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Happy 200 Mr Dickens

So many plans, so much not done.

Now on Twitter @JulieSPorter

Look for some new sheep soon on SpiralSheep.

Posted in AmusmentPark.

From a TARDIS near by

I had to make one of these for myself

It is so easy to put off updating the ol blog. I have been rather busy with several mechanical music jobs, one was a bell unit for an Artizan, The other is a Cremona stack rebuild. It does not help that I am fixing up my shop while working on these things. Not to mention I have a liking for Doctor Who.

The Cremona stack is a challenge, Each pallet has to be drilled and fitted in place. more on this in a future blog.

And then there is the Dickens fair, Which means nothing gets done between October and the first of the year. Managed to get a friend to grab a photo of me. So the photo is credit to Ross Bernheim:

As it is after the first of the year, The blog is getting updated.

The Amy doll was a test for some puppets I am making for a future dickens fair. With luck, sometime in the next few months there will be some activity and previews here and elsewhere.

The comics on spiralsheep are getting some progress too. Spent most of the day updating comic press on that site. More comics have been scanned, a new drive for the G3 and my old copy of photoshop and the wacom tablet re-installed. Hard drive failures are no fun, even when there is a backup. Installing from CDs and original disks takes days if not weeks of time to locate every little driver detail.

This is just an interim update , as The blog seems to have been stuck on Mars for ever too long.

Posted in AmusmentPark.

The Royal order of the Mechanical Masonic Sheep

The last few weeks have been a rather busy blur. This started with the Nova Albion Steampunk exposition. I just returned from mars. More specifically the Contact conference presented by Cultures of the Imagination.

Contact, is an interdisciplinary gathering of Anthropologists, Writers artist, Filmmakers and Engineers. The last few years this has been held on or near the NASA Ames Research Park in Mountain View, Silicon Valley. It may be easy to describe this as the oldest and best known SETI conference. This just may be an excuse for a lot of bright talented people to get together and party. No one has yet to see a little green man (or woman) so, there seems to be some job security for those who like to listen for them.

This year the conference was more focused on the anthropology side. Possibly due to the economy there seemed to be an absence of Science Fiction writers. So get out there and start buying more books. As a robotisist, I tend to hang out with the NASA engineers who get to drive sporty little rovers on the other planet. This is a fun group, and I get to compare how much dust collected on the toy rover I got when Spirit and Opportunity landed, to how much is on the real thing,

MER exploring my messy desk

From Pixar, we had the showstopper of a presentation, The latest in photo-realism. With a series of stills, it was difficult to tell what was real and what was fake. The highlight was a 10 second clip from an introduction to what is possible. This could have been anyone recruited from a temp agency to give a short product pitch. That the product is the pitch makes it only all the more a little closer to the cliff called the uncanny valley. Masahiro Mori[1] proposed this theory as an explanation for the likes of Doctor Coppelia.

Sometimes it takes a strong pair of Doctor Coppelias’s rose tinted glasses to see into this. Even I have found some of my puppets and dolls a bit disturbing. I am not exactly sure what they are up to here. This does bring in some interesting connections to the need for 3D eyeglasses, to complete the illusion. I suggest that one should not get to attached to my friend Olympia. On the other hand frequent older readers to the main, site, have been able to use such rose and cyan tinted glasses to see into the precursor of Olympia, the doll sometimes known as Marianne Droz.

The french really do love Ben Franklin

The most surprising Contact, I made at the conference, was with a Marine Biologist who has done some amazing studies of human dolphin communications. Pop culture films from the 1970s aside, this may be our first contact with a non human equally intelligent species. Something well known to the likes of Homer and the great engineer and puppet maker from Alexander, my own hero, Hero. Here is a snapshot of his take on clockwork dolphins, who take a liking to Ajax.

It is all Greek to me

So leaving this fuzzy world of mars I next attended the AMICA meeting.

Now I love mechanical music, Those rocking rags and blaring marches from the 1910s and 1920s. This is much like fine scotch whiskey. It is an acquired taste. I also like Doctor Who, Puppet show and Mechanical dolls. My favorite episodes of this 40 something year old TV show involve these somewhat uncanny things. The more recent ones written by Stephan Moffatt. Recently he wrote about why actors from over the last 47 or so years should not return:

“… sometimes that can make your new and most cherished viewers feel excluded from the party. And Doctor Who has to absolutely be a brand new show…

…The moment it becomes something your dad wants with old codgers wandering about, it will die. It is not important to bring anything from the past. You could bring nothing back from the past ever again in Doctor Who and it would be fine.”

