Showing posts with label electronics. Show all posts
Showing posts with label electronics. Show all posts

The BeagleBone's I/O pins: inside the software stack that makes them work

The BeagleBone is a inexpensive, credit-card sized computer with many I/O pins. These pins can be easily controlled from software, but it can be very mysterious what is really happening. To control a general purpose input/output (GPIO) pin, you simply write a character to a special file and the pin turns on or off. But how do these files control the hardware pins? In this article, I dig into the device drivers and hardware and explain exactly what happens behind the scenes. Warning: this post uses the 3.8.13-bone79 kernel; many things have changed since then. (Various web pages describe the GPIO pins, but if you just want a practical guide of how to use the GPIO pins, I recommend the detailed and informative book Exploring BeagleBone.)

This article focuses on the BeagleBone Black, the popular new member of the BeagleBoard family. If you're familiar with the Arduino, the BeagleBone is much more complex; while the Arduino is a microcontroller, the BeagleBone is a full computer running Linux. If you need more than an Arduino can easily provide (more processing, Ethernet, WiFi), the BeagleBone may be a good choice.

Beaglebone Black single-board computer. Photo by Gareth Halfacree, CC BY-SA 2.0

The BeagleBone uses the Sitara AM3358 processor chip running at 1 GHz - this is the thumbnail-sized chip in the center of the board above. This chip is surprisingly complicated; it appears they threw every feature someone might want into the chip. The diagram below shows what is inside the chip: it includes a 32-bit ARM processor, 64KB of memory, a real-time clock, USB, Ethernet, an LCD controller, a 3D graphics engine, digital audio, SD card support, various networks, I/O pins, an analog-digital converter, security hardware, a touch screen controller, and much more.[1] To support real-time applications, the Sitara chip also includes two separate 32-bit microcontrollers (on the chip itself - processors within processors!).

Functional diagram of the complex processor powering the BeagleBone Black. The TI AM3358 Sitara processor contains many functional units. Diagram from Texas Instruments.

Functional diagram of the complex processor powering the BeagleBone Black. The TI AM3358 Sitara processor contains many functional units. Diagram from Texas Instruments.

The main document that describes the Sitara chip is the Technical Reference Manual, which I will call the TRM for short. This is a 5041 page document describing all the feature of the Sitara architecture and how to control them. But for specifics on the AM3358 chip used in the BeagleBone, you also need to check the 253 page datasheet. I've gone through these documents, so you won't need to, but I reference the relevant sections in case you want more details.

Using a GPIO pin

The chip's pins can be accessed through two BeagleBone connectors, called P8 and P9. To motivate the discussion, I'll use an LED connected to GPIO 49, which is on pin 23 of header P9 (i.e. P9_23). (How do you know this pin is GPIO 49? I explain that below.) Note that the Sitara chip's outputs can provide much less current than the Arduino, so be careful not to overload the chip; I used a 1K resistor.

To output a signal to this GPIO pin, simply write some strings to some files:

# echo 49 > /sys/class/gpio/export
# echo out > /sys/class/gpio/gpio49/direction
# echo 1 > /sys/class/gpio/gpio49/value

The first line causes a directory for gpio49 to be created. The next line sets the pin mode as output. The third line turns the pin on; writing 0 will turn the pin off.

This may seem like a strange way to control the GPIO pins, using special file system entries. It's also strange that strings ("49", "out", and "1") are used to control the pin. However, the file-based approach fits with the Unix model, is straightforward to use from any language, avoids complex APIs, and hides the complexity of the chip.

The file-system approach is very slow, capable of toggling a GPIO pin at about 160 kHz, which is rather awful performance for a 1 GHz processor.[2] In addition, these oscillations may be interrupted for several milliseconds if the CPU is being used for other tasks, as you can see from the image below. This is because file system operations have a huge amount of overhead and context switches before anything gets done. In addition, Linux is not a real-time operating system. While the processor is doing something else, the CPU won't be toggling the pins.

An I/O pin can be toggled to form an oscillator. Unfortunately, oscillations can stop for several milliseconds if the processor is doing something else.

An I/O pin can be toggled to form an oscillator. Unfortunately, oscillations can stop for several milliseconds if the processor is doing something else.

The moral here is that controlling a pin from Linux is fine if you can handle delays of a few milliseconds. If you want to produce an oscillation, don't manually toggle the pin, use a PWM (pulse width modulator) output instead. If you need more complex real-time outputs, use one of the microcontrollers (called a PRU) inside the processor chip.

What's happening internally with GPIOs?

Next, I'll jump to the low level, explaining what happens inside the chip to control the GPIO pins. A GPIO pin is turned on or off when a chip register at a particular address is updated. To access memory directly, you can use devmem2, a simple program that allows a memory register to be read or written. Using the devmem2 program, we can turn the GPIO pin first on and then off by writing a value to the appropriate register (assuming the pin has been initialized). The first number is the address, and the second number is value written to the address.
devmem2 0x4804C194 w 0x00020000
devmem2 0x4804C190 w 0x00020000

What are all these mystery numbers? GPIO 49 is also known as GPIO1_17, the 17th pin in the GPIO1 bank (as will be explained later). The value written to the register, 0x00020000, is a 1 bit shifted left 17 positions (1<<17) to control pin 17. The address 4804C194 is the address of the register used to turn on a GPIO pin. Specifically it is SETDATAOUT register for the 32 GPIO1 pins. By writing a bit to this register, the corresponding pin is turned on. Similarly, the address 4804C190 is the address of the CLEARDATAOUT register, which turns a pin off.

How do you determine these register addresses? It's all defined in the TRM document if you know where to look. The address 4804C000 is the starting address of GPIO1's registers (see Table 2-3 in the TRM). The offset 194h is the offset of the GPIO_SETDATAOUT register, and 190h is the GPIO_CLEARDATAOUT register (see TRM 25.4.1). Combining these, we get the address 4804C194 for GPIO1's SETDATAOUT and 4804C190 for CLEARDATAOUT. Writing a 1 bit to the SETDATAOUT register will set that GPIO, while leaving others unchanged. Likewise, writing a 1 bit to the CLEARDATOUT register will clear that GPIO. (Note that this design allows the selected register to be modified without risk of modifying other GPIO values.)

Putting this all together, writing the correct bit pattern to the address 0x4804C194 or 0x4804C190 turns the GPIO pin on or off. Even if you use the filesystem API to control the pin, these registers are what end up controlling the pin.

How does devmem2 work? It uses Linux's /dev/mem, which is a device file that is an image of physical memory. devmem2 maps the relevant 4K page of /dev/mem into the process's address space and then reads or writes the address corresponding to the desired physical address.

