Blinkenrocket!
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34th Chaos Communication Congress166 / 167
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00:00
InternetworkingFreewareDijkstra's algorithmLaserRootOnline chatTwitterComputer hardwareSoftwareProgrammer (hardware)MereologyComponent-based software engineeringOpen sourceUniverse (mathematics)Particle systemBit rateBasis <Mathematik>Software development kitHacker (term)Multiplication signComputer programmingSpacetimeBitSpecial unitary groupData conversionMereologyProjective planeStreaming mediaMusical ensembleSoftwareConnected spaceQuicksortLink (knot theory)DataflowPoint (geometry)Moment (mathematics)Roundness (object)Slide ruleBuffer overflowRight angleProgrammer (hardware)Computer animation
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PixelElectronic visual displayMatrix (mathematics)Computer hardwareComponent-based software engineeringCellular automatonEEPROMSoftwareOpen sourceModul <Datentyp>Java appletText editorScripting languageCommunications protocolWaveSquare numberData transmissionError messageChaos (cosmogony)Cartesian closed categoryContext awarenessPersonal identification numberNeuroinformatikRepetitionData storage deviceCartesian coordinate systemMultiplication signElectronic visual displayCellular automatonParticle systemConnectivity (graph theory)Source codeAdditionComputer programmingBit rateRule of inferencePower (physics)MicrocontrollerSoftware development kitSoftware frameworkPixelMereologySquare numberSound effectSoftware developerData transmissionOpen sourceText editorSoftwareFehlererkennungDirection (geometry)SpacetimeMetric systemWeb applicationHacker (term)Web browserProgrammer (hardware)Communications protocolFirmwareWeb 2.0Module (mathematics)Computer animation
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Error messageMoment (mathematics)Water vaporRight angleLaptopCurveProcess (computing)Group actionWeb browserOrder (biology)SurfaceNeuroinformatikMultiplication signSoftware development kitCartesian coordinate systemSound cardError messageData transmissionNormal (geometry)Computer virusLenovo GroupComputer animationDiagram
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PlastikkarteWaveComputer hardwareAnalog-to-digital converterData transmissionSineNormal (geometry)MultiplicationAnalogy2 (number)Multiplication signVector spaceWeb browserGoodness of fitDigitizingFrequencyQuicksortOrder (biology)SubsetShift operatorSound cardDifferent (Kate Ryan album)Level (video gaming)PlastikkarteAbstractionKernel (computing)Computer hardwareData conversionForm (programming)ResultantAxiom of choiceCAN busMereologyArithmetic meanData transmissionObject (grammar)Square numberSineWeb 2.0Software development kitWaveComputer animation
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Modul <Datentyp>Matrix (mathematics)Square numberComputer hardwareRevision controlRevision controlMatrix (mathematics)Square numberModule (mathematics)Dot productWhiteboardDiffuser (automotive)Connectivity (graph theory)Software development kitQuicksortEndliche ModelltheorieSpecial unitary groupElement (mathematics)Order (biology)Product (business)Multiplication signComputer animation
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Revision controlReal numberRevision controlVideo gameEntropie <Informationstheorie>Connectivity (graph theory)Endliche ModelltheorieMatrix (mathematics)Sign (mathematics)MathematicsComputer animation
16:18
Euclidean vectorComputer programmingMassMultiplication signComputer programmingDifferent (Kate Ryan album)Software development kitMereologyProduct (business)Right angleConnectivity (graph theory)Network socketPosition operatorGoodness of fitFilm editingMicrocontrollerScripting languageForcing (mathematics)MassFirmwareOpen setComputer animation
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MereologyMereologySoftware development kitPlastikkarteProduct (business)Multiplication signComputer programmingTransportation theory (mathematics)VideoconferencingVirtual machineProcess (computing)Film editingGroup actionFigurate numberError messageInsertion lossINTEGRALComputer animation
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Virtual machine
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MereologyCodierung <Programmierung>Virtual machineIterationHacker (term)Virtual machineHecke operatorRoboticsMereologyVideoconferencingMultiplication signCodeDrill commandsOpen setPoint (geometry)FirmwareTape driveGraph coloringMassSoftware development kitIterationLaurent seriesView (database)MiniDiscProcedural programmingProcess (computing)DiameterOrder (biology)Computer animation
