CT Scans Help Reverse Engineer Mystery Module

August 7, 2022 by Dan Maloney 15 Comments

The degree to which computed tomography has been a boon to medical science is hard to overstate. CT scans give doctors a look inside the body that gives far more information about the spatial relationship of structures than a plain X-ray can. And as it turns out, CT scans are pretty handy for reverse engineering mystery electronic modules, too.

The fact that the mystery module in question is from Apollo-era test hardware leaves little room for surprise that [Ken Shirriff] is the person behind this fascinating little project. You’ll recall that [Ken] recently radiographically reverse engineered a pluggable module of unknown nature, using plain X-ray images taken at different angles to determine that the undocumented Motorola module was stuffed full of discrete components that formed part of a square wave to sine wave converter.

The module for this project, a flip-flop from Motorola and in the same form factor, went into an industrial CT scanner from an outfit called Lumafield, where X-rays were taken from multiple angles. The images were reassembled into a three-dimensional view by the scanner’s software, which gave a stunningly clear view of the components embedded within the module’s epoxy body. The cordwood construction method is obvious, and it’s pretty easy to tell what each component is. The transistors are obvious, as are the capacitors and diodes. The resistors were a little more subtle, though — careful examination revealed that some are carbon composition, while others are carbon film. It’s even possible to pick out which diodes are Zeners.

The CT scan data, along with some more traditional probing for component values, let [Ken] reverse engineer the whole circuit, which turned out to be a little different than a regular J-K flip-flop. Getting a non-destructive look inside feels a little like sitting alongside the engineers who originally built these things, which is pretty cool.

Reverse Engineering An Apollo-Era Module With X-Ray

June 29, 2022 by Dan Maloney 9 Comments

The gear that helped us walk on the Moon nearly 60 years ago is still giving up its mysteries today, with some equipment from the Apollo era taking a little bit more effort to reverse engineer than others. A case in point is this radiographic reverse engineering of some Apollo test gear, pulled off by [Ken Shirriff] with help from his usual merry band of Apollo aficionados.

The item in question is a test set used for ground testing of the Up-Data Link, which received digital commands from mission controllers. Contrary to the highly integrated construction used in Apollo flight hardware, the test set, which was saved from a scrapyard, used more ad hoc construction, including cards populated by mysterious modules. The pluggable modules bear Motorola branding, and while they bear some resemblance to ICs, they’re clearly not.

[Ken] was able to do some preliminary reverse-engineering using methods we’ve seen him employ before, but ran into a dead end with his scope and meter without documentation. So the modules went under [John McMaster]’s X-ray beam for a peek inside. They discovered that the 13-pin modules are miniature analog circuits using cordwood construction, with common discrete passives stacked vertically between parallel PCBs. The module they imaged showed clear shadows of carbon composition resistors, metal-film capacitors, and some glass-body diodes. Different angles let [Ken] figure out the circuit, which appears to be part of a square wave to sine wave converter.

The bigger mystery here is why the original designer chose this method of construction. There must still be engineers out there who worked on stuff like this, so here’s hoping they chime in on this innovative method.

Can You Hear Me Now? Lunar Edition

May 16, 2022 by Al Williams 9 Comments

Despite what it looks like in the movies, it is hard to communicate with astronauts from Earth. There are delays, and space vehicles don’t usually have a lot of excess power. Plus everything is moving and Doppler shifting and Faraday rotating. Even today, it is tricky. But how did Apollo manage to send back TV, telemetry, and voice back in 1969? [Ken Shirriff] and friends tell us part of the story in a recent post where he looks at the Apollo premodulation processor.

Things like weight and volume are always at a premium in a spacecraft, as is power. When you look at pictures of this solid box that weighs over 14 pounds, you’ll be amazed at how much is crammed into a relatively tiny spot. Remember, if this box was flying in 1969 it had to be built much earlier so there’s no way to expect dense ICs and modern packaging. There’s not even a printed circuit board. The components are attached to metal pegs in a point-to-point fashion. The whole thing lived near the bottom of the Command Module’s lower equipment bay.

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The Apollo Digital Ranging System: More Than Meets The Eye

April 25, 2022 by Ryan Flowers 15 Comments

If you haven’t seen [Ken Shirriff]’s teardowns and reverse engineering expeditions, then you’re in for a treat. His explanation and demonstration of the Apollo digital ranging system is a fascinating read, even if vintage computing and engineering aren’t part of your normal fare.

