NASA Hardware Techniques: Soldering Space Electronics Like It’s 1958

April 13, 2022 by Dave Rowntree 44 Comments

[PeriscopeFilms] on YouTube has many old TV adverts and US government reels archived on their channel, with some really interesting subjects to dive in to. This first one we’re highlighting here is a 1958 film about NASA Soldering Techniques (Video, embedded below), which has some fascinating details about how things were done during the Space Race, and presumably, continue to be done. The overall message about cleanliness couldn’t really be any clearer if they tried — it’s so critical it looks like those chaps in the film spend far more time brushing and cleaning than actually wielding those super clean soldering irons.

Of particular note are some of the details of wire stripping and jointing with components, such as the use of a hot-wire device to remove the insulation from wire, rather than use the kind of stripper we have lying around that cuts into the insulation and slightly distorts the wire in the process. That just won’t do. If they did have to use a cutting-type stripper, it must be precisely the right size for job, and calibrated daily.

The road to the Moon is paved with calibrated wire strippers.

When soldering a pre-tinned wire to a leaded component, a clamp is required to prevent movement of the wire, as is a thermal shunt on the component lead to protect the delicate component from excess heat. They even specify how much to wrap a wire around a terminal to be soldered, never bending the wire more than 180 degrees.

The bottom line in all this is, is that the work must be as perfect as is possible, as there is very little chance of sending someone up to fix a dodgy soldering job, once the assembly is hurtling around the planet. They call it too much of a science to be called an art and too much art to be called a science, and we can sure appreciate that.

As you would expect (and it’s not exactly a big secret) NASA has some very exacting standards for assembly of all hardware, like this great workmanship standard, which is well worth studying. Soldering is an important subject for many of us, we’ve covered the subject of solder metallurgy, as well as looking at how ancient hardware hackers soldered without the benefit of much modern knowledge.

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Old Casio Calculator Learns New Tricks

April 6, 2022 by Chris Wilkinson 12 Comments

[George Stagg] recently found himself stung by the burden of free time while in lockdown. Needing a project to keep him occupied, he decided to upgrade his 90s Casio CFX-9850G calculator to run custom machine code.

All [George] really wanted was for his vintage calculator to understand Reverse Polish Notation (RPN). The calculator in question can already run its own version of BASIC, however the bespoke Hitachi CPU struggles performance-wise with complex programs, and wouldn’t be a realistic way of using RPN on the calculator. An RPN interpreter written in assembly language would be much faster.

The first step in cracking this calculator wide open was a ROM dump, followed by writing a disassembler. Incredibly, the MAME framework already featured a ‘partial implementation’ of the calculator’s CPU, which was a much needed shot in the arm when it came time to write a full-featured emulator.

With the entire calculator emulated in software, the plan from here involved replacing one of the BASIC commands in ROM with new code that would jump to an address in RAM. With 32KB of RAM there ended up being plenty of room for experimentation, and uploading a program into RAM was simplified by using Casio’s original backup software to dump the RAM onto a PC. Here, the contents of RAM could be easily modified with custom code, then uploaded back into the calculator.

With RAM to burn, new routines were created to write custom characters to the screen, and a new font was created to squeeze more characters onto the display than normal. [George] ended up porting a Forth interpreter, which defaults to RPN style, to finally achieve his humble objective. He also managed to get a version of Conway’s Game Of Life running, check out the video after the break.

We can’t get enough of our calculator hacks here, so make sure to check out the CPU transplant on this vintage Soviet calculator.

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Reliving Second-Hand Nostalgia With The PDP-11

March 19, 2022 by Jonathan Bennett 31 Comments

Levy’s Hackers: Heroes of the Computer Revolution is something like required reading for the hacker subculture, and Hackaday by extension. The first section of that book is all about early hackers and their adventures with the PDP-1 at MIT. The PDP-11 has earned a special place in hacker history for being the minicomputer used to write the first Unix. We’re always amazed to find how many of our readers have stories about programming PDP microcomputers, usually the PDP-11. Those of us young enough to have missed out on the PDP experience often have something of a second-hand nostalgia for the old machines. An exceptionally detailed article over at Ars Technica promises to get us started reliving the glory days, even if it is for the first time.

It turns out that there’s an emulator for the old minicomputers, the History Simulator, abbreviated SimH. The article gives step-by-step instructions to get the emulator running, booting Unix 2.11 on a virtual PDP-11. The fun doesn’t stop there. The write-up includes an intro the the PDP-11 hardware, and a crash-course to assembly programming for the beast. It’s a great look at how the stack, branching, and subroutines work under the hood. Most of it still applies to computing today, so it really is worth the read.

Looking for more PDP-11 lore? Check out our coverage of DEC’s history.

The image above is “PDP-11” by ToastyKen, and is licensed under CC BY 2.0

Pick And Place Hack Chat

February 7, 2022 by Dan Maloney No comments

Join us on Wednesday, February 9 at noon Pacific for the Pick and Place Hack Chat with Chris Denney!

We in the hacker trade are pretty used to miracles — we make them all the time. But even the most jaded among us has to admit that modern PCB assembly, where components that could easily hide under a grain of sand are handled by robots, borders on witchcraft. The pick and place machines that work these wonders not only have to hit their marks accurately and precisely, but they also do it at blinding speeds and for days on end.

