CDs were a great advancement in audio quality when they were first put on the market. There’s no vinyl-style degradation of the medium if it’s played over and over, and there’s no risk of turning them into a giant pile of ribbon while rewinding like a cassette tape. The one downside was that if you were to take them on the move you needed special hardware and software to prevent the inevitable skipping. If you look at the skipping not as a downside, though, but as a way to produce interesting music, you might end up with a pretty unique piece of hardware.
[Dmitry] is known for his interesting art installations, and the latest one uses parts from three 1988 Sony D2 CD players that have been reassembled in order to take advantage of a skipping and glitching CD. The modified equipment is able to play during pause or rewind thanks to a processor modification, and can also change the rotational speed of the disc. There are other pieces of hardware included for more fine control of glitching and skipping of the audio being read off of the CD.
A factory is a machine. It takes a fixed set of inputs – circuit boards, plastic enclosures, optimism – and produces a fixed set of outputs in the form of assembled products. Sometimes it is comprised of real machines (see any recent video of a Tesla assembly line) but more often it’s a mixture of mechanical machines and meaty humans working together. Regardless of the exact balance the factory machine is conceived of by a production engineer and goes through the same design, iteration, polish cycle that the rest of the product does (in this sense product development is somewhat fractal). Last year [Michael Ossmann] had a surprise production problem which is both a chilling tale of a nasty hardware bug and a great reminder of how fragile manufacturing can be. It’s a natural fit for this year’s theme of going to production.
The saga begins with [Michael] receiving an urgent message from the factory that an existing product which had been in production for years was failing at such a high rate that they had stopped the production line. There are few worse notes to get from a factory! The issue was apparently “failure to program” and Great Scott Gadgets immediately requested samples from their manufacturer to debug. What follows is a carefully described and very educational debug session from hell, involving reverse engineering ROMs, probing errant voltage rails, and large sample sizes. [Michael] doesn’t give us a sense for how long it took to isolate but given how minute the root cause was we’d bet that it was a long, long time.
The post stands alone as an exemplar for debugging nasty hardware glitches, but we’d like to call attention to the second root cause buried near the end of the post. What stopped the manufacturer wasn’t the hardware problem so much as a process issue which had been exposed. It turned out the bug had always been reproducible in about 3% of units but the factory had never mentioned it. Why? We’d suspect that [Michael]’s guess is correct. The operators who happened to perform the failing step had discovered a workaround years ago and transparently smoothed the failure over. Then there was a staff change and the new operator started flagging the failure instead of fixing it. Arguably this is what should have been happening the entire time, but in this one tiny corner of the process the manufacturing process had been slightly deviated from. For a little more color check out episode #440.2 of the Amp Hour to hear [Chris Gammell] talk about it with [Michael]. It’s a good reminder that a product is only as reliable as the process that builds it, and that process isn’t always as reliable as it seems.
[Micah Elizabeth Scott], aka [scanlime], has been playing around with USB drawing tablets, and got to the point that she wanted with the firmware — to reverse engineer, see what’s going on, and who knows what else. Wacom didn’t design the devices to be user-updateable, so there aren’t copies of the ROMs floating around the web, and the tablet’s microcontroller seems to be locked down to boot.
With the easy avenues turning up dead ends, that means building some custom hardware to get it done and making a very detailed video documenting the project (embedded below). If you’re interested in chip power glitching attacks, and if you don’t suffer from short attention span, watch it, it’s a phenomenal introduction.