I kept thinking of this quote all weekend. “Something your dad wants.” Is this why some say Mechanical Music is doomed? Because it becomes about the music. Ironically, the last gasp of the first generation piano roll production ended with the Beatles in the late 1960s. These guys all passed on. The middle age kids of the time are now the old codgers of today. Ironically most of this generation do not like the blaring of John Phillips Sousa. But it is what they associate with going to the beach amusement park and hearing the rusty old squeezebox blare it out.

Now AMICA sometimes seems like one of these collections. Covered in dust an echo of a forgotten generation. The problem is that the older generation wants to preserve “Their way.” The conservative idea that the world does not change. That children are always the same and must be taught simple things before they become bored. Of course in this day and age, the Disney brothers would be locked up for frightening children and giving them nightmares.

Much of the broken fairgrounds junk was thrown in the trash. What remains is rare and sells for large sums. There are about a dozen mega rich collectors who hoard this stuff in their Mc Mansions, along with auto collections and the like. I say more power to them, the have preserved the world of their youth. Of course outside of places like San Francisco’s Museum Mequanic, children are not allowed to view these toys.

There are cultures where these older mechanical toys are taught to the children. According to one person I spoke with over the weekend, that many Americans are now working for these children. That there race is now somewhat smarter than our race. I do not agree with this assessment. It takes a lot of brainpower and intelligence to be ignorant and dumb and work the social welfare systems inside these tribal family groups.

Today those of us who are makers, some who identify in the steampunk moment, are creating new concepts from these trash heaps. I really wish there was a way, where Makers, Steampunks, Re-enactors and mechanical music enthusiast can come to a common understanding.

Now I have been spending the last month or three reading the history of the Panama canal before bed. This mess was the biggest engineering disaster the world has ever seen. The last of pharo’s gangs of labors toiling for the masters. Actually the canal is quite small, Smaller than San Francisco bay. Modern freeway projects move more dirt. and all that. So what does this have to do with mechanical music?

Well once the mosquitoes were abated by socialism, The white overloads who worked for Caesar Imperious , were able to create secret society clubs. These were all the thing back in the 1880s and such.

So I have decide to create the Secret Society of the Royal order of the Mechanical Masonic Sheep. Membership in this of course is secret. So only those who know that they belong can join. However this is an Open Source masonic order. So therefore any work done by the Mechanical Masonic Sheep, must be open for others to access. This by definition means that everyone is a member of my club. No one is or can ever be excluded.

The first rule is that there is not extortion to be had from other members. To counter this members must be helpful and donate information, to those who do not have it. No member can fine or tax any other member without just compensation. On the other hand members are free to contribute ideas time and material wealth to others. As everyone is automatically a member, this rule is completely voluntary. I am sure most will ignore it.

The tone of this order is modeled as a mash up of Mozart’s Magic Flute with Gilbert and Sullivan’s Iolanthe. So this is also a fairy masonic order. To keep things in line with the crazy weekend, Benjamin Franklin will be the patron of the order. Homer’s Odyssey the framework of the mythos. The god of the order are Isis and Osiris. And my own Palas Athena Governor. The bay Laurel is the official tree, and the rose the flower. Descartes is the philosopher of choice.

Of course this is all nonsense, most of the world is. I set out write something political in this blog and feed into the frenzy of the changing times we are witnessing. Instead I get more abstractinos from practical real world experence.

For me 100 years ago will always be the 1850s and 1860s. Because that was what I learned as a child half a century ago what one hundred years meant. 200 years was the 1770s which were exiting times in the world of mechanical automata, painting and just pure design aesthetic. There is a reason 2001 is my favorite film. I want my clockwork Heaven. The crystal spheres, silver gradients and the brass gears.

Now we find that 100 years is the age of the Panama Canal, The Titanic and ragtime music. A world many want to return to with a divided class labor force. You are as you are born. This is your cast. The height of the Raj of India. One god indivisible with justice for all. Not that I can improve on any of this. I decided a long time ago that I did not like the rotted well water of politics. This does not, invalidate my theory that with politics, is much like a well. That there must be a fair amount of brackish water on the bottom for the sweet water to flow on the top.

Drain the well of taxes and socialism too far and one is left with the bitter taste of bad water. Now I am rather selfish when it comes to politics and opinion, these are mine and You can not have them. Still I tend to be a liberal hawk. Probably from my upbringing inside the Silicon Valley industrial complex. Johnson’s Great society. How Taxes are supposed to work. What does it really matter after 100, a thousand or so of years, If people are lazy or not. Everyone contributes. Some philosopher said “to each according to his need.”

This is how the panama canal was built. How we went to the moon a half century ago. This is also how renaissance fairs, woodstock clones, burning man, science fiction conventions, Rock concerts, and a whole lot of successful things have and will be done. This is what happens when society collapses as the Media is us is soon. After reading Ken Follit’s Pillars of the earth, this may also have been how Cathedrals were built.

