Logic Chip Teardown From Early 1990s IBM ES/9000 Mainframe

The 1980s and early 1990s were a bit of an odd time for semiconductor technology, with the various transistor technologies that had been used over the decades slowly making way for CMOS technology. The 1991-vintage IBM ES/9000 mainframe was one of the last systems to be built around bipolar transistor technology, with [Ken Shirriff] tearing into one of the processor modules (TCM) that made up one of these mainframes.

A Thermal Conduction Module from an IBM ES/9000 mainframe.

Five of these Thermal Conduction Modules (127.5 mm a side) made up the processor in these old mainframes. Most of note are the use of the aforementioned bipolar transistors and the use of DCS-based (differential current switch) logic. With the already power-hungry bipolar transistors driven to their limit in the ES/9000, and the use of rather massive DCS gates, each TCM was not only fed many amperes of electricity, but also capable of dissipating up to 600 Watts of power.

Each TCM didn’t contain a single large die of bipolar transistors either, but instead many smaller dies were bonded on a specially prepared ceramic layer in which the wiring was added through a very precise process. While an absolute marvel of engineering, the ES/9000 was essentially a flop, and by 1997 IBM too would move fully to CMOS transistor technology.

Over the years we’ve featured a lot of [Ken]’s work, perhaps you’d like to know more about his techniques.

Retrotechtacular: Design For Assembly, 1980s-Style

To get its engineers thinking about design for assembly back in the 1980s, Westinghouse made a video about a product optimized for assembly: the IBM Proprinter. The technology may be dated, but the film presents a great look at how companies designed not only for manufacturing, but also for ease of assembly.

It’s not clear whether Westinghouse and IBM collaborated on the project, but given the inside knowledge of the dot-matrix printer’s assembly, it seems like they did. The first few minutes are occupied by an unidentified Westinghouse executive talking about design for assembly in general terms, and how it impacts the bottom line. Skip ahead to 3:41 if talking suits aren’t your thing.

Once the engineer gets going on the printer, though, things get really interesting. The printer’s guts are laid out before him, ready to be assembled. What’s notably absent from the table are tools — the Proprinter was so well designed that the only tool needed is a pair of human hands. And they don’t have to be particularly dexterous hands, either — the design favors motions that are straight down, letting gravity assist the assembly process and preventing assemblers from the need to contort their bodies. Almost everything is held in place by compliant mechanisms built into the plastic parts. There are a few gems in the film, like the plastic lead screw that drives the printhead, obviating the need to string a fussy timing belt, or the unique roller that twists to lock onto a long shaft, rather than having to be pushed to its center.

We found this film which we’ve placed below the break to be very instructive, and the fact that a device as complex as a printer can be assembled in just a few minutes without picking up a single tool is pretty illustrative of the power of designing for assembly. Slick designs that can’t be manufactured at scale are all too common in this age of powerful design tools and desktop manufacturing, so these lessons from the past might be worth relearning.

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Booting A PC From Vinyl For A Warmer, Richer OS

If you’ve scrolled through the list of boot options offered on any PC’s BIOS, it reads like a history of storage technology. Up top we have the options to boot from disk, often a solid-state drive, then USB disk, optical drive, removable media, and down the bottom there’s usually an option to boot from the network. Practically no BIOS, however, has an option to boot a PC from a vinyl record — at least until now.

Clearly a project from the “Because why not?” school of hacking, [Jozef Bogin] came up with the twist to the normal booting process for an IBM-PC. As in the IBM-PC — a model 5150, with the putty-colored case, dual 5-1/4″ floppies, and one of those amazing monochrome displays with the green slow-decay phosphors. To pull off the trick, [Jozef] leverages the rarely used and little known cassette tape interface that PCs had back in the early days. This required building a new bootloader and burning it to ROM to make the PC listen to audio signals with its 8255 programmable peripheral interface chip.

Once the PC had the right bootloader, a 64k FreeDOS bootable disk image was recorded on vinyl. [Jozef] provides infuriatingly little detail about the process other than to mention that the audio was sent directly to the vinyl lathe; we’d have loved to learn more about that. Nonetheless, the resulting 10″ record, played back at 45 RPM with some equalization tweaks to adapt for the RIAA equalization curve of the preamp, boots the PC into FreeDOS just fine, probably in no more time than it would have taken to boot from floppy.

It’s may not be the first time we’ve seen software on vinyl, but it’s still a pretty cool hack. Want to try it yourself but lack a record-cutting lathe? Maybe laser-cutting your boot disc will work.

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Bringing An IBM Model F Into 2020

We know that the Hackaday family includes many enthusiasts for quality keyboards, and thus mention of the fabled ‘boards of yore such as the IBM Model F is sure to set a few pulses racing. Few of us are as lucky as [Brennon], who received the familial IBM PC-XT complete with its sought-after keyboard.

This Model F has a manufacture date in March 1983, and as a testament to its sturdy design was still in one piece with working electronics. It was however in an extremely grimy condition that necessitated a teardown and deep clean. Thus we are lucky enough to get a peek inside, and see just how much heavy engineering went into the construction of an IBM keyboard before the days of the feather-light membrane devices that so many of us use today. There follows a tale of deep cleaning, with a Dremel and brush, and then a liberal application of Goo Gone. The keycaps had a long bath in soapy water to remove the grime, and we’re advised to more thoroughly dry them should we ever try this as some remaining water deep inside them caused corrosion on some of the springs.

