Supercon 2024 Flower SAO Badge Redrawing In KiCad

October 31, 2024 by Chris Lott 11 Comments

Out of curiosity, I redrew the Supercon Vectorscope badge schematics in KiCad last year. As you might suspect, going from PCB to schematic is opposite to the normal design flow of KiCad and most other PCB design tools. As a result, the schematics and PCB of the Vectorscope project were not really linked. I decided to try it again this year, but with the added goal of making a complete KiCad project. As usual, [Voja] provided a well drawn schematic diagram in PDF and CorelDRAW formats, and a PCB design using Altium’s Circuit Maker format (CSPcbDoc file). And for reference, this year I’m using KiCad v8 versus v7 last year.

Importing into KiCad

This went smoothly. KiCad imports Altium files, as I discovered last year. Converting the graphic lines to traces was easier than before, since the graphical lines are deleted in the conversion process. There was a file organizational quirk, however. I made a new, empty project and imported the Circuit Maker PCB file. It wasn’t obvious at first, but the importing action didn’t make use the new project I had just made. Instead, it created a completely new project in the directory holding the imported Circuit Maker file. This caused a lot of head scratching when I was editing the symbol and footprint library table files, and couldn’t figure out why my edits weren’t being seen by KiCad. I’m not sure what the logic of this is, was an easy fix once you know what’s going on. I simply copied everything from the imported project and pasted it in my new, empty project.

While hardly necessary for this design, you can also import graphics into a KiCad schematic in a similar manner to the PCB editor. First, convert the CorelDRAW file into DXF or SVG — I used InkScape to make an SVG. Next do Import -> Graphics in the Kicad schematic editor. However, you immediately realize that, unlike the PCB editor, the schematic editor doesn’t have any concept of drawing layers. As a work around, you can instead import graphics into a new symbol, and place this symbol on a blank page. I’m not sure how helpful this would be in tracing out schematics in a real world scenario, since I just drew mine from scratch. But it’s worth trying if you have complex schematics.

Note: this didn’t work perfectly, however. For some reason, the text doesn’t survive being imported into KiCad. I attribute this to my poor InkScape skills rather than a shortcoming in KiCad or CorelDRAW. Despite having no text, I put this symbol on its own page in sheet two of the schematic, just for reference to see how it can be done.

Just like last year, the footprints in the Circuit Maker PCB file were imported into KiCad in a seemingly random manner. Some footprints import as expected. Others are imported such that each individual pad is a standalone footprint. This didn’t cause me any problems, since I made all new footprints by modifying standard KiCad ones. But if you wanted to save such a footprint-per-pad part into a single KiCad footprint, it would take a bit more effort to get right.

Recreating Schematics and Parts

After redrawing the schematics, I focused on getting the part footprints sorted out. I did them methodically one by one. The process went as follows for each part:

Start with the equivalent footprint from a KiCad library
Duplicate it into a local project library
Add the text SAO to the footprint name to avoid confusion.
Position and align the part on the PCB atop the imported footprint
Note and adjust for any differences — pad size and/or shape, etc.
Update the part in the project library
Attach it to the schematic symbols in the usual manner.
Delete the imported original footprint (can be tricky to select)

Some parts were more interesting than others. For example, the six SAO connectors are placed at various non-obvious angles around the perimeter. I see that [Voja] slipped up once — the angle between connectors 4 and 5 is at a definitely non-oddball angle of 60 degrees.

SAO Angle Difference
#1   326  102  6->1
#2     8   42  1->2
#3    61   53  2->3
#4   118   57  3->4
#5   178   60  4->5
#6   224   46  5->6

With all this complete, the PCB artwork consists of all new footprints but uses the original traces. I needed to tweak a few traces here and there, but hopefully without detracting too much from [Voja]’s style. Speaking of style, for those interested in giving that free-hand look to hand-routed tracks in KiCad, check the options in the Interactive Router Settings menu. Choose the Highlight collisions / Free angle mode and set the PCB grid to a very small value. Free sketch away.

Glitches

Actual jumper on assembled PCB

Circuit Maker PCB File

Schematics showing jumper

I used two photos of the actual board to check when something wasn’t clear. One such puzzle was the 3-pad SMT solder ball jumper. This was shown on the schematic and on the fully assembled PCB, but it was not in the Circuit Maker design files. I assumed that the schematics and photos were the truth, and the PCB artwork was a previous revision. There is a chance that I got it backwards, but it’s an easy to fix if so. Adding the missing jumper took a bit of guesswork regarding the new and adjusted traces, because they were hard to see and/or underneath parts in the photo. This redrawn design may differ slightly in appearance but not in functionality.

DRC checks took a little more iterating than usual, and at one point I did something to break the edge cuts layer. The irregular features on this PCB didn’t help matters, but I eventually got everything cleaned up.