By using mmap and toggling the register directly from a C++ program, the GPIO can be toggled at about 2.8 MHz, much faster than the device driver approach.[3] If you think this approach will solve your problems, think again. As before, there are jitter and multi-millisecond dropouts if there is any other load on the system.

The names of pins

Confusingly, each pin has multiple names and numbers. For instance, pin 23 on header 9 is GPIO1_17, which is GPIO 49, which is pin entry 17 (unrelated to GPIO1_17) which is pin V14 on the chip itself. Meanwhile, the pin has 7 other functions including GMPC_A1, which is the name used for the pin in the documentation. This section explains the different names and where they come form. (If you just want to know the pin names, see the diagrams P8 header and P9 header from Exploring Beaglebone.)

The first complication is that each pin has eight different functions since the processor has many more internal functions than physical pins.[4] (The Sitara chip has about 639 I/O signals, but only 124 output pins available for these signals.) The solution is that each physical pin has eight different internal functions mapped to it. For each pin, you select a mode 0 through 7, which selects which of the eight possible functions you want.

Figuring out "from scratch" which functions are on each BeagleBone header pin is tricky and involves multiple documents. To start, you need to determine what functions are on each physical pin (actually ball) of the chip. Table 4-1 in the chip datasheet shows which signals are associated with each physical pin (see the "ZCZ ball number"). (Or see section 4.3 for the reverse mapping, from the signal to the pin.) Then look at the BeagleBone schematic to see the connection from each pin on the chip (page 3) to an external connector (page 11).

For instance, consider the GPIO pin used earlier. With the ZCZ chip package, chip ball V14 is called GPMC_A1 (in mode 0 this pin is used for the General Purpose Memory Controller). The Beaglebone documentation names the pin with the the more useful mode 7 name "GPIO1_17", indicating GPIO 17 in GPIO bank 1. (Each GPIO bank (0-3) has 32 pins. Bank 0 is numbered 0-31, bank 1 is 32-63, and so forth. So pin 17 in bank 1 is GPIO number 32+17=49.) The schematic shows this chip ball is connected to header P9 pin 23, earning it the name P9_23. This name is relevant when connecting wires to the board. It is also the name used in BeagleScript (discussed later).

Another pin identifier is the sequential pin number based on the the pin control registers. (This number is indicated under the column $PINS in the header diagrams.) Table 9-10 in the TRM lists all the pins in order along with their control address offsets. Inconveniently, the pin names are the mode 0 names (e.g. conf_gpmc_a1), not the more relevant names (e.g. gpio1_17). From this table, we can determine that the offset of con_gpmc_a1 is 844h. Counting the entries (or computing (844h-800h)/4) shows that this is pin 17 in the register list. (It's entirely coincidental that this number 17 matches GPIO1_17). This number is necessary when using the pin multiplexer (described later).

How writing to a file toggles a GPIO

When you write a string to /sys/class/gpio/gpio49/value, how does that end up modifying the GPIO? Now that some background has been presented, this can be explained. At the hardware level, toggling a GPIO pin simply involves setting a bit in a control register, as explained earlier. But it takes thousands of instructions in many layers to get from writing to the file to updating the register and updating the GPIO pin.

The write goes through the standard Linux file system code (user library, system call code, virtual file system layer) and ends up in the sysfs virtual file system. Sysfs is an in-memory file system that exposes kernel objects through virtual files. Sysfs will dispatch the write to the gpio device driver, which processes the request and updates the appropriate GPIO control register.

In more detail, the /sys/class/gpio filesystem entries are provided by the gpio device driver (documentation for sysfs and gpio). The main gpio driver code is gpiolib.c. There are separate drivers for many different types of GPIO chips; the Sitara chip (and the related OMAP family) uses gpio-omap.c. The Linux code is in C, but you can think of gpiolib.c as the superclass, with subclasses for each different chip. C function pointers are used to access the different "methods".

The gpiolib.c code informs sysfs of the various files to control GPIO pin attributes (/active_low, /direction/, /edge, /value), causing them to appear in the file system for each GPIO pin. Writes to the /value file are linked to the function gpio_value_store, which parses the string value, does error checking and calls gpio_set_value_cansleep, which calls chip->set(). This function pointer is where handling switches from the generic gpiolib.c code to the device-specific gpio-omap.c code. It calls gpio_set, which calls _set_gpio_dataout_reg, which determines the register and bit to set. This calls raw_writel, which is inline ARM assembler code to do a STR (store) instruction. This is the point at which the GPIO control register actually gets updated, changing the GPIO pin value.[5] The key point is that a lot of code runs to get from the file system operation to the actual register modification.

How does the code know the addresses of the registers to update? The file gpio-omah.h contains constants for the GPIO register offsets. Note that these are the same values we used earlier when manually updating the registers.

#define OMAP4_GPIO_CLEARDATAOUT  0x0190
#define OMAP4_GPIO_SETDATAOUT  0x0194

But how does the code know that the registers start at 0x4804C000? And how does the system know this is the right device driver to use? These things are specified, not in the code, but in a complex set of configuration files known as Device Trees, explained next.

Device Trees

How does the Linux kernel know what features are on the BeagleBone? How does it know what each pin does? How does it know what device drivers to use and where the registers are located? The BeagleBone uses a Linux feature called the Device Tree, where the hardware configuration is defined in a device tree file.

Linux used to define the hardware configuration in the kernel. But each new ARM chip variant required inconvenient kernel changes, which led to Linus Torvald's epic rant on the situation. The solution was to move this configuration out of kernel code and into files known as the Device Tree, which specifies the hardware associated with the device. This switch, in the 3.8 kernel, is described here.

As if device trees weren't complex enough, the next problem was that BeagleBone users wanted to change pin configuration dynamically. The solution to this was device tree overlays, which allow device tree files to modify other device tree files. With a device tree overlay, the base hardware configuration can be modified by configuration in the overlay file. Then the Capemgr was implemented to dynamically load device tree fragments, to manage the installation of BeagleBoard daughter cards (known as capes).

I won't go into the whole explanation of device trees, but just the parts relevant to our story. For more information see A Tutorial on the Device Tree, Device Tree for Dummies, or Introduction to the BeagleBone Black Device Tree.

The BeagleBone's device tree is defined starting with am335x-boneblack.dts, which includes am33xx.dtsi and am335x-bone-common.dtsi.

The relevant lines are in am33xx.dtsi:

gpio1: [email protected] {
  compatible = "ti,omap4-gpio";
  ti,hwmods = "gpio1";
  gpio-controller;
  interrupt-controller;
  reg = <0x44e07000 0x1000>;
  interrupts = <96>;
};

The "compatible" line is very important as it causes the correct device driver to be loaded. While processing a device tree file, the kernel checks all the device drivers to find one with a matching "compatible" line. In this case, the winning device driver is gpio-omap.c, which we looked at earlier.