Luckily, even those of us who design circuits for a living and depend on PCB assembly services to realize those designs can, at least to some degree, abstract the details of the pick and place phase of the process away. But making it “just work” isn’t a trivial task, and learning a little bit about what it takes to do so can make us better designers. Plus, it’s just plain cool to watch a pick and place do its thing. And to dive a little deeper into pick and place, Chris Denney, CTO of Worthington Assembly and co-host of “Pick, Place, Podcast” will stop by the Hack Chat. If you’ve ever wondered about the inner workings of PCB assembly and the role pick and place plays in it, or if you’re looking for tips on how to optimize your layouts for pick and place, this is one you won’t want to miss!

Our Hack Chats are live community events in the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Wednesday, February 9 at 12:00 PM Pacific time. If time zones have you tied up, we have a handy time zone converter.

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The Linux X86 Journey To Main()

November 5, 2021 by Al Williams 7 Comments

Have you ever had a program crash before your main function executes? it is rare, but it can happen. When it does, you need to understand what happens behind the scenes between the time the operating system starts your program and your first line of code in main executes. Luckily [Patrick Horgan] has a tutorial about the subject that’s very detailed. It doesn’t cover statically linked libraries but, as he points out, if you understand what he does cover, that’s easy to figure out on your own.

The operating system, it turns out, knows nothing about main. It does, however, know about a symbol called _start. Your runtime library provides this. That code contains some stack manipulation and eventually calls __libc_start_main which is also provided by the library. Continue reading “The Linux X86 Journey To Main()” →

An Emulator For OBP, The Spaceflight Computer From The 1960s

November 1, 2021 by Donald Papp 9 Comments

[David Given] frequently dives into retrocomputing, and we don’t just mean he refurbishes old computers. We mean things like creating a simulator and assembler for the OBP spaceflight computer, which was used in the OAO-3 Copernicus space telescope, pictured above. Far from being a niche and forgotten piece of technology, the On-Board Processor (OBP) was used in several spacecraft and succeeded by the Advanced On-board Processor (AOP), which in turn led to the NASA Standard Spaceflight Computer (NSSC-1), used in the Hubble Space Telescope. The OBP was also created entirely from NOR gates, which is pretty neat.

One thing [David] learned in the process is that while this vintage piece of design has its idiosyncrasies, in general, the architecture has many useful features and is pleasant to work with. It is a bit slow, however. It runs at a mere 250 kHz and many instructions take several cycles to complete.

Sample of the natural-language-looking programming syntax for the assembler. (Example from page 68 of the instruction set manual for the OBP.)

One curious thing about the original assembler was documentation showing it was intended to be programmed in a natural-language-looking syntax, of which an example is shown here. To process this, the assembler simply mapped key phrases to specific assembly instructions. As [David] points out, this is an idea that seems to come and go (and indeed the OBP’s successor AOP makes no mention whatsoever of it, so clearly it “went”.) Since a programmer must adhere to a very rigid syntax and structure anyway to make anything work, one might as well just skip dealing with it and write assembly instructions directly, which at least have the benefit of being utterly unambiguous.

We’re not sure who’s up to this level of detail, but embedded below is a video of [David] coding the assembler and OBP emulator, just in case anyone has both an insatiable vintage thirst and a spare eight-and-a-half hours. If you’d prefer just the files, check out the project’s GitHub repository.

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The Epic Saga Of Hacking Knights Of The Round

June 8, 2021 by Tom Nardi 3 Comments

For the uninitiated, Knights of the Round was a hack-and-slash arcade game released by Capcom in 1991 that rather loosely followed the legend of King Arthur and the eponymous Knights of the Round Table. In it, up to three players make their way from stage to stage, vanquishing foes and leveling up their specific character’s weapons and abilities. But [Sebastian Mihai] was looking for a new way to experience this classic title, so he decided to reverse engineer the game and create his own version called Warlock’s Tower.

Those familiar with the original game will no doubt notice some of the differences right away while watching the video below, but for those who don’t have an intimate knowledge of Arthur’s digital adventures, the major changes are listed on the project’s web page. Among the most notable are the removal of cooperative multiplayer and stage time limits. This turns the game from a frantic beat ’em up to a more methodical adventure. Especially since you now have to compete the game in a single life. If we had to guess, we’d say [Sebastian] prefers his games to have a bit of a challenge to them.

Even if you aren’t interested in playing Warlock’s Tower yourself, the story of how [Sebastian] created it is absolutely fascinating. He started with zero knowledge of Motorola 68000 assembly, but by the end of the project, was wrangling multiple debuggers and writing custom tools to help implement the approximately 70 patches that make up the custom build.

The hundreds of hours of work that went into creating these patches is documented as a sort of stream of consciousness on the project page, allowing you to follow along in chronological order. Whether it inspires you to tackle your own reverse engineering project or makes you doubt whether or not you’ve got the patience to see it through, it’s definitely worth a read. If you’re a Knights of the Round fan, you should also take a look at the incredible wealth of information he’s amassed about the original game itself, which honestly serves as an equally impressive project in its own right.

Modified versions of classic games, known colloquially as “ROM hacks” are fairly common among serious fans who want to see their favorite games improved over time. While they aren’t always as ambitious as Warlock’s Tower, they all serve as examples of how a dedicated community can push a product well beyond the scope envisioned by its original creators.

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