The average Hackaday reader should be familiar with the concept of determining the distance of a faraway object by measuring how long it takes a sound or radio wave to be reflected, such as in sonar and radar. Going another step and measuring Doppler Shift – the difference in the returned signal’s frequency – will tell us the velocity of the object relative to our position. It’s so simple that an Arduino can do it. But in the days of Apollo, there was no Arduino. In fact, there were no Integrated Circuits. And Apollo missions went all the way to the moon- far too distant for relatively simple Radar measurements. Continue reading “The Apollo Digital Ranging System: More Than Meets The Eye” →

NASA Continues Slow And Steady Pace Towards Moon

March 28, 2022 by Tom Nardi 61 Comments

It’s often said that the wheels of government turn slowly, and perhaps nowhere is this on better display than at NASA. While it seems like every week we hear about another commercial space launch or venture, projects helmed by the national space agency are often mired by budget cuts and indecisiveness from above. It takes a lot of political will to earmark tens or even hundreds of billions of dollars on a project that could take decades to complete, and not every occupant of the White House has been willing to stake their reputation on such bold ambitions.

In 2019, when Vice President Mike Pence told a cheering crowd at the U.S. Space & Rocket Center that the White House was officially tasking NASA with returning American astronauts to the surface of the Moon by 2024, everyone knew it was an ambitious timeline. But not one without precedent. The speech was a not-so-subtle allusion to President Kennedy’s famous 1962 declaration at Rice University that America would safely land a man on the Moon before the end of the decade, a challenge NASA was able to meet with fewer than six months to spare.

Unfortunately, a rousing speech will only get you so far. Without a significant boost to the agency’s budget, progress on the new Artemis lunar program was limited. To further complicate matters, less than a year after Pence took the stage in Huntsville, there was a new President in the White House. While there was initially some concern that the Biden administration would axe the Artemis program as part of a general “house cleaning”, it was allowed to continue under newly installed NASA Administrator Bill Nelson. The original 2024 deadline, at this point all but unattainable due to delays stemming from the COVID-19 pandemic, has quietly been abandoned.

So where are we now? Is NASA in 2022 any closer to returning humanity to the Moon than they were in 2020 or even 2010? While it might not seem like it from an outsider’s perspective, a close look at some of the recent Artemis program milestones and developments show that the agency is at least moving in the right direction.

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Apollo Comms Flight Hardware Deep Dive

January 21, 2022 by Chris Lott 6 Comments

You no doubt recall the incredible Apollo Guidance Computer (AGC) reverse engineering and restoration project featured on the CuriousMarc YouTube channel a few years ago. Well, [Marc] and the team are at it again, this time restoring the Apollo Unified S-Band tracking and communication system flight hardware. As always, the project is well documented, carefully explained, full of problems, and is proceeding slowly despite the lack of documentation.

Like the guidance computer, the Unified S-Band system was pretty innovative for its day — able to track, provide voice communications, receive television signals, and send commands to and monitor the health of the spacecraft via telemetry. The system operates on three frequencies, an uplink containing ranging code, voice and data. There are two downlinks, one providing ranging, voice, and telemetry, the other used for television and the playback of recorded data. All crammed into two hefty boxes totaling 29 kg.

So far, [Marc] has released part 9 of the series (for reference, the Apollo Guidance Computer took 27 parts plus 8 auxiliary videos). There seems to be even less documentation for this equipment than the AGC, although miraculously the guys keep uncovering more and more as things progress. Also random pieces of essential ground test hardware keep coming out of the woodwork. It’s a fascinating dive into not only the system itself, but the design and construction techniques of the era. Be sure to check out the series (part 1 is below the break) and follow along as they bring this system back to life. [Marc] is posting various documents related to the project on his website. And if you missed the AGC project, here’s the playlist of videos, and the team joined us for a Hackaday Chat back in 2020.

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Astronaut Food Is Light Years Beyond Tang And Freeze-Dried Ice Cream

December 29, 2021 by Kristina Panos 8 Comments

When it comes down to it, we humans have two major concerns when venturing away from home for an extended period of time: what we’ll eat, and where we will sleep. Depending on the mode of travel, you might take some snacks along, or else rely on restaurants and/or the pantry of your possible hosts. Until the day we can reliably grow many types of food in space, or that Milliways, that five-star eatery at the end of the universe is operational, astronauts and other space-bound travelers will have to bring most of their food with them.

Cubes and Tubes

Space food has its roots in military rations, which in the United States were devised during the Revolutionary War. Both the variety and delivery methods of food have changed significantly since the beginning of the space program. While the menu may have at first been limited to tubes of nutrient-rich goo, bite-sized cubes and freeze-dried powdered beverages, the fare is more far-out these days. Astronauts on the ISS even enjoy tortillas, fresh fruits, and vegetables thanks to resupply missions, though they have to eat some of these types of foods quickly.

The average astronaut has also changed quite a bit, too. At first, they were all young and super-fit ex-military men, but nowadays they are more likely to be middle-aged science-y types and women. All three of these groups have different nutritional needs when faced with the rigors of living and working in space.

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