Designing Space-Rated PCBs

We’ve reduced printed circuit board design to practice so much that we hardly give a thought to the details anymore. It’s so easy to bang out a design, send it to a fab house, and have ten boards in your hands in no time at all. All the design complexities are largely hidden from us, abstracted down to a few checkboxes on the vendor’s website.

There’s no doubt that making professional PCB design tools available to the hobbyist has been a net benefit, but there a downside. Not every PCB design can be boiled down to the “one from column A, one from column B” approach. There are plenty of applications where stock materials and manufacturing techniques just won’t cut it. PCBs designed to operate in space is one such application, and while few of us will ever be lucky enough to have a widget blasted to infinity and beyond, learning what’s behind space-rated PCBs is pretty interesting.

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Refurbishing Armored Tablets

Who can resist the insane deals on bizarre hardware that pop up on auction websites? Not [Dane Kouttron], for sure. He stumbled on Armor X7 ruggedized tablets, and had to buy a few. They’d be just perfect for datalogging in remote and/or hostile locations, if only they had better batteries and were outfitted with a GSM data modem… So [Dane] hauled out his screwdrivers and took stuff apart. What follows is a very detailed writeup of the battery management system (BMS), and a complete teardown of this interesting tablet almost as an afterthought.

First, [Dane] tried to just put a bunch more batteries into the thing, but the battery-management chip wouldn’t recognize them. For some inexplicable reason, [Dane] had the programmer for the BMS on-hand, as well as a Windows XP machine to run the antiquated software on. With the BMS firmware updated (and the manufacturer’s name changed to Dan-ger 300!) everything was good again.

Now you may not happen to have a bunch of surplus X7 ruggedized tablets lying around. Neither do we. But we can totally imagine needing to overhaul a battery system, and so it’s nice to have a peek behind the scenes in the BMS. File that away in your memory banks for when you need it. And if you need even more power, check out this writeup of reverse-engineering a Leaf battery pack. Power to the people!

Waterproof iPod Touch video boombox

Popular Mechanics contributor [Anthony Veducci] wanted a virtually indestructible video player that he could use anywhere. Not finding a commercial solution, he decided to build his own. He already had a large waterproof case and another for the iPod Touch. The 8″ display came from an iPod accessory. Unfortunately it was developed before Apple implemented their stupid accessory locking, so he had to use an Apple approved video cable through several adapters to get it to work. The speakers were also salvaged parts. The case was assembled using a jigsaw and a whole lot of epoxy. The speaker openings are covered with latex from a pair of gloves and everything is sealed with silicone. We’re usually trying to escape technology when we head outside, but we’ll be looking back at this the next time we need to ruggedize something.

[via Gizmodo]