Redhatter (VK4MSL)

Toy Synthesizer: 74HC573, no substitute for the ‘574

So… when laying out this board, I decided I’d swap the 74HC374 for the much nicer ‘574 for managing the MOSFETs. No problem, well, one minor snag, neither Jaycar nor Altronics carry the ‘574.

They carry the ‘374… Jaycar is where I got mine originally. They also carry the very similar ‘573. I had intended to order some ‘574s for when the boards arrived, but they sort of turned up unexpectedly… so didn’t get a chance.

The fundamental difference? Apart from the ‘574 being edge triggered, the ‘573 also is active high on the logic enable pin. I had wrongly assumed it was active low .

Naturally, I did try to hack around this fundamental difference:

Tried to get that leg in focus, but it’s difficult when the LCD of the camera is such low resolution (and the viewfinder is an even lower resolution LCD). Basically, I nibbled the leg of the IC with my sidecutters and bent it up. To the pad, I solder the gate of a 2N7000 MOSFET, bend the drain pin up to meet the now floating-in-air LE pin, and run a resistor (a 3k3) to Vcc.

That works somewhat… it might be possible to introduce some more state machine cycles to handle the kludge… although the real fix is to use the correct part in the first place.

Toy Synthesizer: First board built

So, I haven’t yet tried out the MOSFET outputs, but nearly all the GPIO inputs work. I say nearly… there is one that doesn’t on channel 4.

I can test by shorting out the 0V and GPIO pins with a multimeter probe. Not sure why one channel isn’t working yet, that I’ll have to debug tomorrow.

It is worth noting that the MC14066s here are older than I am if I am reading the date codes correctly. Still, they’ve been kept in a tube all these years, so no reason why they’d suddenly pop. More probable, I’ve goofed somewhere in the wiring of this.

At worst, I should be able to de-solder the faulty chip (if that is the case) and put another one in its place… I have plenty lying around. The fact that its mate on the other side is working fine, is promising.

The up side is this board doesn’t look like a big mess of wires like the last prototype. Once I get the faulty channel sorted, I should be able to make the I/O modules that will provide the MOSFET outputs, ESD protection and switch debouncing.

One thing I’ll probably do in future: use bigger vias for my jumper wires, and actually mark on the silk screen component values and the jumper wire routes.


Did some probing… turns out my jumper wire wasn’t making good contact with the via … a dry joint. Definitely I’ll make the vias bigger next time!

Toy Synthesizer: Boards have arrived

So, I had a surprise delivery this morning… 10 PCBs for the new synthesizer.

These are just two-layer affairs… with the idea being that anyone can manufacture these themselves. The top layer if made at home is done just by covering one side of a double-sided PCB with tape. The other can be done by hand with a dalo pen, using photographic methods or using toner transfer.

One thing I did have originally, and lost when I told Kicad to delete all footprints when re-working the design, is the mounting holes in the corners, something I’ll have to re-add.

I’ll have to pick up some 74HC574s (or perhaps ‘573s, since that’s what the hobby shops sell… won’t matter for this project, either will do) and get soldering this weekend.

Toy Synthesizer: First working prototype

So… after some cursing at me being dimwitted enough to get the amplifier around the wrong way… and luckily the amplifier is a tough little beast… I managed to get some basic functions going.

It is supposed to be polyphonic, the synthesizer supports it, and it does actually work, but it seems my GPIO arrangement isn’t picking up multiple buttons correctly.

Ahh well, we’ll get there. 🙂 At least it is making noises and flashing lights on cue, so in that sense, a minimum viable product has been achieved.

Ohh, and I was able to bump the sample rate to 16kHz. 32kHz was a bit much for the little MCU though, it couldn’t quite keep up.

Code size at this point is 3.6kB… so still lots of room left. The answer might be to implement an I²C slave mode so I can interrogate it from the host.

Toy Synthesizer: Getting OC1B & OC1D to play together

So… a bit of head scratching this afternoon. I had working PWM on the LEDs… which was fantastic.

With the trade-off of LEDs being ⅛ brightness maximum, which is fine since the LED strings that I’ve been given for this project would make Manfred Mann proud…

I was a little stumped with my audio PWM. I could not get a peep out of it, not via the amplifier or anything else. Tracing back, I was getting nothing out of the PWM pin. Real strange. Looked up the data sheets, couldn’t see what I was doing wrong.