The PC-XT interface is now so ancient as to have very little readily available in the way of adapters, so at first a PS/2 adapter was used along with a USB to PS/2 converter. Finally though a dedicated PC-XT to USB converter was procured, allowing easy typing on a modern computer.

This isn’t our first look at the Model F, but if you can’t afford a mechanical keyboard don’t worry. Simply download a piece of software that emulates the sound of one.

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Hackaday Links: October 11, 2020

If you’re interested in SDR and digital signal processing but don’t know where to start, you’re in luck. Ben Hillburn, president of the GNU Radio Project, recently tweeted about an online curriculum for learning SDR and DSP using Python. The course was developed by Dr. Mark Lichtman, who was a lead on GNU Radio, and from the look of it, this is the place to go to learn about putting SDRs to use doing cool things. The course is chock full of animations that make the concepts clear, and explain what all the equations mean in a way that’s sure to appeal to practical learners.

It’s not much of a secret that the Hackaday community loves clocks. We build clocks out of everything and anything, and any unique way of telling time is rightly applauded and celebrated on our pages. But does the clock motif make a good basis for a video game? Perhaps not, but that didn’t stop Clock Simulator from becoming a thing. To “play” Clock Simulator, you advance the hands of an on-screen clock by pressing a button once per second. Now, thanks to Michael Dwyer, you don’t even have to do that one simple thing. He developed a hardware cheat for Clock Simulator that takes the 1PPS output from a GPS module and wires it into a mouse. The pulse stream clicks the mouse once per second with atomic precision, rendering the player irrelevant and making the whole thing even more pointless. Or perhaps that is the point.

Maybe we were a little hard on Clock Simulator, though — we can see how it would help achieve a Zen-like state with its requirement for steady rhythm, at least when not cheating. Another source of Zen for some is watching precision machining, and more precise, the better. We ran into this mesmerizing video of a CNC micro-coil winder and found it fascinating to watch, despite the vertical format. The winder is built from a CNC lathe, to the carriage of which a wire dispenser and tensioning attachment have been added. The wire is hair-fine and passes through a ruby nozzle with a 0.6 mm bore, and LinuxCNC controls the tiny back and forth motion of the wire as it winds onto the form. We don’t know what the coil will be used for, but we respect the precision of winding something smaller than a matchhead.

Dave Jones over at EEVblog posted a teardown video this week that goes to a place few of us have ever seen: inside a processor module for an IBM System/390 server. These servers earned the name “Big Iron” for a reason, as everything about them was engineered to perform. The processor module Dave found in his mailbag was worth $250,000 in 1991, and from the look of it was worth every penny. From the 64-layer ceramic substrate supporting up to 121 individual dies to the stout oil-filled aluminum enclosure, everything about this module is impressive. We were particularly intrigued by the spring-loaded copper pistons used to transfer heat away from each die; the 2,772 pins on the other side were pretty neat too.

Here’s an interesting question: what happens if an earthquake occurs in the middle of a 3D printing run? It’s probably not something you’ve given much thought, but it’s something that regular reader Marius Taciuc experienced recently. As he relates, the magnitude 6.7 quake that struck near Kainatu in Papua New Guinea (later adjusted to a 6.3 magnitude) resulted in a solid 15 seconds of shaking at his location, where he was printing a part on his modified Mendel/Prusa i2. The shaking showed up clearly in the part as the machine started swaying with the room. It’s probably not a practical way to make a seismograph, but it’s still an interesting artifact.

Open Hardware Laptop Built On Power PC ISA

Since Apple switched to Intel chips in the mid-00s, the PowerPC chips from Motorola and the PowerPC Instruction Set Architecture (ISA) that they had been using largely fell by the wayside. While true that niche applications like supercomputing still use the Power ISA on other non-Apple hardware, the days of personal computing with PowerPC are largely gone unless you’re still desperately trying to keep your Power Mac G5 out of the landfill or replaying Twilight Princess. Luckily for enthusiasts, though, the Power ISA is now open source and this group has been working on an open-source laptop based on this architecture.

While development is ongoing and there are no end-user products available yet, the progress that this group has made shows promise. They have completed their PCB designs and schematics and have a working bill of materials, including a chassis from Slimbook. There are also prototypes with a T2080RDB development kit and a NXP T2080 processor, although they aren’t running on their intended hardware yet. While still in the infancy, there are promising videos (linked below) which show the prototypes operating smoothly under the auspices of the Debian distribution that is tailored specifically for the Power ISA.

We are excited to see work continue on this project, as the Power ISA has a number of advantages over x86 in performance, ARM when considering that it’s non-proprietary, and even RISC-V since it is older and better understood. If you want a deeper comparison between all of these ISAs, our own [Maya Posch] covered that topic in detail as well as covered the original move that IBM made to open-source the Power ISA.

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Frances Allen Optimised Your Code Without You Even Knowing

In 2020, our digital world and the software we use to create it are a towering structure, built upon countless layers of abstraction and building blocks — just think about all the translations and interactions that occur from loading a webpage. Whilst abstraction is undoubtedly a great thing, it only works if we’re building on solid ground; if the lower levels are stable and fast. What does that mean in practice? It means low-level, compiled languages, which can be heavily optimised and leveraged to make the most of computer hardware. One of the giants in this area was Frances Allen, who recently passed away in early August. Described by IBM as “a pioneer in compiler organization and optimization algorithms,” she made numerous significant contributions to the field. Continue reading “Frances Allen Optimised Your Code Without You Even Knowing”