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Position operatorRoboticsVirtual machineReal-time operating systemConnectivity (graph theory)Real numberMereology1 (number)
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Auto mechanicData structureMatrix (mathematics)ChainChaos (cosmogony)Local ringConnectivity (graph theory)Computer hardwareEmailTwitterTranslation (relic)Level (video gaming)NumberData structureAreaOnline helpSoftware development kitRoundness (object)Multiplication signRight angleCuboidMereologyOpen sourceLocal ringMicrocontrollerVirtual machineSign (mathematics)FreewareEqualiser (mathematics)Repository (publishing)Shared memoryInstance (computer science)WordWeb-DesignerChainCellular automatonGoodness of fitCASE <Informatik>Solid geometrySpacetimePoint (geometry)Software developerBit rateWebsiteHecke operatorAddress spaceError messageConnected spaceVotingNear-ringDataflowCodeLink (knot theory)Buffer overflowComputer animation
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MedianSystem programmingHypermediaComputer animationJSONXMLUML
Transcript: English(auto-generated)
00:16
and welcome. The following session is about the Blinken Rocket, the nifty device that
00:21
some of you might already know. It's a 100% open-source, do-it-yourself soldering kit that offers the best hands-on experience for beginners of all ages. Overflow and Mootsy are here to tell us all about their journey in making the Blinken Rocket fly. Let's hear some applause for Overflow and Mootsy. So, oh well, I can hear my voice, so we're waiting for the slides to appear. And while
00:55
we're waiting for the slides to appear, a warm welcome from my side as well. I'm Mootsy, this is Flo, but we're going to introduce ourselves later on again, so
01:04
let's, well, spend some time waiting for the slides to appear. And also warm welcome to those who are in the streams. At least I got one hint that somebody is on the tram right now, so they probably have good connectivity to watch this talk as well. So you're gonna walk with us through the journey
01:21
of Blinken Rocket, which is this little thing that I have here on this band, and we're going to talk you through various topics. So we're gonna start with our project goals, because you want to have goals before we start something just like with any project we have. Then we're gonna talk you through this little hardware, what we have on there, the design considerations
01:43
behind that, and probably most interesting, the software running on this little device. And after all, we're going to talk you through how to actually productize a do-it-yourself soldering kit, because we know that there are plenty of ideas here in that room, and if you want to distribute your own do-it-yourself soldering kit, well, you can learn
02:03
probably a lot from what we've went through and what we've learned, and also what you can do right in the first place without actually failing one, three or four times. So, shortly about us, this here on my left side is Flo. He's a dad of three and a member of the Metalab, and he's the guy behind
02:25
the Hackenspace shop. That's an online shop for various do-it-yourself kits. You created plenty of do-it-yourself kits in the past, so he's like more experienced than I am. And I would say at daytime, I do big data topics, and at nighttime, once the sun sets, well, I'm creating
02:42
do-it-yourself kits for kids. So, at this point in time, I want to thank all the contributors that helped us making this little thing possible. So, a big shout out and thank you. You're awesome, guys. Yeah, and you can give them a round of applause. So, let's
03:03
start with Project Gold. If you see this little kit, and you have probably seen it already today, because at Jung Hackathag, there are plenty of children actually soldering this. So, we have a target audience. So, first of all, if you create something, you have to think about who uses it, or who is the intentional audience
03:21
behind that. So, we have children, youth, and adults, basically, as our audience. And when they sort of this, they're probably at home or in workshops, in schools, universities, or even hack spaces. Well, most of us here come from hack spaces, so that's kind of obvious. And we have some requirements derived by that.
