When you want to see the stars, find someplace dark
I have been messing about with electronic circuitry for almost four decades. I recently came across an early example of my work. The device is a digital event counter built around classic 74xx series logic. A chain of 74190 decade counters feed a set of 7447 decoder drivers and seven segment LED displays. A plastic project case with switches and connectors reminds me I have been building little devices for a very long time.
I am preparing to release a design under the Open Source Hardware Association definition. By releasing a design this way you allow the electronic maker community to freely share and use the design. When following the community rules for open hardware, you can mark your equipment with the open source hardware logo. The logo itself is released under a Creative Commons licence (CC-SA) and is likewise free to copy and use, if you follow the rules.
While the OSHWA website links the logo in KiCAD and several other formats, it does not provide the logo in Eagle format. Off to the web to find an Eagle library with the logo… Hmmm… Found one, but it has issues.
I am currently putting the finishing touches on another printed circuit board.
A PCB is laid out with specialized software, drawn on the computer screen. The software can then generate CAM files that are sent to a board house, a manufacturer who can take these files and create a physical PCB. The PCB is thin layers of copper etched to create the patterns of traces laminated onto a fiberglass substrate. When designing the PCB each component, each copper conductor, each trace, is carefully positioned by the designer on the screen, dragging objects colored lines about to create a solution.
The golden yellow glow that has dominated the night for generations is disappearing.
The yellow glow of sodium light has been both celebrated and reviled. While the glow can be attractive in night scenery it also creates inhuman tones in faces and photos of people. Movies have been shot under sodium lights, songs reference the golden glow. Astronomers both professional and amateur prefer the lights as the light can be easily filtered from view.
It is always a good day when I drive up the mountain to a broken telescope, then drive down leaving a working telescope. Easy to say, not always easy to accomplish, the simple statement obscuring a day of struggle to solve the problem and fix it.
The Keck 2 telescope drive is a complex beast of dozens of relays, miles of cabling, servo amplifiers and power supplies, plus several circuit boards designed and built in the 1980’s holding a bewildering array of arcane logic.
The Keck Adaptive Optics systems are workhorse scientific instruments. Equipment that has resulted in so many great astronomical discoveries. The AO systems have also seen a great deal of improvements and upgrades through the years. New computers, a new wave-front controller, guide star lasers added, new cameras, different science instruments, and much more.
Eventually I just get fed up with it and insist we spend some time getting rid of it. With no AO use scheduled for a while there is a chance to spend a couple days ripping out this pile of cruft. Identifying and removing unused boxes. Following cables to nowhere, wire cutters in hand to snip away the multitude of nylon zip-ties.
We remove three large armloads of cables and other gear, carring the pile down to the electronics lab for sorting through and disposal. Most of it is horribly obsolete, things like KVM’s for PS/2 style mice and keyboards, or cables for old Sun computers. Most of it will simply be thrown out. It feels so good to get it out of AO and to clean up the place a little.
I called this pile of junk cruft, a word that drew funny looks from my co-workers. You don’t know what cruft is? What sort of nerds are you? Sorry, cruft is what I have always called leftover technical junk.
Cruft is jargon for anything that is left over, redundant and getting in the way. It is used particularly for superseded and unused technical and electronic hardware and useless, superfluous or dysfunctional elements in computer software. – Wikipedia
It turns out that the word has a long history in engineering and computer science with a heritage that includes MIT and Harvard. It is indeed the proper word for the detritus that had been accumulating in the AO vault.
I have previously covered the importance of warping, tuning the Keck primary mirror segments for optimum optical performance. Warping has been my responsibility for some years now. Reading out the settings of the thirty strain gauges on the back of each segment is performed by a test fixture, a computer and a sensitive data acquisition system. Over the last year I have designed, built, and programmed a new test fixture.
As this is the third generation warping test fixture the name of the software is obvious… Warp3
The tropical environment of Hawaiʻi is not kind to optical instruments. Tropical humidity can cause a host of issues ranging from corrosion of metal parts to decay of wooden and cardboard telescope structures. For those of us who build and use small telescopes the issues of tropical heat and humidity are rather concerning.