I had some trouble sometimes assigning nets to the traces. If I was lucky, putting the KiCad footprint on top of the traces assigned them their net names. Other times, I had traces which I had to manually assign to a net. This operation seemed to work sporatically, and I couldn’t figure out why. I was missing a mode that I remember from another decade in a PCB tool, maybe PCAD?, where you would first click on a net. Then you just clicked on any number of other items to stitch them into the net. In KiCad it is not that simple, but understandable given the less-frequent need for this functionality.

You may notice the thru hole leads on the 3D render are way too long. Manufacturers provide 3D files describing the part as they are shipped, which reasonably includes the long leads. They are only trimmed at installation. The virtual technician inside KiCad’s 3D viewer works at inhuman speeds, but has had limited training. She can install or remove all through hold or SMT parts on the board, in the blink of an eye. She can reposition eight lamps and change the background color in mere seconds. These are tasks that would occupy a human technician for hours. But she doesn’t know how to trim the leads off of thru hole parts. Maybe that will come in future versions.

Project Libraries

I like to extract all symbols, part footprints, and 3D files into separate project libraries when the design wraps up. KiCad experts will point out that for several versions now this is not necessary. All (or most) of this information is now stored in the design files, alghouth with one exception — the 3D files. Even so, I still feel safer making these project libraries, probably because I understand the process.

KiCad can now do this with a built-in function. See the Export -> Symbols to New Library and Export -> Footprints to New Library in the schematic and PCB editors, respectively. These actions give you the option to additionally change all references in the design to use this new library. This didn’t work completely for me, for reasons unclear. Eventually I just manually edited the sch and pcb file and fixed the library names with a search and replace operation.

Hint: When configuring project libraries in KiCad, I always give them a nickname that begins with a dot. For example, .badge24 or .stumbler. This always puts project libraries at the top of the long list of libraries, and it makes it easier to do manual search and replaces in the design files if needed.

What about 3D files, you say? That isn’t built into KiCad, but have no fear. [Mitja Nemec] has you covered with the Archive 3D Models KiCad plugin. It was trivial to activate and use in KiCad’s Plugin and Content Manager.

All Done

In the end, the design passed all DRCs, and I could run Update PCB from Schematic... without errors. I went out on a limb and immediately placed an order for five PCBs, hoping I hadn’t overlooked something. But it’s only US$9.00 risk. They are on the way from China as I type this.

All the files can be found in this GitHub repo. If you find any errors, raise an issue there. I have not done this procedure for any of the SAO petals, but when I do, I will place a link in the repository.

Hack All The Things, Get All The Schematics

July 8, 2024 by Arya Voronova 31 Comments

When I was growing up, about 4 or 5 years old, I had an unorthodox favourite type of reading material: service manuals for my dad’s audio equipment. This got to the point that I kept asking my parents for more service manuals, and it became a running joke in our family for a bit. Since then, I’ve spent time repairing tech and laptops in particular as a way of earning money, hanging out at a flea market in the tech section, then spending tons of time at our hackerspace. Nowadays, I’m active in online hacker groups, and I have built series of projects closely interlinked with modern-day consumer-facing tech.

Twenty three years later, is it a wonder I have a soft spot in my heart for schematics? You might not realize this if you’re only upcoming in the hardware hacking scene, but device schematics, whichever way you get them, are a goldmine of information you can use to supercharge your projects, whether you’re hacking on the schematic-ed device itself or not. What’s funny is, not every company wants their schematics to be published, but it’s ultimately helpful for the company in question, anyway.

If you think it’s just about repair – it’s that, sure, but there’s also a number of other things you might’ve never imagined you can do. Still, repair is the most popular one.
Continue reading “Hack All The Things, Get All The Schematics” →

Schematics, For A Modern Flagship Phone

February 7, 2024 by Jenny List 36 Comments

The mobile phone is an expensive and often surprisingly fragile device, whose manufacturers are notorious for making them as difficult to repair as possible. Glued-together cases and unreplaceable batteries abound, and technical information is non-existent. But amongst all that there’s one manufacturer with a different approach — Fairphone. Case in point, they’ve released the full service guide including schematics for their flagship Fairphone 5.

Fairphone’s selling point is the repairability and internal accessibility of their products and of course they’ve made hay with this as a marketing opportunity. But aside from that, it’s a fascinating chance to look in-depth at a modern smartphone from the inside out. We see the next-level PCB layout and how everything is so neatly packed into the minimum space, all without resorting to a heat gun.

It’s great to have another hackable phone, and fair play to Fairphone for releasing all this stuff, but perhaps the most interesting part from where we’re sitting is how and where this phone is being sold. There have been hackable phones before, for many the Pinephone will spring to mind, but they have always been sold to an audience who buy to hack. Here in Europe where this is being written, the Fairphone is being sold as a consumer device. It won’t shake Apple or Samsung from their perches, but for a hackable device to be so generally available to those who wish to do things with it can never be a bad thing.

We took a quick look at Fairphone back in 2015, when they launched.