03:42
First of all, I hate it when I have to use a special programmer to program my devices. If I have something great, I just assembled it, and then I need to assemble something to just program it, that's awful. And also, I hate it when I have to buy something because I forgot to buy it. Like with the little
04:01
Arduino thing, in the past, you had to have this USB to serial converter, and I almost never thought about that. So, that was kind of bad. Also, given the tired audience, children, well, they don't feel small parts, but adults do. So, we try to
04:20
choose big parts, and they're even like little small SMD parts here, and they can be big too. So, we made the footprints wider and bigger so that if you solder them, they will flow nicely, and you cannot do it wrong, virtually. And we wanted to have cheap components, so that if you buy a kit, you do not have to spend too much money, and ideally, it
04:44
should be free anyway, because we do not care about your income, and everything should be free when it comes to learning stuff. Also, the most important aspect, if you make something, it should be, well, useful in the first place. It should be fun and also educational, especially if
05:01
you're targeting children, they should learn something. And with this kit, they can learn how to solder, they will see that something in the digital world can be translated to the real world. So, that was our main aspect. And it's, well, kind of fun to have something that blinks your name or has nice little animations on there. So, based on these
05:23
considerations, the blinking bucket was born about two years ago. And on the front side, you see the 8 by 8 pixel dot metrics display, then the audio jack for uploading data. And that's like one thing that addresses this no programmer needed aspect. Because we wanted to
05:42
have the ability to use your mobile, basically, to upload new text or animation to that little device. So this is kind of special to that digital soldering kit. Also, not interacting with something is kind of boring, so we added little two push buttons so that we can move between the
06:02
animations and text that are scrolled through the display. On the back, we have, of course, a coin cell that powers the whole device. And it lasts about a day or two. So, don't worry about new batteries. Also, we have a little ATtiny microcontroller, which was the cheapest
06:21
microcontroller back in the day with that much pins to drive the display directly. And also, we have storage with 64K of storage available for your animations. And that's roughly 2,000 to 3,000 characters of text. And they can be a little hard to read on that little display, so it should be sufficient for all time. Also, some
06:43
additional little SMD components, well, to solder everything. On the software side of things, everything is open source. Like this awesome Harold already mentioned, we want to make everything open source. And when we talk about everything, it's not just source code
07:01
or the PCB layout. We also made our documentation open source and licensed it the proper way. We made our manual that's actually printed and handed into every kit also open source. And not only the PDF, also the source files that you can assemble it on your own or remix it based on your needs. The
07:22
firmware was written in module C++. I don't think it matters too much, actually. But I think it's worth mentioning, though. Also, we have a web editor for putting little animations and text on this device. So you can use it on any device, whether it be your mobile phone or your computer. Everything with
07:41
a web browser and an audio device is capable of programming the Blinken rocket. And it's written in JavaScript, of course, if it's a web application. And the one initially created it used the awesome ReactJS framework because it, well, made things a little easier. The audio transmission itself is using
08:01
square waves, so little square signals coming out your audio device. And we have a protocol using forward error correction so that if there is a mistake within the transmission, it will be fixed automatically. So after a while, we created a thousand Blinken rockets, so a thousand kits to be
08:21
distributed among children, youth and adults. They were manufactured by lots of volunteers in mid-2016 after roughly half a year of development time in our spare time. It was initially funded by the CCC. I'm not too sure. Who knows the Kars Machtuhle initiative by the CCC? If you
08:41
could raise your hands. Well, it's like the whole crowd. So if you don't know it, go ask your neighbor after this talk what this awesome initiative is. So it was funded to be part of the CCC and for these workshops taking place in the Kars Machtuhle initiative. It was packaged by volunteers at the hack space in
09:01
Stuttgart, so it took roughly a day for ten people to assemble a thousand kits, and it was distributed across all Europe for workshops. And here are some impressions of workshops taking place. They were awesome. The kids had plenty of fun to assemble their Blinken rocket, and in the
09:22
moment, they slid the battery in and everything started to blink. It was just awesome to see their faces and, well, see all that enjoyment in their face. But there was a big catch, and this is where I head over to Flo, because we learned a lot, and he's going to tell us about what
09:40
we've learned. So hello. Is this on? Do you hear me? I'm not sure if I'm on or not. Yes? OK. Hello. So yes. There was a little catch, and we learned a lot. So the first thing, when I got my hand on the first Blinken rocket kit, I realized it was a really good one, and there was potential to make this
10:02
bigger and distributed to more kids. But the first thing, the first problem I, it occurred to me, was that we used square waves to transmit the data, and on the Lenovo Thinkbit, for example, that worked out just fine. But the same manufacturer, for another notebook, it didn't work at all. As you can see here, the data was totally distorted,