The other lines of interest specify the register base address 44e07000. This is how the kernel knows where to find the necessary registers for the chip. Thus, the Device Tree is the "glue" that lets the device drivers in the kernel know the specific details of the registers on the processor chip.

BoneScript

One easy way to control the BeagleBone pins is by using JavaScript along with BoneScript, a Node.js library. The BoneScript API is based on the Arduino model. For instance, the following code will turn on the GPIO on pin 23 of header P9.
var b = require('bonescript');
b.pinMode('P9_23', b.OUTPUT);
b.digitalWrite('P9_23', b.HIGH);

Using BoneScript is very slow: you can toggle a pin at about 370 Hz, with a lot of jitter and the occasional multi-millisecond gap. But for programs that don't require high speed, BoneScript provides a convenient programming model, especially for applications with web interaction.

For the most part, the BoneScript library works by reading and writing the file system pseudo-devices described earlier. You might expect BoneScript to have some simple code to convert the method calls to the appropriate file system operations, but BoneScript is surprisingly complex. The first problem is BoneScript supports different kernel versions with different cape managers and pin multiplexers, so it implements everything four different ways (source).

A bit surprise is that BoneScript generates and installs new device tree files as a program is running. In particular, for the common 3.8.13 kernel, BoneScript creates a new device tree overlay (e.g. /lib/firmware/bspm_P9_23_2f-00A0.dts) on the fly from a template, runs it through the dtc compiler and installs the device tree overlay through the cape manager by writing to /sys/devices/bone_capemgr.N/slots (source). That's right, when you do a pinMode() operation in the code, BoneScript runs a compiler!

Conclusion

The BeagleBone's GPIO pins can be easily controlled through the file system, but a lot goes on behind the scenes, making it very mysterious what is actually happening. Examining the documentation and the device drivers reveals how these file system writes affect the pins by writing to various control registers.[6] Hopefully after reading this article, the internal operation of the Beaglebone will be less mysterious.

Notes and references

[1] Many of the modules of the Sitara chip have cryptic names. A brief explanation of some of them, along with where they are described in the TRM:

  • PRU-ICSS (Programmable Real-Time Unit / Industrial Communication Subsystem, chapter 4): this is the two real-time microcontrollers included in the chip. They contain their own modules.
  • Industrial Ethernet is an extension of Ethernet protocols for industrial environments that require real-time, predictable communication. The Industrial Ethernet module provides timers and I/O lines that can be used to implement these protocols.
  • SGX (chapter 5) is a 2D/3D graphics accelerator.
  • GPMC is the general-purpose memory controller. OCMC is the on-chip memory controller, providing access to 64K of on-chip RAM. EMIF is the external memory interface. It is used on the BeagleBone to access the DDR memory. ELM (error location module) is used with flash memory to detect errors. Memory is discussed in chapter 7 of the TRM.
  • L1, L2, L3, L4: The processor has L1 instruction and data caches, and a larger L2 cache. The L3 interconnect provides high-speed communication between many of the modules of the processor using a "NoC" (Network on Chip) infrastructure. The slower L4 interconnect is used for communication with low-bandwidth modules on the chip. (See chapter 10 of the TRM.)
  • EDMA (enhanced direct memory access, chapter 11) provides transfers between external memory and internal modules.
  • TS_ADC (touchscreen, analog/digital converter, chapter 12) is a general-purpose analog to digital converter subsystem that includes support for resistive touchscreens. This module is used on the BeagleBone for the analog inputs.
  • LCD controller (chapter 13) provides support for LCD screens (up to 2K by 2K pixels). This module provides many signals to the TDA19988 HDMI chip that generates the BeagleBone's HDMI output.
  • EMAC (Ethernet Media Access Controller, chapter 14) is the Ethernet subsystem. RMII (reduced media independent interface) is the Ethernet interface used by the BeagleBone. MDIO (management data I/O) provides control signals for the Ethernet interface. GMII and RGMII are similar for gigabit Ethernet (unused on the BeagleBone).
  • The PWMSS (Pulse-width modulation subsystem, chapter 15) contains three modules. The eHRPWM (enhanced high resolution pulse width modulator) generates PWM signals, digital pulse trains with selectable duty cycle. These are useful for LED brightness or motor speed, for instance. These are sometimes called analog outputs, although technically they are not. This subsystem also includes the eCAP (enhanced capture) module which measures the time of incoming pulses. eQEP (Enhanced quadrature encoder pulse) module is a surprisingly complex module to process optical shaft encoder inputs (e.g. an optical encoder disk in a mouse) to determine its rotation.
  • MMC (multimedia card, chapter 18) provides the SD card interface on the BeagleBone.
  • UART (Universal Asynhronous Receiver/Transmitter, chapter 19) handles serial communication.
  • I2C (chapter 21) is a serial bus used for communication with devices that support this protocol.
  • The McASP (Multichannel audio serial port, chapter 22) provides digital audio input and output.
  • CAN (controller area network, chapter 23) is a bus used for communication on vehicles.
  • McSPI (Multichannel serial port interface, chapter 24) is used for serial communication with devices supporting the SPI protocol.

[2] The following C++ code uses the file system to switch GPIO 49 on and off. Remove the usleeps for maximum speed. Note: this code omits pin initialization; you must manually do "echo 49 > /sys/class/gpio/export" and "echo out > /sys/class/gpio/gpio49/direction".

#include <unistd.h>
#include <fcntl.h>

int main() {
  int fd =  open("/sys/class/gpio/gpio49/value", O_WRONLY);
  while (1) {
    write(fd, "1", 1);
    usleep(100000);
    write(fd, "0", 1);
    usleep(100000);
  }
}

[3] Here's a program based on devmem2 to toggle the GPIO pin by accessing the register directly. The usleeps are delays to make the flashing visible; remove them for maximum speed. For simplicity, this program does not set the pin directions; you must do that manually.

#include <fcntl.h>
#include <sys/mman.h>

int main() {
    int fd = open("/dev/mem", O_RDWR | O_SYNC);
    void *map_base = mmap(0, 4096, PROT_READ | PROT_WRITE, MAP_SHARED,
            fd, 0x4804C000);
    while (1) {
        *(unsigned long *)(map_base + 0x194) = 0x00020000;
        usleep(100000);
        *(unsigned long *)(map_base + 0x190) = 0x00020000;
        usleep(100000);
    }
}

For more on this approach, see BeagleBone Black GPIO through /dev/mem.

