Industrial Automation In Action: Steam Controller Assembly

December 12, 2015 by Dan Maloney 63 Comments

Right up front, we’ll cop to the inevitable “not a hack” comments on this one. This video of the Steam Controller assembly plant is just two minutes of pure robotics porn, plain and simple.

From injection molding of the case parts through assembly, testing and final palletizing of packaged controllers for the trip to distributors, Valve’s video is amazingly detailed and very well made. We’d wager that the crane shots and the shots following product down conveyors were done with a drone. A grin was had with the Aperture Labs logo on the SCARA arms in the assembly and testing work cell, and that inexplicable puff of “steam” from the ceiling behind the pallet in the final shot was a nice touch too. We also enjoyed the all-too-brief time-lapse segment at around 00:16 that shows the empty space in Buffalo Grove, Illinois being fitted out.

This may seem like a frivolous video, but think about it: if you’re a hardware hacker, isn’t this where you want to see your idea end up? Think of it as inspiration to get your widget into production. You’ll want to get there in stages, of course, so make sure you check out [Zach Fredin]’s 2015 Hackaday Superconference talk on pilot-scale production.

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A Modern 386 Development Board

November 17, 2015 by Eric Evenchick 49 Comments

Some readers out there probably have nostalgic feelings for their first 386 based PC, the beeps and hisses of the modem, and the classic sound of a floppy drive’s stepper motor. Perhaps that turbo button that we could never quite figure out.

If you want the power of a 386 processor today, you’re in luck: [Pierre Surply] has developed a modern development board for the 80386SX CPU. This board is based on a 386 processor that comes in a LQFP package for “easy” soldering, and an Altera Cyclone IV FPGA.

To allow the CPU to run, the FPGA emulates the chipset you would usually find on a PC motherboard. The FPGA acts as both a bus controller and a memory controller for the CPU. On the board, there’s an SRAM chip and internal memory on the FPGA, which can be accessed through the 386’s bus access protocol.

The FPGA also provides debugging features. A supervisor application running on the FPGA gives debugging functionality via a FTDI USB to UART chip. This lets you control operation of the CPU from a PC for debugging purposes. The FPGA’s memory can be programmed through a JTAG interface.

The project is very well documented, and is a great read if you’re wondering how your old 386 actually worked. It can even be hand soldered, so the adventurous can grab the design files and give it a go. The francophones reading can also watch the talk in the video below.

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Hacking A Universal Assembler

August 6, 2015 by Al Williams 30 Comments

I have always laughed at people who keep multitools–those modern Swiss army knives–in their toolbox. To me, the whole premise of a multitool is that they keep me from going to the toolbox. If I’ve got time to go to the garage, I’m going to get the right tool for the job.

Not that I don’t like a good multitool. They are expedient and great to get a job done. That’s kind of the way I feel about axasm — a universal assembler I’ve been hacking together. To call it a cross assembler hack doesn’t do it justice. It is a huge and ugly hack, but it does get the job done. If I needed something serious, I’d go to the tool box and get a real assembler, but sometimes you just want to use what’s in your pocket.

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Writing Doom For The Raspberry Pi

July 6, 2015 by James Hobson 35 Comments

We’ve all seen Doom played on the Raspberry Pi before… but this isn’t a port of the game. No, this was a school project at the Imperial College of London — writing the game in bare assembly. They wrote it from scratch.

bare metal doom thumbnail — Complete with a custom home made controller connected directly to the GPIO pins!

Yep. There’s not even an operating system on the Pi. It’s 9800 lines of bare metal ARM assembly. If that doesn’t hurt your brain we dunno what does!

They are using the official textures from the game, and it’s not quite a perfect replica — but it’s pretty darn close.

Part of the project was to build an emulator to make it easier to test the game, but it didn’t work out the greatest — so most of the actual game development was performed on the actual hardware. Yikes!

Stick around after the break to see Doom in all its former glory. Top notch work guys!

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3D Printed Pogo Pin Programmer

April 6, 2015 by Brian Benchoff 21 Comments

The new hotness for Internet of Things hardware is the ESP8266. Alone it can connect to a WiFi network, but it doesn’t really have a lot of output options. Paired with an ATMega, and you really have something. That’s the philosophy behind the WIOT board, and when [Chris] was assembling these boards, he needed a way to flash firmware. The board has an unpopulated ISP header from the assembler, so pogo pins are the answer. How do you make a pogo pin jig? With a 3D printer, of course.

The ISP header wasn’t populated to give the board a slim profile, but this means a jig of sorts would be needed to program the WIOT. The first attempt was buying a few pogo pin adapters from Tindie, but this was terribly uncomfortable to hold while the board was being programmed.

To fix this problem, a small clip device was rigged up, printed out, and used for programming. Interestingly, this clip has a very deep throat, and a few holes used for bolting on a separate programmer. This shows a lot of forward thinking: the programmer can be reused for different boards with completely different layouts and programmers. If the next revision of the WIOT needs a JTAG header to program the micro, the problem of programming it is already covered.

A Automated Optical Inspection machine, inspecting the USB Armory board

Meet The Machines That Build Complex PCBs

March 31, 2015 by Eric Evenchick 12 Comments

You can etch a simple PCB at home with a few chemicals and some patience. However, once you get to multilayer boards, you’re going to want to pay someone to do the dirty work.

The folks behind the USB Armory project visited the factories that build their 6 layer PCB and assemble their final product. Then they posted a full walkthrough of the machines used in the manufacturing process.

The boards start out as layers of copper laminates. Each one is etched by applying a film, using a laser to print the design from a Gerber file, and etching away the unwanted copper in a solution. Then the copper and fibreglass prepreg sandwich is bonded together with epoxy and a big press.

Bonded boards then get drilled for vias, run through plating and solder mask processes and finally plated using an Electroless Nickel Immersion Gold (ENIG) process to give them that shiny gold finish. These completed boards are shipped off to another company, where a pick and place followed by reflow soldering mounts all the components to the board. An X-Ray is used to verify that the BGA parts are soldered correctly.

The walkthrough gives a detailed explanation of the process. It shows us the machines that create products we rely on daily, but never get to see.

A protoboard layout for an ATtiny85 door chime

AES-CMAC On An ATtiny85

February 20, 2015 by Eric Evenchick 35 Comments

[Blancmange] built a custom door chime using an ATtiny85. Unlike most commercial products out there, this one actually tries to be secure, using AES-CMAC for message signing.

The hardware is pretty simple, and a protoboard layout is shown in the image above. It uses the ATtiny85 for control, with an LM380N audio amplifier, and a low cost 315 MHz receiver.

The more impressive part of the build is the firmware. Using AVR assembly, [Blancmange] managed to fit everything into the 8 Kbytes of flash on the ATtiny85. This includes an implementation of AES-CMAC, an AES cypher based message authentication code. The transmitting device signs the request with a key shared between both devices, and the receiver verifies that the message is from a trusted transmitter.

Fortunately, the assembly code is very well commented. If you’ve ever wanted to take a look into some complex ASM assembly, this is a great project to check out. The source code has been released into the public domain, so the rest of us can implement crypto on this cheap microcontroller with much less effort.