!

1985 Electric Vehicle Restoration

December 27, 2018 by 28 Comments

We tend to think of electric vehicles as a recent innovation, however many successful products are not the first ones to appear on the market. We have a habit of forgetting the progenitors such as mechanical scanned TVs or the $10,000 Honeywell kitchen computer. A case in point is [Clive Sinclair]’s C5 electric vehicle from 1985. If you’ve heard of it at all, you probably recall it was considered a stellar disaster when it was released. But it is a part of electric vehicle history and you can see [RetroManCave] talk to [Dave] about how he restored and operates a C5 of his own in the video below. If you want to dig into the actual restoration, [Dave] has three videos about the teardown and rebuild on his channel.

Sinclair saw this as the first shot across the bow with a series of electric vehicles, but it was doomed from the start. It isn’t a car. In fact, it is more like a bicycle with a battery. It seats one occupant who is exposed to the elements. It had a very tiny trunk. It can go — optimistically — 15 miles per hour and runs out of juice after about 20 miles — if you helped out by pedaling. If you weren’t up for the exercise, you’d get less out of the lead-acid battery.

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Top Secret Teardown Reveals Soviet Missile Secrets

December 27, 2018 by 46 Comments

Technology has moved at such a furious pace that what would have been most secret military technology a few decades ago is now surplus on eBay. Case in point: [msylvain59] picked up a Soviet-era K-13 IR seeker used to guide air-to-air missiles to their targets. Inside is a mechanical gyroscope turning at over 4,000 RPM, a filter made of germanium to block visible light, and a photoresistor. It’s sobering to think you can get all of this in a few small packages these days, if not integrated into one IC.

Fitting on top of a missile, the device isn’t that large anyway, but it is nothing like what a modern device would look like. A complex set of electronics processes the signal and moves steering actuators that control fins and other controls to guide the missile’s flight. You can see a video of the device giving up its secrets, below.

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Old Wattmeter Uses Magnetics To Do The Math

December 18, 2018 by 19 Comments

Measuring power transfer through a circuit seems a simple task. Measure the current and voltage, do a little math courtesy of [Joule] and [Ohm], and you’ve got your answer. But what if you want to design an instrument that does the math automatically? And what if you had to do this strictly electromechanically?

That’s the question [Shahriar] tackles in his teardown of an old lab-grade wattmeter. The video is somewhat of a departure for him, honestly; we’re used to seeing instruments come across his bench that would punch a seven-figure hole in one’s wallet if acquired new. These wattmeters are from Weston Instruments and are beautiful examples of sturdy, mid-century industrial design, and seem to have been in service until at least 2013. The heavy bakelite cases and sturdy binding posts for current and voltage inputs make it seem like the meters could laugh off a tumble to the floor.

But as [Shahriar] discovers upon teardown of a sacrificial meter, the electromechanical movement behind the instrument is quite delicate. The wattmeter uses a moving coil meter much like any other panel meter, but replaces the permanent magnet stator with a pair of coils. The voltage binding posts are connected to the fine wire of the moving coil through a series resistance, while the current is passed through the heavier windings of the stator coils. The two magnetic fields act together, multiplying the voltage by the current, and deflect a needle against a spring preload to indicate the power. It’s quite clever, and the inner workings are a joy to behold.

We just love looking inside old electronics, and moving coil meters especially. They’re great gadgets, and fun to repurpose, too.

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1,000 Watt Power Supply Tear Down And Repair

November 30, 2018 by 7 Comments

[TheSignalPath] wanted to repair a broken Instek PSW80-40.5 because it has a lot of output for a programmable power supply — 1,080 watts, to be exact. This isn’t a cheap supply — it looks like it costs about $2,200 new. The unit wasn’t working and when he took it apart, he found a nasty surprise. There is a base PCB and three identical power supply modules, and virtually no access without disconnecting the boards. He continued the teardown, and you can see the results in the video below.

Each of the power supply modules are two separate PCBs and the design has to account for the high currents required. The power supply is a switching design with some filtering on the motherboard. One of the boards of the power supply module rectifies the incoming line voltage to a high DC voltage (about 400 volts). The second board then does DC to DC conversion to the desired output.

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The Electronics Of Cold War Nightmares

November 27, 2018 by 8 Comments

It is a good bet that if you look around you, you’ll be able to find at least one smoke detector in sight. If not, there’s probably one not too far away. Why not? Fires happen and you’d like to know about a fire even if you are sleeping or alert others if you are away. During the cold war, there were other things that people didn’t want to sleep through. [Msylvain59] tears down two examples: a Soviet GSP-11 nerve agent detector and a Polish RS-70 radiation alarm. You can see both videos, below.

In all fairness, the GSP-11 is clearly not meant for consumer use. It actually uses a test strip that changes colors and monitors the color change. Presumably, the people operating it were wearing breathing gear because the machine could take quite a while to provide a positive output. Inside reminded us of a film processing machine, which isn’t too far off.

The radiation monitor looks more like a miniature version of an old floor-standing radio. The case design, the thick-traced, single-sided, hand-drawn printed wiring board, and the –by today’s standards — huge parts within all contribute to making this look like a piece of radio gear from the 1970s or even earlier.

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