What is interesting, is that while there will still continue to be backlash at change, Some inspired some done by stupid methods. There are already forces at work, like the Royal order of the Mechanical Masonic Sheep. That counteract these. Much today would be like people in the 1920s refusing to use electric light, because god intended humans to see the light through candles and rush lights. Perhaps this is why some cultures would like to return to oil lamps. Rub them and the genie appears.

But the genie is already here. Some call this science. The problem I have as an abstract thinker, is that I have seen no evidence of the parental god. The one who punishes when bad and rewards the good. This is not to say that I do not have faith. Here again I am selfish, as my faith is not yours and you can not have it. Can god be simplified in the equation 2+2=4? Descartes though so, when he defined the sign for addition as the holy cross. The equals, shows the view of Solomon, with man below and god above.

So no matter what happens, god will always be with us in science. But should this be kept in ignorance? I am a Pan-deistic,Poly-theist. Or all the gods all the time. No one is right and no one is wrong. The real point from a conference like Contact is just that. What we have is each other, and after an almost infinite amount of time, rocks can sing to the sky, just as birds and fish can live together inside the imagination of the human or abstractly similar mind.

Posted in AmusmentPark.

A short history of the Midi filer project from floppy disk to 8GB SD

This is why I never blog. I get so involved with projects, there is never anytime for anything anywhere. Recently I set about to salvage a project from 2003. If I had been smart I would have blogged the whole thing. Who was to know the future.

Many years ago, or is it really decades ago, I started a project to read MIDI files from floppy disks. As luck would have it, someone actually wanted to pay me to do this. So off to Kentucky I went. The project was a disaster. Many people claimed ownership and the funding failed. After three to five years of development, the shipping date was always 6 months away. In the end they shot the horse.

In the middle of these near fist fights I was able to get the prototype unit working, which read Floppy disks in the popular MIDI formats, Sandard type 0 as well as the Yamaha and Pianodisc variations. This technology I was given as the partner I direclty dealt with wanted to have nothing more to do with it.

One of the other partners suggested I continue with the design. Several clients indicated an interest in another source of midi filers. I was given the specs for the Yamaha MDF-3 as a guideline. I had envisioned a system that would read the compact flash cards. This was actually suggested by my dad.

When I first took the project back to California, I set about to extend it to read Compact flash cards. The main controller was a DS80C320 chip. This was attached to a PSD and 128KB of external memory. Much of the issue the prior developers had, was getting enough data pins out of the system. To fix this a separate Atmel processor was used to scan a button matrix.

My first effort was to improve the button matrix. This I moved to a slightly larger processor (Still Atmel.) This was actually made. I was not given any budget for new main boards. These were large with a lot of dead space on them. I managed to make these things work. The main code was in C, with the button scan in ASM. While the 80C320 has two serial ports, these have to use the same baud rate, which was determined to be the MIDI baud rate.

The little mega 4433 ran circles around the 20mhz 80C320. It looked like a full midi parser would fit. I could greatly reduce the cost by 2/3 if I went only with the atmel chip doing everything. Atmel even made one with the same pin layout as the 80C320. The choice was further defined, when the first partner demanded all his hardware back. The second partner was still supportive, So I returned the hardware to the first and re-designed the whole thing using only Atmel. Only the 128KB memory remained. The second partner continued the funding.

I set a goal to have a dozen units ready for the next MBSI meeting. It was a mad dash. The boards were ready in time, but the program still had issues. I put some photographs from this into the Gallery here. I was surprised to see the corner of the old Overture monster behind my then state of art unit. I was over confident and did not include a debug port. I also made a mistake on the LCD controls, which caused a glitch every time the display was written. I also learned a lot about PC board layout. Fortunatly there are some good online resources such as the EDA tech forum and the conferences and daily updates I get from the UP media group. Check out the Update Newsletter I need to give them a plug every now and then.

Three months after the MBSI meeting a few units were shipped. These worked well. Over time I extended the system to read SMF1 files as well as SMF0 files. By the time I had this working floppy disks were dead. I was also deep into rebuilding the Caliola. The project was such a disaster I wound up out of cash and back living in my parents basement. No more trips to Swizerland.

I still wanted a compact flash reader. I figured to use the file parsing code written for floppy disks. Reading the CF flash card was easy. I quickly reduced the design to fit on a small proto board. The dozen or so unsold floppy units still a bit of a bother. I am a backroom engineer. The LCD display was too big for the case, so it sat on top. At this point, I did not want to spend any more on the floppy box. It worked, but did not look pretty. I have no idea what ever happened to the 5 units I sold. The users never complained, and indicated that the boxes were functional and worked.

I was working with Spencer Chase on improvments to the e-valves. Spencer assisted with the development and the 3 units, of the CF card versions sold quickly. One is in regular use, and has been for a number of years. I took back the Spencer’s to upgrade and it has taken some years to get back to it. I have no idea what happened to the second unit.