[4] Selecting one of the eight functions for each pin is done through the pin multiplexer (pinmux) which uses the pinctrl-single device driver. Pin usage is defined in the device tree. The details of this are complex and change from kernel to kernel. See GPIOs on the Beaglebone Black using the Device Tree Overlays or BeagleBone and the 3.8 Kernel for details.

[5] The function names tend to change in different kernel versions. I'm describing the Linux 3.8 kernel code.

[6] I've discussed just the GPIO pins, but other pins (LED, PWM, timer, etc) have similar file system entries, device drivers, and device tree entries.

Inside the tiny RFID chip that runs San Francisco's "Bay to Breakers" race

How does a tiny chip time the runners in the Bay to Breakers race? In this article, I take die photos of the RFID chip used to track athletes during the race.

Bay to Breakers, 2016. Photo courtesy of David Yu, CC BY-NC-ND 2.0.

Bay to Breakers, 2016. Photo courtesy of David Yu, CC BY-NC-ND 2.0.

Bay to Breakers is the iconic San Francisco race, with tens of thousands of runners (many in costume and some in nothing) running 12km across the city. To determine their race time, each runner wears an identification bib. As you can see below, the back of the bib has a small foam rectangle with a metal foil antenna and a tiny chip underneath. The runners are tracked using a technology called RFID (Radio Frequency Identification).

The bib worn by runners in the Bay to Breakers race. At the top, behind the foam is an antenna and RFID chip used to detect the runner at the start and end of the race.

The bib worn by runners in the Bay to Breakers race. At the top, behind the foam is an antenna and RFID chip used to detect the runner at the start and end of the race.

At the beginning and end of the race, the runners cross special mats that contain antennas and broadcast ultra high frequency radio signals. The runner's RFID chip detects this signal and sends back the athlete's ID number, which is programmed into the chip. By tracking these ID numbers, the system determines the time each runner took to run the race. The cool thing about these RFID chips is they are powered by the received radio signal; they don't need a battery.

Mylaps, whose name appears on the foam rectangle, is a company that supplies sports timing systems: the bibs with embedded RFID chips, the detection mats, and portable detection hardware. The detection system is designed to handle large numbers of runners, scanning more than 50 tags per second.

Removing the foam reveals an unusually-shaped metal antenna, the tiny RFID chip (the black dot above the word "DO", and the barely-visible word "Smartrac". Studying the Smartrac website reveals that this chip is the Impinj Monza 4 RFID chip, which operates in the 860-960 MHz frequency range and is recommended for sports timing.

The RFID circuit used to detect runners in the Bay to Breakers. The metal forms an antenna. The tiny black square in the center is the RFID chip.

The RFID circuit used to detect runners in the Bay to Breakers. The metal forms an antenna. The tiny black square in the center is the RFID chip.

Getting the chip off the bib was a bit tricky. I softened the bib material in Goof Off, dissolved the aluminum antenna metal with HCl and removed the adhesive with a mysterious BGA adhesive solvent I ordered from Shenzhen.

The chip itself is remarkably tiny, about the size of a grain of salt. The picture below shows the chip on a penny, as seen through a microscope: for scale, a grain of salt is by the R and the chip is on the U (in TRUST). This is regular salt, by the way, not coarse sea salt or kosher salt. I spent a lot of time trying to find the chip when it fell on my desk, since it is practically a speck.

The RFID chip used to identify runners is very small, about the size of one of the letters on a penny. A grain of salt (next to R) and the RFID chip (next to U).

The RFID chip used to identify runners is very small, about the size of one of the letters on a penny. A grain of salt (next to R) and the RFID chip (next to U).

In the picture above, you can see the four round contact points where the chip was connected to the antenna. There's still a blob of epoxy or something around the die, making it hard to see the details. The chip decapsulation gurus use use boiling nitric and sulfuric acids to remove epoxy, but I'm not that hardcore so I heated the chip over a stove flame. This burned off the epoxy much better than I expected, making the die clearly visible as you can see in the next photo.

I took 34 die photos using my metallurgical microscope and stitched them together to get a hi-res photo. (I described the stitching process in detail here). The result is the die photo below (click it for the large image). Surprisingly, there is no identifying name or number on the chip. However, comparing my die photo with the picture in the datasheet confirms that the chip is the Monza 4 RFID chip.

I can identify some of the chip's layout, but the chip is too dense and has too many layers for me to reverse engineer the exact details. Thus, the description that follows is slightly speculative.

Die photo of the Impinj Monza 4 RFID chip.

Die photo of the Impinj Monza 4 RFID chip.

The four pins in the corners are where the antenna is connected. (The chip has four pins because two antennas can be used for improved detection.)

The left part of the chip is the analog logic, extracting power from the antenna, reading the transmitted signal, and modulating the return signal. The rectangles on the left are probably transistors and capacitors forming a charge pump to extract power from the radio signal (see patent 7,561,866).

The right third of the chip is so-called "random logic" that carries out the commands sent to the chip. According to the datasheet, the chip uses a digital logic finite state machine, so the chip probably doesn't have a full processor.

The 32 orderly stripes in the middle are the non-volatile memory (NVM). Above the stripes, the address decode circuitry is barely visible. The chip has 928 bits of storage (counting up the memory banks on the datasheet) so I suspect the memory is set up as a 32x29 array. Some NVM details are in patent 7307534.

Along the lower and right edges of the chip, red lines are visible; these connect chips together on the wafer for testing during manufacturing (patent 7307528).

The Impinj Monza 4 RFID chip on top of a 8751 microcontroller chip shows that the RFID chip is very small and dense.

The Impinj Monza 4 RFID chip on top of a 8751 microcontroller chip shows that the RFID chip is very small and dense.

To show how small the chip is, and how technology has changed, I put the RFID chip on top of an 8751 microcontroller die. The 8751 microcontroller is a chip in Intel's popular 8051 family dating from 1983. Note that the circuitry on the RFID chip is denser and the chip is much, much smaller. (The photo looks a bit photoshopped, but it genuinely is the RFID chip sitting on the surface of the 8751 die. I don't know why the RFID chip is pink.)

So, if you ran in the Bay to Breakers, that's the chip that tracked your time during the race. (There aren't a lot of other RFID die photos on the web, but a few are at Bunnie Studios, Zeptobars and ExtremeTech if you want to see more.)

Restoring Y Combinator's Xerox Alto, day 1: Power supplies and disk interface

A few days ago, I wrote about how I'm helping restore a Xerox Alto for Y Combinator. This new post describes the first day of restoration: how we disassembled the computer and disk drive and fixed a power supply problem, but ran into a showstopper problem with the disk interface.