10:24
and we could not process that signal. So transmission from the web browser to the rocket wouldn't work reliable. Some common errors that happened were that the signal would drift over time. Like, in the first picture on the left, you see a yellow curve, and that's the signal that you get out of
10:40
the sound card. And the blue signal, the blue curve is what the computer would make out of that. And by the voltage drifting upside down on the, on the Y axis, you see that this, the signal is really hard to process, and it just wouldn't work out reliably. And also, on the right, you see that they have the, the
11:01
heavily distorted signal. But why? Why is that happening? Well, every sound device works a little different. We have different manufacturers of sound chips, we have different sound cards, and they all do similar things, but not exactly the very same thing. And most
11:21
sound cards are troubled by square waves. So if you make a square wave signal, it goes like this, sound cards cannot reliably produce that, or some of them, most of them. And also there is various layers between the web browser and the actual sound card. For example, you generate a sound
11:40
project, object in, in the web browser, and it's given to the other driver, and that gives it to some hardware abstraction layer, and that gives it to the kernel, and that's handed over to the actual hardware. And in all these steps in between, the signal can be modified and is modified, especially at the hardware level. The signal is
12:01
modified to, it sounds good to the human ear, but it's not really meant to submit data. So, Chris Weigel came up with a solution to this problem by introducing ADC, analog digital converter edge detection, which means he sampled the signal a lot, some,
12:22
yeah, sometimes, and it worked much more reliable than the old way of simply detecting the edges of the square signal. But still, there were some issues. It didn't work a hundred percent, and he spent some more time digging into this problem, and he came up with this solution of frequency shift keying, and
12:42
that worked really good. Frequency shift keying means that you make not square waves, but sine waves. You can see that the form is like, it doesn't go like this, but more, it's more curvy, to say. And that's what sound cards usually do. They provide waves, and that kind of transmission worked out much more
13:04
reliable. It's also much slower, but that's OK. We are talking about some seconds to transmit the data, instead of some milliseconds, so that's totally acceptable. If you plug it in, it will take you, I don't know, two seconds, and then you have the animation on the rocket. Once this was fixed, I started to take
13:24
a look at the hardware level, how the kit could be improved, and one thing that we found out during workshops was that the battery holder was not the best choice, because people would put in the batteries in various ways that were not intended. So this is what the original battery holder looked
13:42
like, and you could insert the battery like this, which is actually wrong. It looks right, but it's not, because a part of it is bent, and there's also this other way of inserting it that happened a lot, and in this way, the rocket wouldn't work, so yeah. I got rid of the battery holder and introduced this one. It has some benefits. It's a
14:04
little more expensive than the other one, but the battery slides in from the top, and there is just one way to insert the battery the wrong way, and that doesn't happen too often. But with the other battery holder, there were eight possibilities to insert the battery in the wrong way. So that took off, took
14:23
Yeah. Then, the original matrix module that was included was also very cheap, but I thought that if you make a kit that you would hang around your neck, it should look nice. It shouldn't be 10 cents cheaper, but it's worth to add a little extra and have good looks, so we introduced this new matrix
14:41
module that has square dots and diffused lights, and it just looks better. And then I revised the PCB design a lot, and not a lot, a little. I just shuffled around the components, and I panelized the design for production, which means that I took one rocket and put it on a panel like this, so
15:02
we have 14 rockets, and you can fit this into a pick-and-place machine to automatically produce the boards. So why is that? Because pre-populated versions are targeting different users. The kit, when I got it for the first time, it was rather complex, and you had to solder the MCU and the
15:22
EEPROM yourself, and I'm now offering three different versions, one where you solder all the stuff yourself for experienced users, and one where the EEPROM and the MCU is already in place for targeting kids, and one version where all the SMT components are already on the board, and you just solder the six through-hole components
15:41
yourself, which targets very young people. Like, my daughter made one, and she's six years old. So this is when version two was born. Yeah, you see the new matrix model there, you see the battery holder, and the components are more far away than in the old design to make it easier to solder. And that's the
16:05
thing. If you make one board, it's quite easy. You make the design, you order it from China, get your tank copies, and then you assemble it. But if you make a thousand of something, you run into various challenges and problems. So, for example,
16:21
for the first production run, the original kits that were made in 2016, everything was done by hand. So Mutzi built this mass programming fixture with a zero-injection force socket, where you place the microcontroller inside and have a little script that flashes the microcontroller with the actual firmware.