My code for initialising Timer1 looked like this:

	/* Timer 1 configuration for PWM */
	OCR1B = 128;			/* Initial PWM value: audio */
	OCR1D = 32;			/* Initial PWM value: light */
	OCR1C = 255;			/* Maximum PWM value */
	TCCR1A = (2 << COM1B0)		/* Clear OC1B on match,
					   nOC1B not used */
		| (1 << PWM1B);		/* Enable PWM channel B */
	TCCR1B = (1 << CS10);		/* No prescaling, max speed */
	TCCR1C = (3 << COM1D0)		/* Set OC1D on match,
					   nOC1D not used */
		| (1 << PWM1D);		/* Enable PWM channel D */
	TCCR1D = (0 << WGM10); /* Fast PWM mode */

It looked fine… even checked the header files to see there wasn’t some cock up in the headers. Never had an issue with avr-libc, but you never know, and of course, no problem there.

In exasperation, I swapped setting up TCCR1A and TCCR1C. Bingo, I had PWM both channels. Why? Turns out there are some bits in TCCR1C that shadow TCCR1A, and I was inadvertently setting those back to 0 when I set up TCCR1C. So my code now:

	/* Timer 1 configuration for PWM */
	OCR1C = 255;			/* Maximum PWM value */
	TC1H = 0;			/* Reset counter high bits */
	TCNT1 = 0;			/* Reset counter low bits */
	OCR1A = 0;			/* Initial PWM value: spare */
	OCR1B = 127;			/* Initial PWM value: audio */
	OCR1D = 127;			/* Initial PWM value: light */
	TCCR1A = (1 << PWM1B);		/*
					 * Clear TCCR1A except for PWM1B,
					 * we'll configure OC1B
					 * via the shadow bits in TCCR1C
					 */
	TCCR1B = (1 << CS10);		/* No prescaling, max speed */
	TCCR1C = (2 << COM1B0S)		/* Clear OC1B on match,
					   nOC1B not used */
		| (3 << COM1D0)		/* Set OC1D on match,
					   nOC1D not used */
		| (1 << PWM1D);		/* Enable PWM channel D */
	TCCR1D = (0 << WGM10);		/* Fast PWM mode */
	TCCR1E = 0;			/* Not used: PWM6 mode */

We still need to turn PWM1B on via TCCR1A… but we set the output control mode via TCCR1C to avoid clobbering our settings.

Having fixed that, I now have a second problem, in my dead-bugging of the amp, I got my left and right arse-about, which would explain why my amp is making no noise. That’ll be a tomorrow job methinks, at 22:30 UTC+10:00 it is too dark to work on PCBs. I’ll just keep myself amused looking at the waveform on the oscilloscope.

Toy Synthesizer: Peripheral detection and I²C bus enumeration

So these are some completely untested notes on how I might achieve auto-detection of peripherals and I²C devices.

The idea here is that a peripheral can be plugged into any of the 8 ports on the device. It won’t matter, because there’ll be a standard boot-up procedure, consisting of:

  1. Deriving an I²C bus address (possibly by sampling ADC LSB bits to generate a random address) and verifying that there are no clashes by attempting to poll the derived address a few times.
  2. Performing a read of the bus roll-call I²C address to enumerate the IDs of all automatically-addressed I²C devices on the bus. During this step, the GPIOs are monitored: the slave should pulse the GPIO it is connected to as it “calls out” its ID.
  3. Measuring ADC readings at the GPIO pins and observing power-up state (common GPIO pin in high-impedance state)
  4. Pulling the common GPIO pin (MISO) high and seeing which GPIO pins go high.
  5. Pulling the common GPIO pin (MISO) low and seeing which GPIO pins go low.

The peripherals may be connected via a number of ways:

The boot-up procedure is used to determine what is attached, by performing some simple actions and observing the GPIO pin, which thanks to the ‘4066s, also doubles as an ADC.

As for I²C addressing… I do not want to have to program a unique address into each device. The concept here is instead that each device generates its own address, waits for a clear moment on the bus, then tries polling its proposed address to see if it gets an ACK. In the case of a time-out, it waits a random length of time and tries again when the bus is clear, and after a few times, can safely assume it has the address.

This gives rise to a problem though, knowing what the addresses of the neighbours are.