The Xerox Alto was a revolutionary computer from 1973, designed by computer pioneer Chuck Thacker at Xerox PARC to investigate ideas for personal computing. The Alto was the first computer built around a mouse and GUI, as well as introducing Ethernet and laser printers to the world. The Alto famously inspired Steve Jobs, who used many of its ideas in the Lisa and Macintosh computer.

Alan Kay, whose vision for a personal computer guided the Alto, recently gave an Alto computer to Y Combinator. Getting this system running again is a big effort but fortunately I'm working with a strong team, largely from the IBM 1401 restoration team. Marc Verdiell, Luca Severini, Ron, Carl Claunch, and I started on restoration a few days ago, as shown in Marc's video below.

Disassembling the Alto

We started by disassembling the computer. The Xerox Alto has a metal cabinet about the size of a dorm mini-fridge, with a Diablo hard disk drive on top, and a chassis with power supplies and the circuit boards below. With some tugging, the chassis slides out of the cabinet on rails as you can see in the photo below. At the front are the four cooling fans, normally protected by a decorative panel. Note the unusual portrait layout of the display.

The Xerox Alto II XM 'personal computer'. The card cage below the disk drive has been partially removed. Four cooling fans are visible at the front of it.

The Xerox Alto II XM 'personal computer'. The card cage below the disk drive has been partially removed. Four cooling fans are visible at the front of it.

With the chassis fully removed, you can see the four switching power supplies on the left, the blue metal boxes. The computer's circuit boards are on the right, not visible in this picture. The wiring for the backplane is visible at right front, with pins connected by wire-wrapped wire connections. This wiring connects the circuit boards together.[1]

The Alto's chassis has been removed. On the left are the four switching power supplies (blue boxes). On the right, the connections for the wire-wrapped backplane are visible. The circuit boards plug into this backplane.

The Alto's chassis has been removed. On the left are the four switching power supplies (blue boxes). On the right, the connections for the wire-wrapped backplane are visible. The circuit boards plug into this backplane.

The power supplies

Our first goal was to make sure the power supplies worked after decades of sitting idle. The Alto uses high-efficiency switching power supplies.[2] To explain the power supplies in brief, input power is chopped up thousands of times a second to produce a regulated voltage. Unlike modern computer power supplies, there's a second switching stage (the inverter), which drops the voltage to the desired 15 volts. This was more complexity than I expected, but fortunately the detailed power supply manual was available online, thanks to Al Kossow's bitsavers.[3] We tested each power supply with a resistor as a dummy load and checked that the output voltage was correct. We also used an oscilloscope to make sure the output was stable. All the power supplies worked fine, except for the +15V supply (top center), which had trouble getting up to 15 volts and staying there.

We disassembled the faulty power supply to track down the problem. The photo of the power supply below shows how densely components are crammed into the power supply. Two of the circuit boards have been removed and are at the back. Note the three large filter capacitors at the front.

Switching power supply from the Xerox Alto computer. Two of the control boards have been removed and are visible at back.

Switching power supply from the Xerox Alto computer. Two of the control boards have been removed and are visible at back.

We noted signs of overheating on the AC connector, as well as a somewhat sketchy looking repair (a trace replaced by a wire) and some signs of corrosion. Apparently the power supply had problems in the past and had been serviced. We cleaned up the corrosion and it appeared to be superficial.

The power supply disassembled easily for repair, as you can see below. The main board is at the right. The tower of three inductors on the main board is an unusual way of mounting inductors. Three circuit boards (top) plug into the main board. Because the power supply uses discrete components instead of a modern SMPS control IC, it needs a lot of control circuitry. The switching transistors (lower center) are mounted onto metal heat sinks for cooling.

The Alto's switching power supply, disassembled. The main board is in the lower right. The three circuit boards are at top, below the large input capacitors.

The Alto's switching power supply, disassembled. The main board is in the lower right. The three circuit boards are at top, below the large input capacitors.

The large capacitors were attached with screws, making it easy to remove them for testing. A capacitance meter showed that the three large capacitors had failed, explaining why the power supply had trouble outputting the desired voltage. Ron went off and found replacement capacitors, although they weren't an exact match for the originals. With the new capacitors mounted in place, the power supply worked properly.

Inside the Diablo disk drive

We also looked at the Diablo disk drive, which provides 2.5MB of storage for the Xerox Alto. The first step was removing the disk pack. In normal operation, the front of the drive is locked shut to keep the disk from being removed during use. To remove the disk without powering up the drive, we had to open the drive and manually trip the latch that locks it shut (see Diablo drive manual).

This picture shows the disk pack being reinserted into the drive. Unlike modern hard disk drives, the Alto's disk can be removed from the drive. Users typically used different disks for different tasks — a programming disk, a word processing disk, and so forth. The disk pack is a fairly large white package, resembling a cross between an overgrown Frisbee and a poorly-detailed Star Wars spaceship. The drive's multiple circuit boards are also visible in the photo.[4]

Inserting a 2.5 MB hard disk pack into the Diablo drive used by the Xerox Alto computer.

Inserting a 2.5 MB hard disk pack into the Diablo drive used by the Xerox Alto computer.

As the disk pack enters the drive, it opens up to provide access to the disk surface. The photo below shows the exposed surface of the disk, brownish from the magnetizable iron oxide layer over the aluminum platter. The read/write head is visible above the disk's surface, with another head below the disk. The disk stores data in 203 concentric pairs of tracks, with the heads moving in and out together to access each pair of tracks.

Closeup of the hard disk inside the Diablo drive. The read/write head (metal/yellow) is visible above the disk surface (brown).

Closeup of the hard disk inside the Diablo drive. The read/write head (metal/yellow) is visible above the disk surface (brown).

Although the heads are widely separated during disk pack insertion, they move very close to the disk surface during operation, floating about one thousandth of a millimeter above the surface. The diagram below from the manual helps visualize this minute distance, and illustrates the danger of particles on the disk's surface.

The Diablo disk and why contaminants are bad, from the Alto disk manual.

The Diablo disk and why contaminants are bad, from the Alto disk manual.

The disk interface cliffhanger

The final activity of the day was making sure all the Alto's circuit boards were in the right slots and the cables were all hooked up properly.[5] Everything went smoothly until I tried to hook up the Diablo disk drive to the disk interface card: the disk drive cable didn't fit on the card's connector!

The cable to the Alto disk didn't fit onto the disk interface card!

The cable to the Alto disk didn't fit onto the disk interface card!