In the image gallery, one of these “Toaster” units is shown. I found some old photographs, one which shows the large floppy board next to the “mini” unit for reading Compact flash cards. I could not afford a FAT32 card and the small FAT12 cards worked funny. The solution was easy, to add one more address line and read the disk sector as a memory map. Easy to debug. set the registers and the AVR studio debugger would show the sector. Bit dicey though as the bytes have to be read in order

Other projects intervened, and I pretty much decided I had done with MIDI filers. As with all dead end projects, I figured to revive them somehow and sell off what assets I could in time. The little CF readers are cute, and can do a lot. I was more than happy to revive and make a new batch for Larry Doe and the Keystone. The catch was that MIDI in was needed.

So the code was completely re-written. After some extensive testing, a unit was shipped. This had a problem with the system resetting during the perforation. While updating the companion MIDI “primary” controller board, I discovered and issue where input collisions happen in the interrupt even though the flag is technically clear.

Now for the pea soup course. In early 2009 I learned about the reprap project, which is a 3D printer. As I was installing a Theater organ and building a 20 note busker, I did not have the time to look into 3D printing. A desirable device, when one wants pretty cases for electronics. Then an old friend wanted a “primary” board. Sell the rest on eBay, he suggested. Even that was two years ago.

Back to the Reprap. The hardware on this is almost identical to my Midi filer, and the MIDI “Primary” boards. Same processor. There is also someone in Germany selling a system using SD/MMC cards. The boards are full of SD “How to” postings.

Is SD really that simple? Compact flash was trivial, but it needs a lot of I/O pins and a large layout on the board. SD on the other hand promises to only use the same pins as the system program interface. On the Floppy midi filer, I used some of these pins for the key matrix. Could one be modified to use SD instead of a floppy?

I built a reprap motherboard with SD. Even started to convert my 8K fat reader from MIDI to G-code. Yes, Sophie, I am actually getting to things that happened this month! So I went back to the old unsold floppy filer boards. That lack of a debug port really hurts. If I had 17 seconds to do over, I would have put that footprint down. The CF boards have a debug port, But the Ice200 broke, and the mega162 put the JTAG on the same pins I use for the CF DMA. Another dead project revived. Using stuff about the house I made a USB adapter. Ice200 comes back to life.

Many time I have attempted to fix the issue with the LCD on the filer board not being memory mapped. Backing up a bit, I went over the logic again. On the CF version I used a 74LS138 as I should have in the first place. With only two selects on the filer and one a select high, I went all cutesy and did it with logic gates. The problem was I was always one inverter short.

I fixed the filer, by adding in gate to OR and invert the readwrite line. This was all and well, apart from that the memory mapped all over the lower 32K with duplicate windows everywhere. I never liked this fix. it did not work with the mega162, which is needed if one wants to write MIDI as well as read MIDI.

A few days ago, I figured it out. By combining the read write invert with the address invert, I am able to fit the needed logic into the two existing chips on the filer. I also decided to move the selection back down to the lower memory. In debug mode the m162 only has a tiny window for memory mapping. Even with the current fix, the DMA takes 256 bytes per address. I really do not like switching on the latched memory buss pins. The 128K memory is sensitive as it is.

Now it is possible to write fat code that fits into 8K and in C too. At least for FAT 16 cards. On the other hand I have the 128K boards and I really need to sell them off to make the world better and people happy. So I set out to rework the filer boards. The first was to make the CF filer board the same as the floppy filer. This to test the LCD logic.

A new issue arose, The button matrix, which dates back to the old 4433 processor, used the system program pins. The LED indicators were always an option. So these could be done away with. This left two lines to be used by the matrix. Two lines also needed to detect Card insertion and write protect. As the chip is full, no writing is possible, so that can be ignored. Detecting the card is done at power on, so this can be a poll on the card ready bit. — Then an epiphany. Play is often combined with pause, so that frees a location in the key matrix. This is perfect for placing the write switch such an input can be shared with the record logic. It is also possible to add the card detect to the key matrix. A problem, that has bothered for some time suddenly disappears like an illusionist trick. The problem never existed in the first place.

So the lashup was complete. The logic worked on the mega 162 board. Fixing the Ice200 and connecting the SD card to the system program pins. The magician stands ready. Nothing up the sleeves he says. And the directory loads into the external Sram. Changes are made, The 8GB card comes ready. The directory loads. One single cluster, 32K fills one bank of the 128K external memory.

What a sight. The entire contents of the first developments Hard drive was only two gigabytes. Here it is loadable into what was originally a system for reading tiny little floppy disks. Every midi file I have takes a small fraction of this card. It is a lot of button pushes to get to any one of them, at least I implemented hierarchical directories.