The idea here is to use a roll-call address. This is common to all units implementing the auto-addressing protocol. When a device hears the roll-call address, it tries to send its ID in reply. When another device with a numerically lower ID sends at the same time, the device sees the collision and tries again on the next byte. As each calls out its ID, it pulses the interrupt pin low (if it uses one).

The result from the master’s perspective is it sees a stream of IDs sorted from numerically lowest to highest, terminated by a stream of 0xff bytes. Direct peers are able to then detect who their peers are.

Timing of all of this will be the challenge. We want to ensure everyone has a unique ID by he time the first roll-call is performed so we can move on to detecting the dumb devices (LEDs and buttons). This network feature will be a stretch-goal of the project though, so plenty of time to think about that.

Toy Synthesizer: PWM Outputs work

So, I’ve done some tweaks to the prototype… namely fixing some wire assignments. I also had to drop my 1kΩ resistor on the input to a 100Ω as the voltage drop of the 1k was too high.

At the moment, I am seeing ~3V at the MCU, which is good enough.

Beneath the afro of wires, is the prototype.

… and this is the PWM LED control in action (animated GIF). So PWMing the output enable of a 74LS374 works, and doing the same on a 74HC574 should too.

So, I’ve done some tweaks to the prototype… namely fixing some wire assignments. I also had to drop my 1kΩ resistor on the input to a 100Ω as the voltage drop of the 1k was too high.

At the moment, I am seeing ~3V at the MCU, which is good enough.

Beneath the afro of wires, is the prototype.

Bootstrapping Gentoo Linux

So, in amongst my pile of crusty old hardware is the old netbook I used to use in the latter part of my univerity days. It is a Lemote Yeeloong, and sports a ~700MHz Loongson 2F CPU (MIPS III little endian ISA) and 1GB RAM.

Back in the day it was a brilliant little machine. It came out of the box running a localised (for China) version of Debian, and had pretty much everything you’d need. I natually repartitioned the machine, setting up Gentoo and I had a separate partition for Debian, so I could actually dual-boot between them.

Fast forward 10 years, the machine runs, but the battery is dead, and Debian no longer supports MIPS-III machines. Debian Jessie does, but Stretch, likely due for release some time this year, will not, if you haven’t got a CPU that supports mips32r2 or mips64r2, you’re stuffed.

I don’t want to throw this machine away.  Being as esoteric as it is, it is an unlikely target for theft, as to the casual observer, it’ll just be “some crappy netbook”.  If someone were to try and steal it, there’s a very high probability I’ll recover it with my data because the day its PMON2000 boot firmware successfully boots a x86-64 OS like Ubuntu or Windows without the assistance of a VM of some kind would be the day Satan puts a requisition order in for anti-freeze and winter mittens.

My use case is for a machine I can take with me on the bicycle.  My needs aren’t huge: I won’t be playing video on this thing, it’ll be largely for web browsing and email.  The web browser needs to support JavaScript, so that rules out options like ELinks or Dillo, my preferred browser is Firefox but I’ll settle for something Webkit-based if that’s all that’s out there.

So what operating systems do I have for a machine that sports a MIPS-III CPU and 1GB RAM?  Fedora has a MIPS port, but that, like Debian, is for the newer MIPS systems.  Arch Linux too is for newer architectures.

I could bootstrap Alpine Linux… and maybe that’s worth looking into, they seem to be doing some nice work in producing a small and capable Linux distribution.  They don’t yet support MIPS though.

Linux From Scratch is an option, if a little labour intensive.  (Been there, done that.)

OpenBSD directly supports this machine, and so I gave OpenBSD 6.0 a try.  It’s a very capable OS, and while it isn’t Linux, there isn’t much that an experienced Linux user like myself needs to adapt to in order to effectively use the OS.  pkgsrc is a great asset to OpenBSD, with a large selection of pre-built packages already available.  Using that, it is possible to get a workable environment up and running very quickly.  OpenBSD/loongson uses the n64 ABI.

Due to licensing worries, they use a particularly old version of binutils as their linker and assembler.  The plan seems to be they wish to wean themselves off the GNU toolchain in favour of LLVM.  At this time though, much of the system is built using the GNU toolchain with some custom patches.  I found that, on the Yeeloong, 1GB RAM was not sufficient for compiling LLVM, even after adding additional swap files, and some packages I needed weren’t available in pkgsrc, nor would they build with the version of GNU tools available.