After trying various combinations of cables and edge connectors, we discovered that the rainbow-colored ribbon cable you can see in the lower right above did fit the disk interface card. But instead of going to the Diablo disk drive, this cable went to a connector on the back of the Alto labeled "Tricon". Tricon is the controller for the Trident Disk, a high-capacity disk drive that could be used with the Alto, providing 80 MB instead of the just 2.5 MB that the standard Diablo drive provides. Looking at the disk interface card more closely, we saw it was labeled "Alto II Trident Disk Interface" (upper left corner of the photo below), confirming that it was for the Trident.

Trident Disk Interface card for Xerox Alto computer. (See label in upper left.)

Trident Disk Interface card for Xerox Alto computer. (See label in upper left.)

It was a shock to discover the disk interface card was for the Trident drive, since our Alto has the standard Diablo drive, which is completely incompatible with the Trident.[6] We checked all the boards and verified that the system was missing the Diablo interface board. This was a showstopper problem; with the wrong board, the disk drive would be unusable and we wouldn't be able to boot up the system. What could we do? Network boot the Alto? Build a disk simulator? Find a Trident drive on eBay? (We actually found a Trident disk platter on eBay for $129, but no drive.)

Tune in next episode to find out what we did about the disk interface problem. (Spoiler: we found a solution thanks to Al Kossow.)

Notes and references

[1] The physical layout of the power supplies is specified on page 11 of the Alto documentation introduction. On the top are three Raytheon/Sorensen power supplies, +12V (15A), +15V (12A), and -15V (12A). At the bottom is a large LH Research Mighty Mite power supply providing +5V (60A) and -5V (12A).

Why the variety of voltages? Most of the circuitry in the Alto uses 5V, which is standard for TTL chips. The MOS memory chips use +5V, -5V and +12V. The Ethernet card uses +15V and -15V, with +15V powering the transceiver. The disk drive uses +/- 15V.

[2] Steve Jobs claimed that the Apple II's use of a switching power supply was a revolutionary idea ripped off by other computer manufacturers. However, the Alto is just one of many computers that used switching power supplies before Apple (details).

[3] For full details on the power supply operation, see the block diagram. First, the 115V AC line input is converted to 300V DC by a rectifier and voltage doubler. (The voltage doubler is a clever way of supporting both 115V and 230V inputs; using the doubler with 115V. This is why older PCs have a switch on the power supply to select 115V or 230V. Modern power supplies handle a wide input range, and don't require a switch.) Next, the power supply has a chopper, a PWM transistor circuit that chops up the 300V DC, producing a regulated 120V-200V DC, depending on the output load. This goes to the inverter, which drives a step-down/isolation transformer that produces the desired 15V output. A regulation circuit sends feedback to the chopper based on the output voltage. Meanwhile, an entirely separate switching power supply circuit generates voltages (including +150V) used by the power supply internally.

Modern power supplies use a single switching stage in place of the separate chopper and inverter. I believe the two stages were used to reduce the load on the bipolar switching transistors, which don't have the performance of modern MOSFET switching transistors. (As Ron pointed out, modern power supplies often have a PFC (power factor correction) stage for improved efficiency. Thus, the two-stage design has returned, although the stages are entirely different now.)

Modern power supplies use a power supply control IC. The Alto's power supply instead has control circuits built from simple components: transistors, op amps, 555 timers. This is one reason the power supply requires three circuit boards.

[4] The following table from the Alto disk manual gives the stats for the drive.

Statistics on the Diablo 31 disk used with the Xerox Alto computer.

Statistics on the Diablo 31 disk used with the Xerox Alto computer.

[5] The Alto backplane has 21 slots, not all of which are used in our system. The list of which board goes into which slot is on page 8 of the Alto documentation.

[6] I suspect that the Y Combinator Alto originally had both a Trident drive and a Diablo drive (as well as four Orbit boards to drive a laser printer), and when it was taken out of service, the Trident drive, the Diablo interface board, and the Orbit boards went off somewhere else. This left the Alto with a drive that didn't match the interface card.

For reference, schematics and documentation on the Trident interface board are here. Despite all the chips on the disk interface board, it doesn't do very much, since each TTL chip is fairly simple. The interface board has some counters, one word data buffers, parallel/serial conversion, and a bit of control logic. The Alto was designed to offload many hardware tasks to microcode, so the hard work of disk I/O is performed in microcode (software).

Y Combinator's Xerox Alto: restoring the legendary 1970s GUI computer

Alan Kay recently gave his 1970's Xerox Alto to Y Combinator and I'm helping with the restoration of this legendary system. The Alto was the first computer designed around a graphical user interface and introduced Ethernet and the laser printer[1] to the world. The Alto also was one of the first object-oriented systems, supporting the Mesa and Smalltalk languages. The Alto was truly revolutionary when it came out in 1973, designed by computer pioneer Chuck Thacker.

Xerox built about 2000 Altos for use in Xerox, universities and research labs, but the Alto was never sold as a product. Xerox used the ideas from the Alto in the Xerox Star, which was expensive and only moderately successful. The biggest impact of the Alto was in 1979 when Steve Jobs famously toured Xerox and saw the Alto and other machines. When Jobs saw the advanced graphics of the Alto, he was inspired to base the user interfaces of the Lisa and Macintosh systems on Xerox's ideas, making the GUI available to the mass market.[2]

How did Y Combinator end up with a Xerox Alto? Sam Altman, president of Y Combinator has a strong interest in the Alto and its place in computer history. When he mentioned to Alan Kay that it would be fun to see one running, Alan gave him one.

This article gives an overview of the Alto, its impact, and how it was implemented. Later articles will discuss the restoration process as we fix components that have broken over the decades and get the system running.

The Xerox Alto II XM computer. Note the video screen is arranged in portrait mode. Next to the keyboard is a mouse. The Diablo disk drive is below the keyboard. The base contains the circuit boards and power supplies.

The Xerox Alto II XM computer. Note the video screen is arranged in portrait mode. Next to the keyboard is a mouse. The Diablo disk drive is below the keyboard. The base contains the circuit boards and power supplies.

The photo above shows Y Combinator's Alto computer. The Alto has an unusual portrait-format display, intended to match an 8½" by 11" page of paper. Most displays of the time were character-oriented, but the Alto had a bitmapped display, with each of the 606x808 pixels controllable independently. This provided unprecedented flexibility for the display and allowed WYSIWYG (what-you-see-is-what-you-get) editing. The bitmapped display memory used almost half the memory of the original Alto, however

In front of the keyboard is the three-button mouse. Xerox made the mouse a fundamental input device for the Alto and designed the user interface around the mouse. The disk drive at the top of the cabinet takes a removable 2.5 megabyte disk cartridge. The small capacity of the disk was a problem for users, but files could also be accessed over the Ethernet from file servers. The lower part of the cabinet contains the computer's circuit boards and power supplies, which will be discussed below.

