Teardown Of An Aircraft Video Symbol Generator

June 19, 2023 by Dave Rowntree 17 Comments

[Adrian Smith] recently scored an avionics module taken from a British Aerospace 146 airliner and ripped it open for our viewing pleasure. This particular aircraft was designed in the early 1980s when the electronics used to feed the various displays in the cockpit were very different from modern designs. This particular box is called a ‘symbol generator’ and is used to generate the various real-time video feeds that are sent to the cockpit display units. Various instruments, for example, the weather radar, feed into it, and it then reformats the video if needed, mixing in any required additional display.

Top view of the symbol generator instrument rack

There are many gold-plated chips on these boards, which indicates these may be radiation-hardened versions of familiar devices, most of which are 54xx series logic. 54xx series logic is essentially the same functionally as the corresponding 74xx series, except for the much wider operating temperature range mandated by military and, by extension, commercial aviation needs. The main CPU board appears to be based around the Intel 8086, with some Zilog Z180 compatible processors used on the two video display controller boards. We noted the Zilog Z0853604, which is their counter/timer/GPIO chip. Obviously, there are many custom ASICs produced by Honeywell as well as other special order items that you’ll never find the datasheet for. Now there’s a challenge!

Finally, we note the standard 400 Hz avionics-standard power supply, which, as some may know, is the standard operating frequency for the AC power system used within modern aircraft systems. The higher frequency (compared to 50 or 60 Hz) means the magnetic components can be physically smaller and, therefore, lighter for a given power handling capability.

We see a lot of avionics teardowns, likely because they’re fascinating. Here’s some more British military gear, an interesting RF distance measuring box from the 1970s, and finally, some brave soul building their own avionics gear. What could possibly go wrong?

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A Look Inside A Vintage Aircraft Altimeter

May 10, 2023 by Dan Maloney 21 Comments

There’s a strange synchronicity in the projects we see here at Hackaday, where different people come up with strikingly similar stuff at nearly the same time. We’re not sure why this is, but it’s easily observable, with this vintage altimeter teardown and repair by our good friend [CuriousMarc] as the latest example.

The altimeter that [Marc] dissects in the video below was made by Kollsman, which is what prompted us to recall this recent project that turned a jet engine tachometer into a CPU utilization gauge. That instrument was also manufactured by Kollsman, but was electrically driven. [Marc]’s project required an all-mechanical altimeter, so he ordered a couple from eBay.

Unfortunately, thanks to rough handling in transit they arrived in less than working condition, necessitating the look inside. For which we’re thankful, of course, because the guts of these aneroid altimeters are quite impressive. The mechanism is all mechanical, with parts that look like something [Click Spring] would make for a fine timepiece. [Marc]’s inspection revealed the problem: a broken pivot screw keeping the expansion and contraction of the aneroid diaphragms from transmitting force to the gear train that moves the needles. The repair was a little improvisational, with 0.5-mm steel balls used to stand in for the borked piece. It may not be flight ready, but it worked well enough to get the instrument back in action.

We suspect that [Marc] won’t be able to leave well enough alone on this one, so we’ll be on the lookout for a proper repair. In the meantime, he’ll be able to use this altimeter in the test setup he’s building to test a Bendix air data computer from a 1950s-era jet fighter. Continue reading “A Look Inside A Vintage Aircraft Altimeter” →

Jet Engine Tachometer Turned Into Unique CPU Utilization Meter

May 4, 2023 by Dan Maloney 16 Comments

When you’ve got a piece of interesting old aviation hardware on your desk, what do you do with it? If you’re not willing to relegate it to paperweight status, your only real choice is to tear it down to see what makes it tick. And if you’re lucky, you’ll be able to put it to work based on what you learned.