16:41
Making a thousand kits means opening the socket, entering the MCU, closing the socket, hitting the button 1,000 times. How long did it take you? Well, roughly a day of just, well, removing a single chip out of the packet, well, putting it in, closing the lid, pressing a button, opening the
17:00
lid, well, moving everything out into a little plastic bag. And these were kind of nasty, because they were like those Ziploc bags, and, well, they were hard to open. So I spent roughly eight hours flapping a thousand microcontrollers, which was awful. Believe me. It's not fun. If you ever make a kit, this is something you don't want to do. Don't do it.
17:21
Don't do this. There are alternatives. I will show you later. And then, as you can see on the right, components were put on labels. So the kit consists of the actual MCU and EEPROM and eight different other components, like resistors, capacitors, and diodes. And they have different values. So what they did in the first production run is they took little stickers,
17:41
little labels, and cut all the components up, and put them in the correct position on the sticky notes, and put them in the kit. Eight parts times a thousand kits is eight thousand cuts. Being there with skissors, eight thousand times cutting up parts. You need a lot of people or a lot of time or both. How long did that take? Well, we had roughly ten people helping
18:01
out, thankfully. Otherwise, I would spend like weeks or months doing it. And we spent roughly a day with ten people to create a thousand kits. And that includes also like cutting down parts. And people were really eager to help, so I was really thankful. But this wasn't feasible for the next thousand kits.
18:20
Absolutely not. Yeah. It's not fun. It's not a fun activity when building kits. This part should be done by machines. That's what they're for. So when I kind of took over the production of the kits, I figured I should save time by using machines. Even if it costs a little extra, it's probably worth
18:42
the time and money. And I should get pre-programmed MCUs. You can pay a little extra, some cents, and you get the MCU with the program in it from the manufacturer. It costs like ten or fifteen cents, something around that. And it's totally worth the effort. And I introduced color coding of SMT parts.
19:00
In the old kit layout, you had the label that said R1, and then you put the part right there. In the new kit, you have a part that is labeled, there is no text on it, but it's a red part or a green part or a blue part. And you get a little card that says put the red part on R1 and the blue part there. That took away a lot of time when assembling the kits. And finally I introduced a new package. It now comes
19:22
in a little plastic package that you can use for transportation. And also during assembly. It's very handy. So yeah, I mentioned robots before. When I was faced with the job of making a thousand kits, I thought that I would not be able to cut these parts up myself and I should make a machine for that.
19:41
And let the differential robot take over, and that's what it did. I'm going to show you a short video now where you see how that worked out. Yeah, a little fast forward there.
20:17
Yeah, so I called this machine That's a hacker.
20:22
Thanks. Yeah, that's a hacker. It took me some time to build it. I thought, yeah, take some scissors and a motor and it'll work. Took me four iterations. What it does is it cuts SMD parts
20:41
from the drill. It also color codes the parts while cutting them. So there's a little marker that you can see here that puts a strip, a color on the strip before cutting it up. So I can just replace that for each part so they are color-encoded. And I have two buttons where I can adjust how many holes I want to move forward before cutting it up.
21:02
Because I have some parts where I need three pieces in the kit and I have others where I just need one. And it cuts a lot fast. It's really fast. I cut up a thousand parts an hour, which saved me days of work to make these kits. It was totally worth the effort. But it took me four iterations to get the machine right. The main point to learn is that scissors
21:21
are a spare part that should be, must be replaceable. You don't want to build a machine that has some kind of mechanic to cut up parts that is not replaceable. So I used open mass curtain with all these 3D printed designs to hold the scissors in place. And you see here ball bearings from roller blades that push down the scissors.
21:43
There's one part, it's called a sprocket. A sprocket is like a little wheel that has spikes. And that's something I actually bought in China for $15. And that gets in there and it's used in commercial pick and place machines to move forward the tape.
22:01
So PCB fabrication. Once I had all these parts cut up and the firmware issues fixed, it was time to go to the fab house and have the PCBs manufactured. Because I got the panels that we showed you earlier from China. And I wanted the parts on there. And I made a little video of how the process works. It was really fun to be there and
22:21
it was a very nice afternoon to watch all these huge robots doing the work. So I will show you a little how that turned out. So here's panels and this is when the solder paste is applied. The solder paste is now on the panels. And then they go into the pick and place machine
22:41
which is configured before. And this is real time footage. That's how the robot really looks in real time. It moves quite fast. It scans the part, adjusts it. If the position is adjustment, it goes into the oven and once it's baked, it comes out of the oven and ta-da! It blinks. You just have to assemble the through-hole components yourself and then you're done.