Of course it is only a magicians trick, The code sees the 32K sector wrap to zero and the system crashes. Sill the 8GB are readable. As all ways there is more to do. Sectoring logic to be written so that one can step through hundreds, if not thousands of files. The SD code is also a bit more complex than CF, I had to switch off FAT12 and Piano disk support to add the init code in. The floppy and CF access was DMA, so a few bytes to set a register and then read the DMA window. SD requires almost 64 bytes of tables to be saved which detail the commands Used for card type detection. While a lot of these are zeros, it takes two bytes to load them into a register, where as if stored as a table, the read loop takes only a handful of bytes.

There is still much more to do, But the main issues are resolved, The old boards awakened from sleep. Not Zombies or Gouhls, these boards were never finished, the unmade, or unborne fairies of the aiether. Soon to come forth, with new dresses, and fly on the desires and dreams of all who want a dependable and reliable way of saving more MIDI music than can be had at any cost.

Posted in Rbt Houdin's house of magic.

Rebuilding the UM1

Some years ago I was given a UM1 that had the logic supply connected to enough voltage to crack the power regulator. Most likely every chip was blown apart.

I had used a similar processor for a video conversion project, which has long sat documented in the video section of my website, an early form of blogging from the late 1990s. I still had a tube of these processors, although the ones I had were 52 pins, where the processor on the um1 had 44 pins.

Since I frequent the surplus shops of the silicon valley, I located most of the chips used in this board. Given supply issues, I have for other clients developed a similar board using a more modern embedded micro. More on this in a later blog. The short version is that I had a UM0 and wanted to keep the same setup codes and configuration on my Caliola.

By connecting a MIDI sniffer to the wire, I was able to detail how the setup system exclusive messages worked. Technically these are supposed to be documented in the manual. The manufacture is not registered so the device setup for these exclusives is the research mark. Which means that this data is open and unprotected, so I could use it.

I noticed that the Octet setup program had a mechanism for uploading new firmware updates. These updates were available on the web. When opened they were found to be in the common format used by the MC68HC11. There was even included a small program called a talker.

Locating the needed chips, the question remained, would it be possible to reprogram the actual UM1 unit from the web updates?

The first step of the process was to remove all the old chips. This was done with a heat gun. The board is slowly heated to 210degrees C. My thermocouple slipped and some of the sockets got a little cooked, the result was a clean board. The front panel was the worse for wear as the switches melted completely.

After the chips were removed, the traces were cleaned up and documented with the Eagle layout program. Oh for the days of Sam’s Photofacts. I wonder if the library still has the shelves of 1950s and 1960s era television schematics. Actually I was able to get schematics for my late 1990s Panasonic, telly. So major manufactures do still provide repair personnel this needed information.

The designer of the UM1 had been dead for some decades now. The successor does provide manuals and firmware files as noted. I took a peek inside these files and located where the device tables go. In order to bring a new system up from scratch, a few additional items such as the serial number are needed. This was easy to get, as it was pasted onto the blown up chip. The firmware for some reason does not contain the device string, which for some reason is always UM1 even on a UM0.

I was a bit concerned that I would have to solder in the new processor. These are surprisingly still available. This package called a PLCC is no longer made. When the EU adopted RoHS this format was discontinued. In the surplus store I was able to find a socket that would solder onto the board, so anyone in the future who needs to fix this can swap the chip out.

Once the new chips were in place it was time to reprogram the unit. I could have connected in through the MIDI interface. The 68HC11 contains a serial boot mode. There is a photograph of this in the attached image gallery. These signals are easy to access on the 74HC02 chip labeled U9. For future reference the pins are Rx on pin 8 and Tx on pin 6. Laurent must have used jbug as the wiring of these pins is straight out of the college textbooks.

The 68HC11D0 contains no internal flash memory. It is easy from looking at the schematic, to see where the memory starts. 0x2000. This is where the jbug11 talker is loaded. The firmware loads in at 0xE000. This is where the SYSEX tables are stored.

The first step is to upload the firmware from the website or setup disks(If available) This can be uploaded by simply renaming the file extension from .frm to .s19. Since the firmware does not overwirte the device information, this will need to be copied from a working UM1 The format is exactly the same as what the UM0/UM1 setup software sends, so this can simply be done by dumping the read firmware sysex

Once this data is written to the first sector of the 0xE000 address, there should be enough code to get the whole unit working. In my case I replaced the MIDI opo-isolator and the U9 74HC02 chip. I was able to connect using the Octet setup program. Just to be safe I re-ran the firmware upgrade.

It should be obvious that a working UMx is needed to get things stared, this blog is about repairing units. There are much better and cheaper ways to make similar devices, which is why my own boards are only functionally equivalent, with no common hardware.