Maybe as they iron out the kinks in their build environment with LLVM, this will be worth re-visiting.  They’ve done a nice job so far, but it’s not quite up to where I need it to be.

Gentoo actually gives me the choice of two possible ABIs: o32 and n32o32 is the old 32-bit ABI, and suffers a number of performance problems, but generally works.  It’s what Debian Jessie and earlier supplies, and what their mips32 port will produce from Stretch onwards.

n32 is the MIPS equivalent of what some of you may know as x32 on AMD64 platforms, it is a 32-bit environment with 64-bit long pointers… the idea being that very few applications actually benefit from the use of 64-bit data types, and so the usual quantities like int and long remain the same as what they’d be on o32, saving memory.  The long long data type gets a boost because, although “32-bit”, the 64-bit operations are still available for use.

The trouble is, some applications have problems with this mode.  Either the code sees “mips64” in the CHOST and assumes a full 64-bit system (aka n64), or it assumes the pointers are the same width as a long, or the build system makes silly assumptions as to where things get put.  (virtualenv comes to mind, which is what started me on this journey.  The same problem affects x32 on AMD64.)

So I thought, I’d give n64 a try.  I’d see if I can build a cross-compiler on my AMD64 host, and bootstrap Gentoo from that.

Step 1: Cross-compiler

For the cross-compiler, Gentoo has a killer feature that I have not seen in too many other distributions: crossdev.  This is a toolchain build tool that can generate cross-compiler toolchains for most processor architectures and environments.

This is installed by running emerge sys-devel/crossdev.

A gotcha with hardened

I run “hardened” AMD64 stages on my machines, and there’s a little gotcha to be aware of: the hardened USE flag gets set by crossdev, and that can cause fun and games if, like on MIPS, the hardening features haven’t been ported.  My first attempt at this produced a n64 userland where pretty much everything generated a segmentation fault, the one exception being Python 2.7.  If I booted with init=/bin/bash (or init=/bin/bb), my virtual environment died, if I booted with init=/usr/bin/python2.7, I’d be dropped straight into a Python shell, where I could import the subprocess module and try to run things.

Cleaning up, and forcing crossdev to leave off hardened support, got things working.

Building the toolchain

With the above gotcha in mind:

# crossdev --abis n64 \
           --env 'USE="-hardened"' \
           -s4 -t mips64el-unknown-linux-gnu

The --abis n64 tells crossdev you want a n64 ABI toolchain, and the --env will hopefully keep the hardened flag unset. Failing that, try this:

# cat > /etc/portage/package.use/mips64 <<EOF
cross-mips64el-unknown-linux-gnu/binutils -hardened
cross-mips64el-unknown-linux-gnu/gcc -hardened
cross-mips64el-unknown-linux-gnu/glibc -hardened
EOF

If you want a combination of specific toolchain components to try, I’m using:

  • Binutils: 2.28
  • GCC: 5.4.0-r3
  • glibc: 2.25
  • headers: 4.10

Step 2: Checking our toolchain

This is where I went wrong the first time, I tried building the entire OS, only to discover I had wasted hours of CPU time building non-functional binaries. Save yourself some frustration. Start with a small binary to test.

A good target for this is busybox. Run mips64el-unknown-linux-gnu-emerge busybox, and wait for a bit.

When it completes, you should hopefully have a busybox binary:

RC=0 stuartl@beast ~ $ file /usr/mips64el-unknown-linux-gnu/bin/busybox 
/usr/mips64el-unknown-linux-gnu/bin/busybox: ELF 64-bit LSB executable, MIPS, MIPS-III version 1 (SYSV), statically linked, for GNU/Linux 3.2.0, stripped

Testing busybox

There is qemu-user-mips64el, but last time I tried it, I found it broken. So an easier option is to use real hardware or QEMU emulating a full system. In either case, you’ll want to ensure you have your system-of-choice running with a working 64-bit kernel already, if your real hardware isn’t already running a 64-bit Linux kernel, use QEMU.

For QEMU, the path-of-least-resistance I found was to use Debian. Aurélien Jarno has graciously provided QEMU images and corresponding kernels for a good number of ports, including little-endian MIPS.