I have seen camera lenses lost to the white fungus. A friend once showed me a Canon 70-200 f/2.8 L, a $2000 lens, with fungus covering internal elements. Even on the “dry side” of Waimea the humidity was high enough to allow fungus to destroy this lens.
The problem is not an issue on the summit of Mauna Kea. The high altitude air typically exhibits a relative humidity of less than 10%. Several references note that a humidity of above 70% is needed to promote fungal growth on optics. We see no issues with fungal damage to the mirrors or instruments on the big ‘scopes.
Below the tropical inversion layer (about 6-7k feet) it is another issue entirely. Near sea level, where most of us live, humidity can remain above 80% much of the year. The warm and humid conditions of these islands are idea for growing anything, including the omnipresent fungal gardens that create the smells of a tropical landscape. Fungus is inescapable in this world, the spores drift on the wind and an stay dormant for decades, anywhere conditions are suitable fungus will grow.
The possibility of equipment damage was a major element in our buying a house. Waikoloa is located within one of the driest areas of the island. The humidity typically hovers in the 50’s, dry enough that I have had no issues with the multiple telescopes stored in the garage. Still, I do inspect stored equipment periodically, looking for the dreaded white fungus or other damage wrought by this tropical climate.
It is not a single species of fungus responsible for the problem. Apparently quite a few species are able to colonize an optical surface. Looking through the literature I find referenced to multiple species that can grow on optical glass…
The fungi which grow in optical instruments belong to the groups Phycomycetes, Ascomycetes and Fungi Imperfecti. The following species were frequently isolated from instruments which had been in New Guinea: Penicillium spinulosum, Thom.; P. commune, Thom.; P. citrinum, Thom.; Aspergillus niger, Van Tiegh.; Trichoderma viride, Pers. ex-Fr.; Mucor racemosus, Fres.; and M. ramannianus, A. Moeller. So far, Monilia crassa has not been isolated from Australian instruments, although Dr. W. G. Hutchinson (5) of the United States, found this to be a common species in the Panama zone, and it has also been recorded as frequent in West Africa by Major I. G. Campbell. – J.S. Turner, et al.1
I admit that the fungus can be pretty, in an odd sort of way considering the damage. Under a microscope it appears lacy, the mycelium fibrils growing across the glass in search of more nutrients to support the colony. In the center small round fruiting bodies are the launching point for new fungal spores.
I recently had another round of battle with fungus while restoring a collection of instruments that had been stored in a garage on the side of Hualalai. The high humidity had wrought impressive damage on both the optics and metal components of the telescopes. And there is fungus! Found in the eyepieces and on the telescope mirrors. During the cleaning and restoration of the instruments I found it necessary to completely dismantle many optical assemblies just to remove and kill the fungus. I some cases I was in time, but not completely, it is not without regret that I throw a $400 eyepiece into the trash.
Dealing with the fungus is imperative, cleaning and killing the growth before severe damage can be done may save the equipment. If the growth is severe enough the glass surface and the coatings can be damaged. Apparently the fungi can excrete hydrochloric acid, etching the surface and creating permanent damage.
Killing the fungi requires a solvent that will both kill the fungus while not damaging the optical surface. I find references to both alcohol as well as other solvents. A mix of 50/50 hydrogen peroxide and ammonia is recommended by some references. Along with cleaning the glass I am careful to soak all of the structural elements as well. The tube, the spacers and lock-rings can all harbor minuscule colonies or spores awaiting suitable conditions to grow again.
Optical fungicide solutions tend to be expensive and hard to obtain, but they are available from some optical equipment manufacturers. Alternatively, you can use a 50/50 mix of hydrogen peroxide (H2O2) and ammonia (NH3). Usually, 5 ml of each is adequate (10 cc in total). Mix just prior to use and do not store the mixed product. – Ismael Cordero, Community Eye Health Journal2
Living in a warm humid environment one must be vigilant and ready to deal with issues when found. Examine optics regularly, keep a can of WD-40 next to the tool box (and use it), store optics and electronics with plenty of ventilation and reduce the humidity to well below 70% if needed. Extra vigilance to preserve valuable equipment is the price of living in paradise.