That’s what happened when [Glen Akins] came across a tachometer for a jet airplane, which he promptly turned into a unique CPU utilization gauge for his computer. Much of the write-up is concerned with probing the instrument’s innards to learn its secrets, although it was clear from the outset that his tachometer, from Kollsman Instruments, was electrically driven. [Glen]’s investigation revealed a 3-phase synchronous motor inside the tach. The motor drives a permanent magnet, which spins inside a copper cup attached to the needle on the tach’s face. Eddy currents induced in the cup by the spinning magnet create a torque that turns the needle against the force of a hairspring. Pretty simple — but how to put the instrument to work?

[Glen]’s solution was to build what amounts to a variable frequency drive (VFD). His power supply is based on techniques he used to explore aircraft synchros, which we covered a while back. The drive uses a trio of MCP4802 8-bit DACs to generate three phase-shifted sine waves via direct digital synthesis with an RP2040. The 3-phase signal drives the motor and spins the dial, with 84-Hz corresponding to full-scale deflection.

The video below shows the resulting CPU utilization gauge — which just queries for the current load level and sends it to the RP2040 over serial — in action. It’s not exactly responsive to rapid changes, but that’s to be expected from a mechanical system. And compared to exploring such a nice instrument, it really doesn’t matter.

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Mechanical GIF Animates With The Power Of Magnets

April 8, 2023 by Dan Maloney 16 Comments

It doesn’t matter how you pronounce it, because whichever way you choose to say “GIF” is guaranteed to cheese off about half the people listening. Such is the state of our polarized world, we suppose, but there’s one thing we all can agree on — that a mechanical GIF is a pretty cool thing.

What’s even better about this thing is that [Mitch], aka [Hack Modular], put some very interesting old aircraft hardware to use to make it. He came upon a set of cockpit indicators from a Cold War-era RAF airplane — sorry, “aeroplane” — that used a magnetically driven rack and pinion to swivel a set of prism-shaped pieces to one of three positions. Which of the three symbols displayed depended on which faces were turned toward the pilot; they were highly visible displays that were also satisfyingly clicky.

After a teardown in which [Mitch] briefly discusses the mechanism behind these displays, he set about customizing the graphics. Rather than the boring RAF defaults, he chose three frames from the famous Horse in Motion proto-motion picture by [Eadweard Muybridge]. After attaching vertical strips from each frame to the three sides of each prism, [Mitch] came up with a driver for the display; he could have used a 555, but more fittingly chose series-connected relays to do the job. Capacitors slow down the switching cascade and the frame rate; a rotary switch selects different caps to make the horse appear to be walking, trotting, cantering, or galloping — yes, we know they’re each physically distinct motions, but work with us here.

The whole thing looks — and sounds — great mounted in a nice plastic enclosure. The video below shows it in action, and we find it pretty amazing the amount of information that can be conveyed with just three frames. And we’re surprised we’ve never seen these displays before; they seem like something [Fran Blanche] or [Curious Marc] would love.

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1950s Fighter Jet Air Computer Shows What Analog Could Do

February 14, 2023 by Dan Maloney 40 Comments

Imagine you’re a young engineer whose boss drops by one morning with a sheaf of complicated fluid dynamics equations. “We need you to design a system to solve these equations for the latest fighter jet,” bossman intones, and although you groan as you recall the hell of your fluid dynamics courses, you realize that it should be easy enough to whip up a program to do the job. But then you remember that it’s like 1950, and that digital computers — at least ones that can fit in an airplane — haven’t been invented yet, and that you’re going to have to do this the hard way.

The scenario is obviously contrived, but this peek inside the Bendix MG-1 Central Air Data Computer reveals the engineer’s nightmare fuel that was needed to accomplish some pretty complex computations in a severely resource-constrained environment. As [Ken Shirriff] explains, this particular device was used aboard USAF fighter aircraft in the mid-50s, when the complexities of supersonic flight were beginning to outpace the instrumentation needed to safely fly in that regime. Thanks to the way air behaves near the speed of sound, a simple pitot tube system for measuring airspeed was no longer enough; analog computers like the MG-1 were designed to deal with these changes and integrate them into a host of other measurements critical to the pilot.