Naturally the diagnostics did not pass as I had not seated in the driver chips. These are often out of stock and I had to get some from other units for testing. Once installed, The diagnostics pass muster and the unit is once more operational apart from a missing chip for the PWM and the melted front panel. The UM1 works fine without the front panel, but there are some unsightly holes where it goes.

Repairing the front panel did not have quite the same success. I socketed these chips, which means the display plate no longer fits. The surplus hex switches are also much larger and do not have the same pinout, so give the wrong midi channel. There is also quite a bit of flicker on the LeDs. Most of these units are set once anyway, so the front panel is a nice extra, but not needed.

It is interesting to compare my “clean room” copy to the original. There is no hardware in common. I do parse some of the same setup code which is what makes my unit a clone.

The repair on this is also quite expensive, The obsolete processor sells for 10s of dollars, when in stock. [Currently at this I have some similar E2 processors for sale on eBay]. Atmel processors sell for a few dollars each, These contain many times the storage space and do not need the external logic. The replacement parts on the UM1 were around 35 dollars not counting the driver chips. It probably would be cheaper to buy a new unit, if such were available.

Over the next few months, I expect to sell some of my compatible prototypes online. I much prefer consulting and building devices to order. I also am willing to take on repair of the octet systems as well as any Broadmore power rolls that may still exist.

Posted in AmusmentPark, Rbt Houdin's house of magic.

RepRat main controler

I mistyped the name Reprap in the firmware code. Happy accident, I now have a name for my Repstap/Mendle project. This fits in well with the ratsnest of wires on the SDK500 mega168 project lashup.

As I do not care for the bloat of Arduino, I am writing my own firmware in assembly. Much of this I borrowed from one of the MIDI compact flash projects. This way I can use my already small footprint FAT12/16/32 code.

SD uses a serial interface for comms, so much of the low level code for initializing the card and reading blocks needs to be re-written. Using an AVR freaks tutorial, for butterfly SD card connectivity is a good way to test the code.

The supplier makerbot had a few remaining v1.2 controllers. This enabled me to not make a board from scratch. Since the SD card socket is in place I swiched over from the rats nest to the v1.2 board.

Weirdstuff, a surplus store in the silicon valley has some SD/MMC adapter cards for about 20 cents [USD] at this price I bought a couple dozen. With a heatgun and a thermocouple poping the connector off is a simple process. Provided one does not melt the plastic.

The makerbot/reprap “motherboard” controler v1.2 board has the pads and holes in the right place for these sockets. The shield on the cheap sockets is a bit smaller. Removing solder mask in these places allows for the MMC card to be attached to the board. Image 1 in the gallery below details where the solder mask was removed.

The board can be assembled either for use with an ATX supply or with a power brick. The 3.3 volt regulator I got from jameco has a different footprint than the recommended one. It is not a good idea to power a 3.3v regulator off of a 5v regulator. There is not enough headroom for the regulator to work. Looking at the ATX connector, it seemed the most efficient way to get power would be to tap the 12v line and add a standard 5v regulator. It worked out nicely to make a little bridge using the leads on the filter caps. This also gives some points where the bench supply can inject power.

The schematic indicates that the 12V is sent through the RJ45 connectors to the external controller boards. I like to recycle/reuse stuff, so I got some block of RJ45 from weirdstuff, which I de-soldered. Some of these I melted the tabs as I did not have any heatsheld. I mounted one of these extra connectors in case I want to inject power through this connector.

It is a bit annoying that the power switch is a relay trip. This means the AVR must always be powered. I still need to make some usb/rs232 boards for the FTDI chips I have about. These use an odd pitch footprint, which requires at least a breakout board. Ironically, I want to get this stuff working so I can drill the boards. I guess that is the rep part of the system. The rapid part is what my (C)NC is not.

The gallery below shows some of the steps in bringing these boards online. I moved the ex at90s8515 code from the mega88/mega168 to the mega644. The mega168 to mega644 path is fairly straightforward. Some of the interrupt vectors are different. Mostly due to the second optional USART.

Now that I have a more stable less of a ratsnest prototyping setup, I expect to make more changes to the firmware. I am still considering using i2c to drive the steppers. The current layout consumes most of the pins. This makes adding multiple heads/axis a bit awkward. There are also a shortage of pins which can be used for button panels and readout displays. Of course these can be implemented through the serial coms, which would involve removing the existing code from the system.

Posted in Egyptian Hall of Mystery.

3D printing for the rest of us, The project

Recently I have been active posting to the reprap forums. There I started a thread relating to my observations after reading the forums almost daily for a year. This thread can be read on those forums.

I have a rather macabre and dry sense of humor. Much like the mummys here in the hall of mystery.

