After re-programming Sony DCU, noticed some weird muting while securing DCU.
Registered User
Joined: Oct 2000
Posts: 7,134
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From: Columbia, MD
Kaptain et.al.,
Try and get me a copy of the schematic, if possible. I could weed through the code and look for possible errors, but looking for hardware issues is significantly easier, especially if he doesn't comment his code well. If I can't find anything on the schematic, I'll take a lokk at a couple of units.
Let's hope there's nothing wrong with Scot, and that he is merely taking a break from the board. I hate to see anyone lose their money over this...
Try and get me a copy of the schematic, if possible. I could weed through the code and look for possible errors, but looking for hardware issues is significantly easier, especially if he doesn't comment his code well. If I can't find anything on the schematic, I'll take a lokk at a couple of units.
Let's hope there's nothing wrong with Scot, and that he is merely taking a break from the board. I hate to see anyone lose their money over this...
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Joined: Nov 2000
Posts: 131
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From: San Diego
I received the e-mail from Kaptain Insano. I've been away from the board.
The problem with the units losing their programming is not software related. It is hardware related. I've had an engineer look over the problem and he determined that the trouble is with the solder joints in the units. The inputs from the buttons are detected via a voltage divider. The voltage level across the divider is measured using an A-D converter built into the Atmel Micro. The problem is that the units were built using a hand soldering process which evidently did not create 100% solid joints in all cases. That is why the units work fine for many people, but do not work for a long period of time for others. The imperfections in the joints are affected by temperature and humidity.
I have been trying to get a new batch of units made to replace the units that have problems (and also Tedsters that got lost in the mail), but I simply have not been able to come up with the money to pay for it. The money that was sent for the original units was used to create the original units plus 5 or 6 extras. These extra units have been used for replacements and are all gone now.
I have many of the parts needed, but still need to order more parts and then have to pay for the assembly. I need to order about $400 more parts. I found a shop that will wave-solder them which should solve the problems that folks are seeing with reliability, but I have to get 50 of them made. He quoted me $6/ea for assembly a few months ago. That is $300 of assembly charges. That comes up to $700 that I just don't have. I'm in the tech sector and as I'm sure you all know things are tight. I'm lucky to be working at all. I don't have $700 extra to spend on making replacements for these units, I have to pay my bills.
The schematic isn't mine to release. I had an engineer design the circuit for me and it is his circuit. I've talked to him and he doesn't want it released.
The code really won't do you any good since I can't release the schematics, it is assembly and it is very difficult to read. It would not make any sense at all without a lot of explanation and schematics.
I don't really know what else to say. I'd get more made using the wave soldering process, but I don't have the money and can't see that I will anytime soon. I really wish I had never tried to do this at all. I originally wanted to do this for myself and never intended to sell them. So many people bugged me about that I finally decided to sell them to those who wanted them. I sold them too cheap, lost money on them (lost over $2000) and now there are some people who are upset because their unit quit working. (although there are many who continue to use it with no problems)
The problem with the units losing their programming is not software related. It is hardware related. I've had an engineer look over the problem and he determined that the trouble is with the solder joints in the units. The inputs from the buttons are detected via a voltage divider. The voltage level across the divider is measured using an A-D converter built into the Atmel Micro. The problem is that the units were built using a hand soldering process which evidently did not create 100% solid joints in all cases. That is why the units work fine for many people, but do not work for a long period of time for others. The imperfections in the joints are affected by temperature and humidity.
I have been trying to get a new batch of units made to replace the units that have problems (and also Tedsters that got lost in the mail), but I simply have not been able to come up with the money to pay for it. The money that was sent for the original units was used to create the original units plus 5 or 6 extras. These extra units have been used for replacements and are all gone now.
I have many of the parts needed, but still need to order more parts and then have to pay for the assembly. I need to order about $400 more parts. I found a shop that will wave-solder them which should solve the problems that folks are seeing with reliability, but I have to get 50 of them made. He quoted me $6/ea for assembly a few months ago. That is $300 of assembly charges. That comes up to $700 that I just don't have. I'm in the tech sector and as I'm sure you all know things are tight. I'm lucky to be working at all. I don't have $700 extra to spend on making replacements for these units, I have to pay my bills.
The schematic isn't mine to release. I had an engineer design the circuit for me and it is his circuit. I've talked to him and he doesn't want it released.
The code really won't do you any good since I can't release the schematics, it is assembly and it is very difficult to read. It would not make any sense at all without a lot of explanation and schematics.
I don't really know what else to say. I'd get more made using the wave soldering process, but I don't have the money and can't see that I will anytime soon. I really wish I had never tried to do this at all. I originally wanted to do this for myself and never intended to sell them. So many people bugged me about that I finally decided to sell them to those who wanted them. I sold them too cheap, lost money on them (lost over $2000) and now there are some people who are upset because their unit quit working. (although there are many who continue to use it with no problems)
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Joined: Nov 2000
Posts: 131
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From: San Diego
Modifry:
I can do better than that. I'll send you an empty PCB, the main connector and a programmed micro. The rest of the components you'll have to fill in for yourself so I'll send you a parts list as well. I'll gather this together this weekend and get it sent to you (if you want it).
Human:
It really isn't that simple. If it was only one joint that would be great. The problem is that any part of the circuit that malfunctions can cause the same types of issues. There are over 100 solder joints on this thing and at least half of them could cause the unit to appear to 'lose' the programming. If you want to re-heat all of the joints on the board, try it. I'm not sure it is going to fix the problem though. I was told that there are problems with contaminants during the assembly process (such as oil from the assembly persons hand). I don't know if this can be fixed by simply re-heating or adding solder.
I can do better than that. I'll send you an empty PCB, the main connector and a programmed micro. The rest of the components you'll have to fill in for yourself so I'll send you a parts list as well. I'll gather this together this weekend and get it sent to you (if you want it).
Human:
It really isn't that simple. If it was only one joint that would be great. The problem is that any part of the circuit that malfunctions can cause the same types of issues. There are over 100 solder joints on this thing and at least half of them could cause the unit to appear to 'lose' the programming. If you want to re-heat all of the joints on the board, try it. I'm not sure it is going to fix the problem though. I was told that there are problems with contaminants during the assembly process (such as oil from the assembly persons hand). I don't know if this can be fixed by simply re-heating or adding solder.
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Joined: Oct 2000
Posts: 4,144
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From: Seattle
Scott,
it's good to see that you're still alive and at least thinking about the DCU. I am sympathetic to your position, too (hey, I've just been laid off from my software job).
But why won't you at least take a few minutes to reply to my emails? I haven't heard from you in about two months. You've had my money for six months. I just want to know what to expect.
Ted
it's good to see that you're still alive and at least thinking about the DCU. I am sympathetic to your position, too (hey, I've just been laid off from my software job).
But why won't you at least take a few minutes to reply to my emails? I haven't heard from you in about two months. You've had my money for six months. I just want to know what to expect.
Ted
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Joined: Oct 2000
Posts: 7,134
Likes: 3
From: Columbia, MD
For those of you who are solder-capable, I suggest reflowing all joints on the board, and this will more than likely fix the programming issue for most. For those not solder-capable, see if you can take it to a local tech school or university, pay some kid $20 to reflow the joints (it should take him 15 minutes, tops).
Modifry, by all means, redesign this thing form the ground up. I'd do it myself and release the schematic, but I just have way too much on my plate at the moment.
Modifry, by all means, redesign this thing form the ground up. I'd do it myself and release the schematic, but I just have way too much on my plate at the moment.