I am no stranger to point-to-point wiring. I routinely use the technique to build small circuit boards. Well done point-to-point is a permanent and reliable way to build a complex electronic device.
But then there is this circuit board assembly I came across… At first glance it looks like a wire wrap board. But there are no posts, the wires are flush to the board. Neither is it traditional point-to-point wiring, the wires are not terminated to solder pads beside the pins being connected. I had never seen a construction technique like this.
The board is an old PCB assembly found in a storage cabinet while clearing out the old junk that has accumulated about the observatory. No idea where it came from or what it was used for, the only clue is some writing on the box… “Keck level shifter”, Perhaps a piece of a detector controller? Someone clearly put a lot of work into the board at one time, now it sits in my office as unknown junk. It is the odd construction technique that caught my eye and led me to hang on to the board, at least temporarily. What is this?
A closer look under a microscope shows a connection clearly made by some sort of spot welder. There is a neat little hole through the insulation at each connection. Stripping back the insulation reveals a very neatly welded wire. Each wire is welded to the flat bottom of each pin socket. Every component pin is socketed, this includes all passives, which are mounted to headers and plugged in alongside the IC’s.
There are a number of advantages to this wiring method… The connections should be very reliable and robust, the weld is a nearly ideal electrical connection. As no connection pads are needed beside each socket the density is much higher using less circuit board real estate per component, you can cram more on the board. Interestingly the connection technique can be used without terminating the wire, daisy chaining to the next connection point.
There are disadvantages as well… The method clearly requires some sort of welding equipment with perhaps an automatic wire feeder and cutter, a built-in microscope for positioning the weld, and more. Clearly an expensive piece of kit. No components can be present during welding as they may suffer damage from the high electrical currents needed for spot welding, thus everything must be socketed. All those little sockets are expensive! Rework or repair would need to be done with more traditional soldering techniques.
I would love to see the machine that did this board assembly. Maybe even a chance to use it. More information on the process seems difficult to find on the web without a trade name or other keyword that would clearly identify the process.
Not that these welded wires would be of much use today. The technique is clearly ideal for complex digital circuits of the style and speed that was common through the 1980’s to around 2000 or so. After that the prevalence of surface mount technology and the abandonment of the DIP package would doom the method. Modern high speed circuits benefit greatly from the more controlled traces of a printed circuit board and would not fare well on a welded wire board. In these days of easy computer layout and cheap printed circuit boards welding would not be my fabrication method of choice.
My slide digitizing project is now producing data by the gigabyte. As expected I am filling up the drives on my desktop computer. Not that there was a lot of space available in the first place, less than 50Gb was clear on the primary data drive. Time to buy a new hard drive! At least when I built the computer I bought a gaming cabinet with plenty of drive bays.
The reviews on Amazon and other retailers are nearly useless on hard drives. There will always be failures of devices like this, and angry buyers are very likely to leave negative reviews. Thus the data looks very skewed and it is hard to evaluate the reliability in any sort on meaningful way. Much less compare one drive to another.
There is real data! The cloud storage provider BackBlaze runs thousands upon thousands of hard drives. Obviously hard drive failure rates are of paramount importance to them and they closely track each type of drive they buy. Fortunately for the rest of us they publish this data and allow us to see what does, and does not work.
There are several obvious lessons in the data… Stay away from the 3Tb drive from Seagate and to a lesser extent the 3Tb drives from Western Digital. Several 4Tb models appear to be far more reliable. The failure rates on the worst drives can be upwards of 20% to 30% per year, while the better drives well under 5%. Those rates may seem high, you need to consider the hard use these drives get in a data center.
Based on this I have a new HGST 4Tb drive installed in my computer. All looks good so far, a trouble free installation and my photo collection copied over without issue. Now to see how long the drive lasts when I put some hours on it.