Grab the Wheezy disk image and the corresponding kernel, then run the following command:

# qemu-system-mips64el -M malta \
    -kernel vmlinux-3.2.0-4-5kc-malta \
    -hda debian_wheezy_mipsel_standard.qcow2 \
    -append "root=/dev/sda1 console=ttyS0,115200" \
    -serial stdio -nographic -net nic -net user

Let it boot up, then log in with username root, password root.

Install openssh-client and rsync (this does not ship with the image):

# apt-get update
# apt-get install openssh-client rsync

Now, you can create a directory, and pull the relevant files from your host, then try the binary out:

# mkdir gentoo
# rsync -aP 10.0.2.2:/usr/mips64el-unknown-linux-gnu/ gentoo/
# chroot gentoo bin/busybox ash

With luck, you should be in the chroot now, using Busybox.

Step 3: Building the system

Having done a “hello world” test, we’re now ready to build everything else. Start by tweaking your /usr/mips64el-unknown-linux-gnu/etc/portage/make.conf to your liking then adjust /usr/mips64el-unknown-linux-gnu/etc/portage/make.profile to point to one of the MIPS profiles. For reference, on my system:

RC=0 stuartl@beast ~ $ ls -l /usr/mips64el-unknown-linux-gnu/etc/portage/make.profile
lrwxrwxrwx 1 root root 49 May  1 09:26 /usr/mips64el-unknown-linux-gnu/etc/portage/make.profile -> /usr/portage/profiles/default/linux/mips/13.0/n64
RC=0 stuartl@beast ~ $ cat /usr/mips64el-unknown-linux-gnu/etc/portage/make.conf 
CHOST=mips64el-unknown-linux-gnu
CBUILD=x86_64-pc-linux-gnu
ARCH=mips

HOSTCC=x86_64-pc-linux-gnu-gcc

ROOT=/usr/${CHOST}/

ACCEPT_KEYWORDS="mips ~mips"

USE="${ARCH} -pam"

CFLAGS="-O2 -pipe -fomit-frame-pointer"
CXXFLAGS="${CFLAGS}"

FEATURES="-collision-protect sandbox buildpkg noman noinfo nodoc"
# Be sure we dont overwrite pkgs from another repo..
PKGDIR=${ROOT}packages/
PORTAGE_TMPDIR=${ROOT}tmp/

ELIBC="glibc"

PKG_CONFIG_PATH="${ROOT}usr/lib/pkgconfig/"
#PORTDIR_OVERLAY="/usr/portage/local/"

Now, you should be ready to start building:

# mips64el-unknown-linux-gnu-emerge -e \
    --keep-going -j6 --load-average 12.0 @system

Now, go away, and do something else for several hours.  It’ll take that long, depending on the speed of your machine.  In my case, the machine is an AMD Phenom II x6 with 8GB RAM, which was brand new in 2010.  It took a good day or so.

Step 4: Testing our system

We should have enough that we can boot our QEMU VM with this image instead.  One way of trying it would be to copy across the userland tree the same way we did for pulling in busybox and chrooting back in again.

In my case, I took the opportunity to build a kernel specifically for the VM that I’m using, and made up a disk image using the new files.

Building a kernel

Your toolchain should be able to cross-build a kernel for the virtual machine.  To get you started, here’s a kernel config file.  Download it, decompress it, then drop it into your kernel source tree as .config.

Having done that, run make olddefconfig ARCH=mips to set the defaults, then make menuconfig ARCH=mips and customise to your hearts content. When finished, run make -j6 vmlinux modules CROSS_COMPILE=mips64el-unknown-linux-gnu- to build the kernel and modules.

Finally, run make modules_install firmware_install INSTALL_MOD_PATH=$PWD/modules CROSS_COMPILE=mips64el-unknown-linux-gnu- to install the kernel modules and firmware into a convenient place.

Making a root disk

Create a blank, raw disk image using qemu-img, then partition it as you like and mount it as a loopback device:

# qemu-img create -f raw gentoo.raw 8G
# fdisk gentoo.raw
(do your partitioning here)
# losetup -P /dev/loop0 $PWD/gentoo.raw

Now you can format the partitions /dev/loop0pX as you see fit, then mount them in some convenient place. I’ll assume that’s /mnt/vm for now. You’re ready to start copying everything in:

# rsync -aP /usr/mips64el-unknown-linux-gnu/ /mnt/vm/
# rsync -aP /path/to/kernel/tree/modules/ /mnt/vm/

You can use this opportunity to make some tweaks to configuration files, like updating etc/fstab, tweaking etc/portage/make.conf (changing ROOT, removing CBUILD), and setting up a getty on ttyS0. I also like to symlink lib to lib64 in non-multilib environments such as this: Don’t symlink lib and lib64! See below.