23:02
So... Yeah. And what caught me by surprise was the cost structure to make this kit. I did not expect that the cost would be this much. So... Well, we have assembly, tooling and supply chain cost of about 50% of the actual
23:20
kit costs. And 50% is material. So even if you use machines to make a kit, it takes time. And in this case, it took more time than I expected. So I'm currently selling those kits at my shop for 25 euros each and you buy basically two kits. And one is given into a little
23:41
box. And if you make a workshop with kids at a school where they don't pay for it, I take the kit out of there and give it to the kids for free. And you might get a little email with pictures afterwards. We can actually see what happened with your donation. Yeah. So that was my part of the talk. I will hand over to Muzzi again.
24:01
So I think we learned a valuable lesson about the cost structure because that will affect all of you creating such DIY kits. Because the cost might not be obvious if you go through shops and see that likely your microcontroller costs less than euro, but then all the other costs
24:20
can add up to, well, what we've seen there. So it can be surprising and you should be aware of that. So we all ask ourselves right now, what's next? And I had a look in the audience while Flo was talking and I've seen plenty of blinkin' rockets. So that's already a good sign. So what's next? Today there are soldering workshops for children here
24:42
on the Congress. So if you are, I'm not sure about the age, but if you are a children, go there, have fun, and get your blinkin' rocket. There will be more workshops because the first kits were distributed well in 2016 and Flo did create another
25:00
thousand kits, so there will be more to be distributed for those workshops. There will be Jugend Hecht workshops in Austria next year. So if you're from Austria or living nearby, then you might want to consider going there or, well, if you're not an adult, of course.
25:20
And solder your own custom blinkin' rocket. But even if you're an adult, that's not a problem because you could create a workshop in your community. So if you like to have a nice blinkin' rocket soldering workshop, don't hesitate to ask us. We have all the material required to create your own workshop. We have guidance, we have manuals, we have best practices,
25:41
so just ask us and we'll try our best to make your workshop a success. And also you, as Flo already told us, you can buy a kit in his shop and there's automatically one kit being donated to such a children workshop because we do believe that if a child does attend a workshop, there should be no fee attached to that
26:00
because, well, we want to treat everybody equal and money should not be a thing there. So if you buy one there, of course, it will go to one free workshop for a kid. So I think that's a good thing. If you've got some time to spare, and I think everybody does, especially if you're
26:20
in your local Hecht space, you could plan a local workshop, so please do so. If you're a web developer willing to spend some time to improve everything, well, there's a GitHub repository with all the code in there. You can create a fork, you could work on the issues to make everything even better, like
26:40
for instance better support for animations or better editing tools or create a share button for sharing animations with your friends. Or you could just spread the word. Everything is open source, so we want to encourage you guys to actually use what we've created to create your own stuff. So please be welcome to do so. This is
27:02
the reason for making everything open source and we would kindly ask you to do the same with your own stuff. This is our talk already. There follows a Q&A session right now. If you want to ask in German if you're not so familiar with English, don't worry, we will translate everything to English first and then answer it in English and
27:22
there will be the translation angels translating it to German on the right channel. If you want to contact us after the talk, there is an email address, there is a Twitter handle, and there's also a decked phone number. It was 7... 7-8-8-5 I think? Yeah, 7-8-8-5. Or just come to the stage right after the talk
27:42
so we can have a chat and we can show you everything in detail and, well, help you out. So, thanks a lot. Thank you very much. An applause for the speakers. We have four microphones set up
28:01
in this hall. Please come forward with your questions and we also take questions from online. Anybody? Don't be shy. No questions? No questions! Ah, there was a question. Just a quick question. Do you also sell the kids on site?
28:22
Yes, I do, actually. We do. The kids are available in the hardware hacking area right there in hall C with the white umbrellas it says FPGA right there. You can just follow him after the session, so I think he's willing to give you one.
28:40
Or more. Thank you. Is there anybody else? Well, I guess not. Thank you very much. Over for Munzi. Round of applause, please! Have a great congress!