Reprap is a bit of a mystery. Something real that has come out of what is a dream and a bit of a lie. There is still much promise to be had with the current technology. Most of the old timers must think me a bit loopy as I tend to rant against software versification. That only the newest hardware and software are worth using.

For almost 20 years from 1982 to 1998 I made my living directly off either selling or working on the design QA team of apple products. Steve Jobs was my boss’s boss. We did what Steve wanted. If not, well lets just say Apple no longer designs laser printers. At least my products were a success. The short of it is I use Apple products. I do not download revisions because I am told to. I download what I need when I need it. Because it is a better product.

This is what damaged apple in the late 1990s. I did not agree with it then and do not agree with it now. If it is not broken, there is no need to fix it for the sake the repair bill. Which is usually padded anyway.

If this is how you feel, then stop reading now and return to the facebook fad crowd, because this sheep is an Arcadian sheep, who believes in recycle and re-use. If it is not obsolete, then why bother with it, it will become obsolete soon enough.

So what made Apple great, and why I like so much the work of the Disney brothers is that they produced something new. Reprap is like this a new way of looking at how one can make things.

Unlike the lie of most dreams, reprap has some truth that makes it quite likely to succeed. There are a lot of issues still to be had. One of these issues is speed. This has been a problem with my existing CNC equipment. It is too slow and the design path takes forever. I am lucky if I can scan in a part and make a 3d model in less than 16 to 18 hours.

Then comes the issue of making the part printable. There are several divergent paths for the reprap. The core team made a java applet. This does not work on the mac. Since the hardware was expensive and built to last, there is no one to test the code, so the code sits somewhere in cvs hell. The problem is that most modern programmers depend on the corporate need to upgrade early and often. Little thought is given to simplifying the code to run on the lowest common denominator.

So instead of bothering to fix the mess, a new branch went off using python. So we are in the jungle anyway. One adapts. This is an experiment anyway, with just the right amount of anarchy.

The real gating force is that my machine tools are slow. So the best place to start is with the bottleneck of the 1989 drazzi motor controller. I need to make some rollframe parts for a client, so what better than to upgrade the system and mill these parts. At the same time look into how the system can be improved.

The shop is not really a place for the latest in computer hardware, So the goal is more for an NC controller than a CNC, where the build files can be read off of a smart card. I already have the electronics for reading compact flash card MIDI, so making these changes should be quick. We will see. a days project turned into a week, and is more likely to take a month.

The real question is making the motors move. In practice we are just drawing a picture. In 1773, Swiss engineers could do this with cams, so it must be a trivial process. The Swiss even used a Z axis on the pen or pencil so the final pictures look hand drawn. The doll that draws with a pen even knows when to shake the ink from the tip. The artist doll with a pencil blows the dust away.

Of course the french kings that these toys were made for were beheaded, But that is only poor solution to the problems of management. The new managers, were quick to realize that scaled up these simple toys could be used to rivet battleships automatically. This was also a simple solution to the Irish problem. Since automation did away with labor.

As I have noted, my late friend John Grass sold me the machine to prove a point. That one needed to understand the basics first. I was the only one who could make the drazzi work. It only would run one program and draw a picture of a running horse. The reprap seems to have the same issue, it currently is designed to keep the unemployed labor occupied dreaming of change, and not of what is needed.

Posted in Egyptian Hall of Mystery.

Make a mechanical computer

Through my computer history and horology contacts, along with some targeted searching on the net, I have collected a good deal of the designs for Babbage’s Analytical engine. The next step would be to visit the archives where the papers are stored. Doran Swade estimated that it would take his team some millions of dollars to do much of what I have done.

Of course our methods are different. Doran, is working to make it just like it would have existed in the 1850s or 1860s. Doran has good arguments as to why a mechanical computer, designed in the 1830s is not likely to have been made before about 1853. His goal is to answer the question, could it have been done then? His approach is to match the metallurgy, surface finish and make a 19th century machine in the 21st century.

My approach is more pragmatic. As far as Alan Bromly or Tim Robinson were able to learn, Babbage did not have the concept of an instruction set. This makes any modern re-construction suspect. The other issue is that the Analytical Engine was huge, about the size of a steamboat or locomotive.

Bromly left some fascinating articles written in the early computing and horology journals. These observations combined with a simple paper training computer called Cardiac, produced by Bell labs is a great entry point into making a 3 digit decimal computer using Babbage’s concepts.

By scanning in much of the publicly available information, I have made some 3D models of the adding mechinisims, These look perfect for making on a repap 3d printer. This is where I was a year ago when I discovered the world of three dee printing.

So over the course of the next few blogs, I will take a look at the reprap process, and just how practical will it be to repstrap a Mendel.

Posted in Egyptian Hall of Mystery.