Dynabook and the vision of the Alto

The motivation for the Alto was Alan Kay's Dynabook project. In 1972, he wrote A Personal Computer for Children of All Ages, setting out his vision for a personal, portable computer for education (or business), with access to the world's knowledge. In effect, Alan Kay presented a detailed vision for the touchscreen tablet decades before it was practical.[3]

Alan Kay with a mockup of the Dynabook. Photo by Marcin Wichary,  CC BY 2.0.

Alan Kay with a mockup of the Dynabook. Although the Dynabook was proposed years before the necessary hardware was available, the ideas could be tried out on the Alto, an "interim Dynabook". Photo by Marcin Wichary, CC BY 2.0.
The Dynabook (seen in mockup above) was to be a low-cost, battery-powered, portable computer with a touchscreen and graphics, able to access information over the network. The system would be highly interactive and programmable in an object-oriented language. As well as the keyboard, voice input could be used. Books could be downloaded and purchased.

Since the necessary hardware was science fiction when the Dynabook was proposed, the Alto was built as an "interim Dynabook" for research. Butler Lampson's 1972 memo entitled "Why Alto" proposed using the Alto for research in distributed computing, office computing, graphics, and personal computing. He stated, "If our theories about the utility of cheap, powerful personal computers are correct, we should be able to demonstrate them convincingly on Alto." Xerox used the Alto to research and develop the ideas of personal computing.[4]

Software

The Alto had a large collection of software, largely implemented in the BCPL (predecessor to C), Mesa and Smalltalk languages. The Bravo text editor (seen below) is considered the first WYSIWYG editor, with formatted text on the screen matching the laser printer output. Also below is the Draw illustration program which used the mouse and an icon menu to create drawings. Other significant programs included email, file transfer (FTP) and an integrated circuit editor. The Alto also ran some of the first networked multiplayer games such as Alto Trek and Maze War.

Bravo was the word processor for the Xerox Alto, providing WYSIWYG text editing. The Draw program for the Xerox Alto uses the mouse and icons for drawing.

Bravo was the word processor for the Xerox Alto, providing WYSIWYG text editing. The Draw program for the Xerox Alto uses the mouse and icons for drawing. The Alto simulator Salto was used for these images.

Hardware

The Alto was introduced in 1973. To understand this time in computer hardware, the primitive 4004 microprocessor had been introduced a couple years earlier. Practical microprocessors such as the 6502 and Z-80 were still a couple years in the future and the Apple II wouldn't be released until 1977. At the time, minicomputers such as the Data General Nova and PDP-11 built processors out of hundreds of simple but fast TTL integrated circuits, rather than using slow, unreliable MOS chips. The Alto was built similarly, and is a minicomputer, not a microcomputer.[5]

The Alto has 13 circuit boards, crammed full of chips. Each board is a bit smaller than a page of paper, about 7-5/16" by 10", and holds roughly 100 chips (depending on the board). For the most part, the chips are bipolar TTL chips in the popular 7400 series. (The MOS memory chips are an exception.) The image below shows the Alto's card rack and some of the boards.

The Xerox Alto contains 21 slots for circuit boards. Each board is crammed with chips, mostly TTL.

The Xerox Alto contains 21 slots for circuit boards. Each board is crammed with chips, mostly TTL.

The Alto's CPU consists of three boards. The Control board is the heart of the processor: it manages the 16 microcode tasks and contains microcode in PROM. The ALU board performs arithmetic and logic operations, and provides the main register storage. The Control RAM board provides additional microcode storage in RAM and additional processor registers. (Note that in a few years, a single chip microprocessor could replace these three boards.)

The photo below shows the ALU board. The 16-bit addition, subtraction and Boolean operations are performed by four of the popular 74181 ALU chip, used in many other processors of the era. Each 16-bit register requires multiple chips for storage. The 32x16 register file is historically interesting as it is built from i3101 64-bit bipolar memory chips, Intel's first-ever product.

The ALU board from the Xerox Alto.

The ALU board from the Xerox Alto.

The Alto came out at a time when memory was expensive and somewhat unreliable.[6] In 1970, Intel introduced the first commercially available DRAM memory, the 1103 chip, holding 1 kilobit of storage and making magnetic core memory obsolete. The original Alto used 16 boards crammed full of these chips to provide 128 kilobytes of memory. The Alto we have is a more modern Alto II XM (eXtended Memory) with 512 kilobytes of storage on four boards. Even so, the limited memory capacity was a difficulty for programmers and users. The photo below shows one of the memory board, packed with denser 16 kilobit chips.

A 128KB memory card from the Xerox Alto.

A 128KB memory card from the Xerox Alto. It uses eighty 4116 memory chips, each with 16 kilobits of storage.

Microcode

The Alto hardware provides a simple micro-instruction set and uses microcode to implement a full instruction set on top of this,[7] including some very complex instructions. The Alto introduced the BITBLT graphics instruction, which draws an arbitrary bitmap to the display in a variety of ways (e.g. paint over, gray stipple or XOR). "Blitting" became a standard graphics operation, still be found in Windows.

The Alto takes microcode further than most computers, implementing many functions in microcode that most computers implement in hardware, making the Alto hardware simpler and more flexible.[8] Microcode tasks copy every pixel to the display 30 times a second, refresh dynamic memory, read the mouse, handle disk operations, drive Ethernet — operations performed in hardware on most computers. Much of the Alto microcode is stored in RAM, so languages or even user programs can run custom microcode.

Next steps

The first step to getting the system running will be to make sure the power supplies work and provide the proper voltages. The Alto uses four complex but highly efficient switching power supplies: +15V, -15V, +12V, and +/-5V.[9] (Most of the chips use +5V, but the memory chips and some interfaces require unusual voltages.)

The power supplies are mounted in the cabinet behind the card cage, as you can see in the photo below. The +/-5V supply is on the right, and the three other power supplies are on the left.

Looking into the back of the Alto, you can see the four switching power supplies (blue). The card cage is behind them. The disk drive has been removed from the top of the cabinet. On the back of the cabinet, connectors to the display, Ethernet, and other devices are visible.

Looking into the back of the Alto, you can see the four switching power supplies (blue). The card cage is behind them. The disk drive has been removed from the top of the cabinet. On the back of the cabinet, connectors to the display, Ethernet, and other devices are visible.

