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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