Welcome to the Egyptian Hall of Mystery

Welcome to the Egyptian Hall of Mysteries…

The yellow Drazzi …

Many years ago my late friend and mentor John Grass sold me a desktop CNC machine. John was a machinist of the old school, and could not make the machine work. I think he wanted to prove a point, that having something was not the same as wanting something.

Here is an image from the sales brochure:

What the machine looked like when new.

The machine came complete with all the manuals, and a Dos program called RobotMart. Many times I searched the net for more information on this. Several years after I acquired the machine in I was able to upgrade the Dos program and purchase a few more collects and accessories. I set the machine to making roll transports for Piano roll scanning. I also used it to create some parts for a mechanical doll. More recently I modified some hobby gears for use in a difference engine model.

At the time I lived in a 2 bedroom apartment, I leased the machine in exchange for shop space at a friends company. This worked out well. I was also able to make an EDM sinker machine and a watch pinion cutter. The the dot com era came to an end. My friend moved his tools into a Silicon Valley Garage, where I continued to use it for making roll-scanner parts.

We nicknamed the machine “Yellow Drazzi” as the eastern European name rhymed with an alien species on the Babylon-5 show, popular at the time. Where there were Green and Purple Drazis.

My work took me to Kentucky were I worked for piano movers designing a floppy disk MIDI playback system for pianos. This company failed after a few months and I was left with the floppy disk player to manufacture on behalf of one of the partners. This poor machine sat idle.

My workshops are in a barn like structure in my parents back yard. This is a potting shed, not water tight. I did not want the machine rusting, so left it in my friends unheated garage, Which also gave me access to the Bridgeport mill and atlas lathe. When it came time to make the feet for my Caliola Pipes, having to travel 60 miles to use it I moved the machine to my parents garage.

Over the years I have owned this machine, I have wanted to speed up the axis, which move around 5 to 10 inches per minute. When the machine sat idle, the fans developed a rattle, which was annoying. A few weeks ago I took the controller apart. Replacing the fans with new ones that glow with blue LEDs, these fans were half the price of the black ones.

While I had the machine apart I drew a schematic of the controller. The electronics were made in 1989. The stepper chips were manufactured through 2008. Searches of the network, I found better programs such as KCam and Mach3 to run the machine. The controller was compatible with these programs. It is like getting a whole new machine to play with.

For the last year I have been reading the Reprap forums and blogs Having worked with printers and scanners in the 1990s I have collected quite a few rods and steppers. Having spent so much time consuming information from these forums and blogs, It is time to start sharing my own progress under the name of sheep. Since I am simply just another sheep in the fold.

The first plan was to use the Yellow Drazzi as a repstrap. This may be a bit slow, as the old stepper controllers are resistive limited and max out around 10 inches/minute. A desire for speed improvements, has lead me to completing the reprap (now Mendel version) stepper electronics. While this will not run the coffee can steppers, I should be able to mill the Mendel parts on the Drazzi.

The ultimate goal here is to be able to replicate, not only a Jaquet-Droze style keyboard player, but the connected pieces, such as Babbages analytical computer, The mechanical calculators from Swilgue’s astronomical clocks, and the Antikeythera device. This while at the same time looking for work/contracts, speaking at conventions and working out a new act for the Dickens Christmas fair. So there may be gaps here as these project progress. No promises on updates, bit there is a lot to share and much more to come…

Posted in Egyptian Hall of Mystery.

Bird in a box.

Somewhere I seem to have lost almost a year. Should you find it, please return it. Hopefully I can maintain a better blogging schedule. There are some exiting new things happening.

Last spring I came close to making a small 20 note organ in 1 week. Everything was completed except the pipework. Shortly after I started making and voicing the pipes, a family of birds moved in and made a nest in a box of pallets, which are for my w146 band organ.

It was difficult getting photographs of the birds. With some effort I managed to snap this picture. The birds were bold and seemed to enjoy watching me voice the pipes. Later when I took the nest apart after the young one left, I discovered that they were using the shavings from the pipes, as I made the pipes! Clever birds.

Bird who moved in

Bird in a box

Finally a I got around to downloading the photographs of the completed pipes. Here is the image.

It has taken me some months to get these items uploaded. I was called back in to complete the Theater organ I was installing. This project took until October of 2009!.

The 20 note organ was a success. I was able to take it to Several events and rallies. Below is a photograph from 2009 sutter creek.

I was also able to take the little 20 note organ to Participate in the 2009 Dickens Christmas Fair. Since the photographs were taken I added a nice top. I also made a new costume. Part of the reason I have been behind on my blogging. Of course, when one is so busy with a production like Dickens (there were 1000 performers this year) I have no photographs of me entertaining the folk entering the cow palace.

If someone did get a photograph, I would like to see it. Of course I have plenty of photographs from when I was in the Dark Garden window. That seems to be the nature of the show.

Posted in AmusmentPark.