Vectorscope KiCad Redrawing Project

November 13, 2023 by Chris Lott 23 Comments

When I saw this year’s Supercon Vectorscope badge, I decided that I had to build one for myself. Since I couldn’t attend in-person, I immediately got the PCBs and parts on order. Noting that the GitHub repository only had the KiCad PCB file and not the associated schematics and project file, I assumed this was because everyone was in a rush during the days leading up to Supercon weekend. I later learned, however, that there really wasn’t a KiCad project — the original design was done in Circuit Maker and the PCB was converted into KiCad. I thought, “how hard can this be?” and decided to try my hand at completing the KiCad project.

Fortunately I didn’t have to start from scratch. The PCB schematics were provided, although only as image files. They are nicely laid out and fortunately don’t suffer the scourge of many schematics these days — “visual net lists” that are neither good schematics nor useful net lists. To the contrary, these schematics, while having a slightly unorthodox top to bottom flow, are an example of good schematic design. Continue reading “Vectorscope KiCad Redrawing Project” →

Pocket Radio Powered By Tiny Microcontroller

July 6, 2022 by Bryan Cockfield 33 Comments

Before the days of MP3 players and smartphones, and even before portable CD players, those of us of a certain age remember that our cassette players were about the only way to take music on-the-go. If we were lucky, they also had a built-in radio for when the single tape exhausted both of its sides. Compared to then, it’s much easier to build a portable radio even though cassettes are largely forgotten, as [wagiminator] shows us with this radio design based on an ATtiny.

The build is about as compact as possible, with the aforementioned ATtiny 402/412 as its core, it also makes use of an integrated circuit FM tuner, an integrated audio amplifier with its own single speaker, and a small OLED display. The unit also boasts its own lithium-polymer battery charger and its user interface consists of only three buttons, plenty for browsing radio stations and controlling volume.

The entire build fits easily in the palm of a hand and is quite capable for a mobile radio, plus all of the schematics and code is available on the project page. While it doesn’t include AM capability, just the fact that FM is this accessible nowadays when a few decades ago it was cutting-edge technology is quite remarkable. If you’re looking for an even smaller FM receiver without some of the bells and whistles of this one, take a look at this project too.

Reverse Engineering The SEGA Mega Drive

January 19, 2022 by Bryan Cockfield 16 Comments

With the widespread adoption of emulators, almost anyone can start playing video games from bygone eras. Some systems are even capable of supporting homebrew games, with several having active communities that are still creating new games even decades later. This ease of programming for non-PC platforms wasn’t always so easy, though. If you wanted to develop games on a now-antique console when it was still relatively new, you had to jump through a lot of hoops. [Tore] shows us how it would have been done with his Sega Mega Drive development kit that he built from scratch.

While [Tore] had an Atari ST, he wanted to do something a little more cutting edge and at the time there was nothing better than the Mega Drive (or the Genesis as it was known in North America). It had a number of features that lent the platform to development, namely the Motorola 68000 chip that was very common for the time and as a result had plenty of documentation available. He still needed to do quite a bit of reverse engineering of the system to get a proper dev board running, though, starting with figuring out how the cartridge system worked. He was able to build a memory bank that functioned as a re-writable game cartridge.

With the hard parts out of the way [Tore] set about building the glue logic, the startup firmware which interfaced with his Atari ST, and then of course wiring it all together. He was eventually able to get far enough along to send programs to the Mega Drive that would allow him to control sprites on a screen with the controller, but unfortunately he was interrupted before he could develop any complete games. The amount of research and work to get this far is incredible, though, and there may be some helpful nuggets for anyone in the homebrew Mega Drive community today. If you don’t want to get this deep into the Mega Drive hardware, though, you can build a cartridge that allows for development on native Sega hardware instead.

ASCII Schematic Diagrams

April 29, 2021 by Chris Lott 40 Comments

We wondered recently about those crude ASCII schematics you see in some documentation — are there any dedicated schematic-focused tools to draw them, or are they just hand-crafted using various ASCII-art drawing tools? To our surprise, there is such a tool. It is called AACircuit and was developed by [Andreas Weber]. It has a history going back to 2001 when it was first introduced as ASCIIPaint. Be forewarned, however, the quality of the code may be questionable. According to the notes on [Andy]’s GitHub repository:

WARNING: a lot of spaghetti code ahead

This code was created in 2001-2004 when I taught Borland Delphi 3 to myself. It contains many, many global variables, unstructured and undocumented procedural code and bad variable names.

If you don’t want to wrestle with old and sketchy object-oriented Pascal code, you’re in luck. [Chaos Ordered] has made a Pythonized version which you can get from his GitHub repository. We tried it out and got it working on Ubuntu in short order (after wrestling with a pycairo dependencies). This might not be everyone’s cup of tea, but it has some uses now and then. While we wouldn’t want to document a computer motherboard with ASCII schematics, it’s great for a quick-and-dirty circuit diagrams.

Not exactly schematics, but [Duckman] has some Arduino pinout diagrams he made using ASCII-art. These could be useful when pasted into source code as comments, documenting the pinouts for your project.

Do you recommend any tools for making ASCII schematics, or this just a waste of time?