Well, the point I was making was that financial
pressures sometimes make things that started out well
designed not well built. Interesting you brought up
Muntz - although his televisions were made from pure
evil (running tubes in parallel to get the 6.3v, fer
instance), he did make cheap TV's that less wealthy
people could buy, that worked fairly well as long as
you were in a big city, and until it broke. I have the
schematics for the Xerox/Diablo HyType II printer here
- made by a company with quite considerable
engineering and manufacturing know-how - and what you
describe happened in this design, someone took out too
many bypass caps, then someone ECO'd them back in. And
this was not a "cheap" printer. Obviously, someone
tried to shave every nickel. I know that in super-high
volume products, engineers do have to fight for every
single part - because this cost board space, stocking,
etc, and so on. A 0.005 cent resistor actually costs
quite a bit more more on the board. But this is a
classic engineering/cost engineering problem, common
in any kind of engineering/manufacturing endeavor. If
engineers had their way, blank check, to make a
"perfect" product, no one would be able to afford any
of the "goodies" we have today. But, I state the
obvious.
I marvel at how well the HP2644A I have is built. But
really, did it have to be built so well that it would
be working 27 years later, long after it was obsolete?
The original purchaser paid for a lot more than they
used. HP used to make the best stuff. But if they
still made stuff that way, they would be out of
business. Such is the world we live in.
--- Eric Smith <eric(a)brouhaha.com> wrote:
I asked how
come there were only a few
bypass caps instead of the traditional one per
chip,
and the chief engineer (who wrote The famous
Microcomputer Design book, Don Martin of Martin
Research), who definitely knew how to build
things,
told me that the board would start with them all
in.
Then they would be removed until the board
stopped
working. Then they'd put that one back in!
The Earl "Madman" Muntz approach. Just because you
think he knew
how to build things didn't make that good
engineering practice.
You should have *more* bypass caps than you need
under normal
conditions, because there will be real-world
conditions that
don't match your lab bench.
There are definitely ways to determine a reasonable
minimum number
of bypass capacitors as an engineering exercise, but
this is MUCH
more complicated than taking them out until the
product breaks, and
adding one back in. In particular, it's not just
the total count
of bypass capacitors that's important. They have to
be in the
right places. Just because they're conceptually all
in parallel
doesn't mean that they can be anywhere on the board.
The power and
ground traces (or planes) have resistance and
inductance, which is
part of the reason that you need bypass capacitors
in the first place.
So the bypass capacitors must be physically near the
components that
have large current fluctuations.
"One per chip" or "one per two chips" are rules of
thumb that can be
used with some kinds of logic chips to get
reasonably bypassing
without having to do detailed analysis. Yes, you
can get by with
less, but not simply by randomly removing some and
hoping for the
best.
How do I know this is a problem? From personal
experience with
two companies that left out bypass capacitors
despite the
objections of the hardware engineer, because it
still seemed to
work OK in the lab. In both cases, I had to debug
the resulting
problems, which were blamed on software. At first I
believed it
was the software, but eventually I discovered that
adding the bypass
capacitor back into the circuit fixed the problem.
Once I'd finally
proven this to management, it was ECO'd back in. In
one case, a
bunch of inventory had to be reworked (expensive!),
and in the other
case, the inventory was scrapped. But the worst
part was the units
already in the field. RMAs cost a *lot* of money.
Seriously,
they would look at the power supply and use just
enough with a little extra margin.
You can't determine how many bypass capacitors you
need
by looking at the power supply.
It's my understanding that electrommagnetic
deflected
vector displays take very, very high-power
deflection
coils and drivers, and this is where the real
money is
in these units. I don't know if the Imlac is
electrostatic or electromagnetic deflection
(electromagnetic, I suspect).
That has *nothing* to do with using lots of RC
delays in
the design of the digital logic of a processor. I
won't
go so far as to say that doing so is always wrong,
but
you would need an awful lot of justification for
doing it.
From what I've seen, the Imlac was in fact poorly
designed,
just as others have asserted. They might have
reduced
their manufacturing cost, or they might not have.
But
they decreased the reliability of the machine
considerably.
Usually a tradeoff like that winds up being a false
economy
for the company -- penny wise, pound foolish.
Eric
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