# cd /mnt/vm
# mv lib/* lib64
# rmdir lib
# ln -s lib64 lib
# cd usr
# mv lib/* lib64
# rmdir lib
# ln -s lib64 lib

When you’re done, unmount.

First boot

Run QEMU with the following arguments:

# qemu-system-mips64el -M malta \
    -kernel /path/to/your/kernel/vmlinux \
    -hda /path/to/your/gentoo.raw \
    -append "root=/dev/sda1 console=ttyS0,115200 init=/bin/bash" \
    -serial stdio -nographic -net nic -net user

It should boot straight to a bash prompt. Mount the root read/write, and then you can make any edits you need to do before boot, such as changing the root password. When done, re-mount the root as read-only, then exec /sbin/init.

# mount / -o rw,remount
# passwd
… etc
# mount / -o ro,remount
# exec /sbin/init

With luck, it should boot to completion.

Step 5: Making the VM a system service

Now, it’d be real nice if libvirt actually supported MIPS VMs, but it doesn’t appear that it does, or at least I couldn’t get it to work.  virt-manager certainly doesn’t support it.

No matter, we can make do with a telnet console (on loopback), and supervisord to daemonise QEMU.  I use the following supervisord configuration file to start my VMs:

[unix_http_server]
file=/tmp/supervisor.sock   ; (the path to the socket file)

[supervisord]
logfile=/tmp/supervisord.log ; (main log file;default $CWD/supervisord.log)
logfile_maxbytes=50MB        ; (max main logfile bytes b4 rotation;default 50MB)
logfile_backups=10           ; (num of main logfile rotation backups;default 10)
loglevel=info                ; (log level;default info; others: debug,warn,trace)
pidfile=/tmp/supervisord.pid ; (supervisord pidfile;default supervisord.pid)
nodaemon=false               ; (start in foreground if true;default false)
minfds=1024                  ; (min. avail startup file descriptors;default 1024)
minprocs=200                 ; (min. avail process descriptors;default 200)

; the below section must remain in the config file for RPC
; (supervisorctl/web interface) to work, additional interfaces may be
; added by defining them in separate rpcinterface: sections
[rpcinterface:supervisor]
supervisor.rpcinterface_factory = supervisor.rpcinterface:make_main_rpcinterface

[supervisorctl]
serverurl=unix:///tmp/supervisor.sock ; use a unix:// URL  for a unix socket

[program:qemu-mips64el]
command=/usr/bin/qemu-system-mips64el -cpu MIPS64R2-generic -m 2G -spice disable-ticketing,port=5900 -M malta -kernel /home/stuartl/kernels/qemu-mips/vmlinux -hda /var/lib/libvirt/images/gentoo-mips64el.raw -append "mem=256m@0x0 mem=1792m@0x90000000 root=/dev/sda1 console=ttyS0,115200" -chardev socket,id=char0,port=65223,host=::1,server,telnet,nowait -chardev socket,id=char1,port=65224,host=::1,server,telnet,nowait -serial chardev:char0 -mon chardev=char1,mode=readline -net nic -net bridge,helper=/usr/libexec/qemu-bridge-helper,br=br0

The following creates two telnet sockets, port 65223 is the VM’s console, 65224 is the QEMU control console. The VM has the maximum 2GB RAM possible and uses bridged networking to the network bridge br0. There is a graphical console available via SPICE.

All telnet and SPICE interfaces are bound to loopback, so one must use SSH tunnelling to reach those ports from another host. You can change the above command line to use VNC if that’s what you prefer.

At this point, the VM should be able to boot on its own. I’d start with installing some basic packages, and move on from there. You’ll find the environment is very sparse (my build had no Perl binary for example) but the basics for building everything should be there.

You may also find that what is there, isn’t quite installed right… I found that sshd wasn’t functional due to missing users… a problem soon fixed by doing an emerge -K openssh (the earlier step will have produced binary packages).