To be fair, [Ken] doesn’t do a teardown here, at least in the traditional sense. We completely understand that — this machine is literally stuffed full of a mind-boggling number of gears, cams, levers, differentials, shafts, and pneumatics. Taking it apart with the intention of getting it back together again would be a nightmare. But we do get some really beautiful shots of the innards, which reveal a lot about how it worked. Of particular interest are the torque-amplifying servo mechanism used in the pressure transducers, and the warped-plate cams used to finely adjust some of the functions the machine computes.

If it all sounds a bit hard to understand, you’re right — it’s a complex device. But [Ken] does his usual great job of breaking it down into digestible pieces. And luckily, partner-in-crime [CuriousMarc] has a companion video if you need some visual help. You might also want to read up on synchros, since this device uses a ton of them too.

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Not A Pot, Not An Encoder: Exploring Synchros For Rotational Sensing

February 1, 2023 by Dan Maloney 25 Comments

We’re all familiar with getting feedback from a rotating shaft, for which we usually employ a potentiometer or encoder. But there’s another device that, while less well-known, has some advantages that just might make it worth figuring out how to include it in hobbyist projects: the synchro.

If you’ve never heard of a synchro, don’t feel bad; as [Glen Akins] explains, it’s an expensive bit of kit most commonly found in avionics gear. It’s in effect a set of coaxial transformers with a three-phase stator coil and a single-phase rotor. When excited by an AC reference voltage, the voltage induced on the rotor coil is proportional to the cosine of the angle between the rotor and stator. It seems simple enough, but the reality is that synchros present some interfacing challenges.

[Glen] chose a surplus altitude alert indicator for his experiments, a formidable-looking piece of avionics. Also formidable was the bench full of electronics needed to drive and decode the synchro inside it — a 26-volt 400-Hz AC reference voltage generator, an industrial data acquisition module to digitize the synchro output, and an ESP32 dev board with a little OLED display to show the results. And those are impressive; as seen in the video below, the whole setup is capable of detecting tenth-of-a-degree differences in rotation.

The blog post has a wealth of detail on using synchros, as does this Retrotechtacular piece from our own [Al Williams]. Are they practical for general hobbyist use? Probably not, but it’s still cool to see them put to use.

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Listening To The Sounds Of An 1960s Military Computer

December 1, 2021 by Moritz v. Sivers 44 Comments

Restoring vintage computers is the favorite task of many hardware hackers. Retrocomputing probably makes you think of home computer brands like Commodore, Amiga, or Apple but [Erik Baigar] is deeply into collecting early military computers from the UK-based Elliott company. Earlier this year he made a detailed video that shows how he successfully brought an Elliott 920M from the 1960s back to life.

It is quite amazing that the Elliott company already managed to fit their 1960s computer into a shoebox-sized footprint. As computers had not yet settled on the common 8bit word size back then the Elliott 900 series are rather exotic 18bit or 12bit machines. The 920M was used as a guidance computer for European space rockets in the 1960s and ’70s but also for navigational purposes in fighter jets until as late as 2010.

Opening up the innards of this machine reveals some exotic quirks of early electronics manufacturing. The logic modules contain multilayer PCBs where components were welded instead of soldered onto thin sheets of mylar foil that were then potted in Araldite.

To get the computer running [Erik Baigar] first had to recreate the custom connectors using a milling machine. He then used an Arduino to simulate a paper tape reader and load programs into the machine. An interesting hack is when he makes the memory reading and writing audible by simply placing a radio next to the machine. [Erik Baigar] finishes off his demonstration of the computer by running some classic BASIC games like tic-tac-toe and a maze creator.

If you would like to code your own BASIC programs on more modern hardware you should check out this BASIC interpreter for the Raspberry Pi Pico.

Video after the break.

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