In my case, that’s installing a decent text editor (vim) and GNU screen so I can start a build, then detach.  Lastly, I’ll need catalyst, which is Gentoo’s release engineering tool.

At the moment, this is where I’m at.  GNU screen has indirectly pulled in Perl as a dependency, and that is building as I type this.  It is building faster than the little netbook does, and I have the bonus that I can throw more RAM at the problem than I can on the real hardware. The plan from here:

  1. emerge -ek @system, to build everything that got missed before.
  2. ROOT=/tmp/seed emerge -eK @system, to bundle everything up into a staging area
  3. populating /tmp/seed/dev with device files
  4. tar-ing up /tmp/seed to make my initial “seed” stage for catalyst.
  5. building the first n64 stages for Gentoo using catalyst
  6. building the packages I want for the netbook in a chroot
  7. transferring the chroot to the netbook

Symlinking lib and lib64… don’t do it!

So, I was doing this years ago when n32 was experimental.  I recall it being necessary then as this was before Portage having proper multilib support.  The earlier mipsel n32 stages I built, which started out from kanaka‘s even more experimental multilib stages, required this kludge to work-around the lack of support in Portage.

Portage has changed, it now properly handles multilib, and so the symlink kludge is not only not necessary, it breaks things rather badly, as I discovered.  When packages merge files to /lib, rather than following the symlink, they’ll replace it with a directory.  At that point, all hell breaks loose, because stuff that “appeared” in /lib before is no longer there.

I was able to recover by rsync-ing /lib64 to /lib, which isn’t a pretty solution, but it’ll be enough to get an initial “seed” stage.  Running that seed stage through Catalyst will clean up the remnants of that bungle.

Solar Cluster: Selecting batteries and sources

I’ve been doing quite a bit of thinking on this. Solid-state works but suffers from voltage drop. Relays work but either require the coil to be energised constantly (~1W load) unless you look for latching relays, for which 30A units are hard to come by.

These look promising though. A latching relay is nice since I only need to pulse the coil, not hold it on indefinitely.

That got me thinking what else can I use to switch power? The ideal for me is something that has practically no voltage drop and remembers its state without power. A latching relay fits this requirement. So does a uniselector or stepping switch. Those were commonplace in telephone exchanges years ago, but have since gone the way of the dodo as semiconductor technology replaced it.

The nice thing about a uniselector though for my application is you can switch between N points, instead of just two like a regular relay. So if I buy a third battery, I can wire it up to the uniselector, and have it switch the compute load between the batteries. Likewise, I can connect a charger to the battery most in need of a charge. MCU measures battery voltages, picks the battery with highest voltage to run the load, and the lowest voltage to get a charge. Easy.

That got me thinking… can I make a uniselector? Well of course I can! I basically need to make a rotary switch that can revolve around indefinitely. The shaft of the switch would then be turned by a DC motor.

The stator of a N-way switch would have N+1 pads, one which is the “common”, and the other N would be to each selection. The common pad would be a 180° arc, the others would be 180°/N.

The rotor would feature two brushes 180° apart with a wire connecting them. It is free to move vertically, but must rotate with the shaft, a spring between a nut on the end of the shaft and the rotor applies tension to keep the rotor pressed firmly against the stator.

The interface between rotor and stator features some triangular grooves, so that when the rotor is turned, it pushes it away from the stator, breaking contact. When the rotor passes a critical point, the spring pressing the rotor against these grooves makes the rotor “want” to continue turning until it hits the bottom of the groove, at which point it “sinks” down towards the stator and eventually makes contact again.

Visually, it looks like this:

A small microswitch mounted on the stator could tell us when touch-down takes place, if we use the normally-closed contact to power the motor it will automatically stop the motor when the next position is reached. We then just need to override that open switch by applying a pulse to get things moving.

Power is only needed when we want to change the selector switch. This should be simple enough to fabricate here out of plywood. I don’t have a 3D printer, but you could do it with one of those very easily.

The nature of this switch makes it a break-before-make switch, which has a downside when using it to select which battery to use: there’s a momentary break in power.

I can use diodes to carry the current temporarily. If I run a high-current diode from each battery to the output via a current sensor. If the current sensor measures current flowing through the diodes whilst a battery is selected, then we know that battery is lower than the others by at least the diode voltage drop, and we should consider switching.