Restoring this systems is a big effort but fortunately there's a strong team working on it, largely from the IBM 1401 restoration team. The main Alto restorers so far are Marc Verdiell, Luca Severini, Ron, and Carl Claunch. Major technical contributions have been provided by Al Kossow (who has done extensive Alto restoration work in the past and is at the Computer History Museum) and the two Keiths (who have restored Altos at the Living Computer Museum). For updates on the restoration, follow kenshirriff on Twitter.[10]

Notes and references

[1] The laser printer was invented at Xerox by Gary Starkweather and networked laser printers were soon in use with the Alto. Y Combinator's Alto is an "Orbit" model, with slots for the four boards that drive the laser printer, laboriously rendering 16 rows of pixels at a time.

[2] Malcolm Gladwell describes Steve Jobs' visit to Xerox in detail in Creation Myth. The article claims that Xerox licensed its technology to Apple, but strangely that license wasn't mentioned in earlier articles about Xerox's lawsuit against Apple. The facts here seem murky.

[3] Amazingly, Alan Kay even predicted ad blockers in his 1972 Dynabook paper: "One can imagine one of the first programs an owner will write is a filter to eliminate advertising!" I thought that Alan Kay missed WiFi in the Dynabook design, but as he points out in the comments, wireless networking was a Dynabook feature.

[4] Xerox called the Alto "a small personal computing system", saying, "By 'personal computer' we mean a non-shared system containing sufficient processing power, storage, and input-output capability to satisfy the computational needs of a single user." (See ALTO: A Personal Computer System Hardware Manual.) Xerox's vision of personal computing is described in the retrospective Alto: A personal computer.

Since the concept of "personal computer" is ill-defined, I won't argue whether the Alto is really a personal computer or not. Costing tens of thousands of dollars, the Alto was much more expensive than what people usually think of as a personal computer. The book Fumbling the Future: How Xerox Invented, then Ignored, the First Personal Computer calls Xerox the inventor of the personal computer. (Or you can read Datapoint: The Lost Story of the Texans Who Invented the Personal Computer Revolution, which makes a convincing case for the Datapoint 2200 as the first personal computer.) For a long list of candidates for the first personal computer, see blinkenlights.com.

[5] The Alto documentation refers to the microprocessor, but this term describes the microcode processor. The Alto does not use a microprocessor in the modern sense.

[6] Since memory chips of the era were somewhat unreliable (especially in large quantities), the Alto used parity plus 6 bits of error correcting code to improve reliability. As well as the four memory boards, the Alto has three memory control boards to decode addresses and implement error correction.

[7] The Alto's microcode instructions and "real" instructions (called Emulated Instructions) are described in the Hardware Reference. The Alto's instruction set is similar to the Data General Nova.

[8] The Alto has 16 separate microcode tasks, scheduled based on their priority. The Alto's microcode tasks are described in Appendix D of the Hardware Manual. The display task illustrates how low-level the microcode tasks are. In a "normal" computer, the display control hardware fetches pixels from memory. In the Alto, the display task in microcode copies pixels from memory to the display hardware's 16 word pixel buffer as each line is being written to the display. The point is that the hardware is simplified, but the microcode task is working very hard, copying every pixel to the display 30 times a second. Similarly the Ethernet hardware is simplified, since the microcode task does much of the work.

[9] Steve Jobs claimed that the Apple II's use of a switching power supply was a revolutionary idea ripped off by other computer manufacturers. However, the Alto is just one of many computers that used switching power supplies before Apple (details).

[10] Many sources have additional information on the Alto. Bitsavers has a large collection of Alto documentation. DigiBarn has photos and more information on the Alto. The Computer History Museum has a large collection of Alto source code online here. The Alto simulator Salto is available here if you want to try out the Alto experience. Wikipedia has a detailed article on the Alto.

555 timer teardown: inside the world's most popular IC

This article is translated into Vietnamese at: Bên trong chíp định thời 555.

If you've played around with electronic circuits, you probably know[1] the 555 timer integrated circuit, said to be the world's best-selling integrated circuit with billions sold. Designed by analog IC wizard Hans Camenzind[2] in 1970, the 555 has been called one of the greatest chips of all time with whole books devoted to 555 timer circuits.

Given the popularity of the 555 timer, I thought it would be interesting to find out what's inside the 555 timer and how it works. While the 555 timer is usually sold as a black plastic IC, it is also available in a metal can, which can be cut open with a hacksaw[3] revealing the tiny die inside.

Inside the 555 timer. The tiny die in the package is connected to the 8 pins by wires.

Inside the 555 timer. The tiny die in the package is connected to the 8 pins by wires.

A brief explanation of the 555 timer

The 555 timer has hundreds of applications, operating as anything from a timer or latch to a voltage-controlled oscillator or modulator. The diagram below illustrates how the 555 timer operates as a simple oscillator. Inside the 555 chip, three resistors form a divider generating references voltages of 1/3 and 2/3 of the supply voltage. The external capacitor will charge and discharge between these limits, producing an oscillation. In more detail, the capacitor will slowly charge (A) through the external resistors until its voltage hits the 2/3 reference. At that point (B), the upper (threshold) comparator switches the flip flop off and the output off. This turns on the discharge transistor, slowly discharging the capacitor (C). When the voltage on the capacitor hits the 1/3 reference (D), the lower (trigger) comparator turns on, setting the flip flop and the output, and the cycle repeats. The values of the resistors and capacitor control the timing, from microseconds to hours.[4]

Diagram showing how the 555 timer can operate as an oscillator.

Diagram showing how the 555 timer can operate as an oscillator.

To summarize, the key components of the 555 timer are the comparators to detect the upper and lower voltage limits, the three-resistor divider to set these limits, and the flip flop to keep track of whether the circuit is charging or discharging. The 555 timer has two other pins (reset and control voltage) that I haven't covered above; they can be used for more complex circuits.

The structure of the integrated circuit

The photo below shows the silicon die of the 555 through a microscope. On top of the silicon, a thin layer of metal connects different parts of the chip. This metal is clearly visible in the photo as yellowish-white traces and regions. Under the metal, a thin, glassy silicon dioxide layer provides insulation between the metal and the silicon, except where contact holes in the silicon dioxide allow the metal to connect to the silicon. At the edge of the chip, thin wires connect the metal pads to the chip's external pins.

Die photo of the 555 timer.

Die photo of the 555 timer.

The different types of silicon on the chip are harder to see. Regions of the chip are treated (doped) with impurities to change the electrical properties of the silicon. N-type silicon has an excess of electrons (negative), while P-type silicon lacks electrons (positive). In the photo, these regions show up as a slightly different color surrounded by a thin black border. These regions are the building blocks of the chip, forming transistors and resistors.

NPN transistors inside the IC

Transistors are the key components in a chip. The 555 timer uses NPN and PNP bipolar transistors. If you've studied electronics, you've probably seen a diagram of an NPN transistor like the one below, showing the collector (C), base (B), and emitter (E) of the transistor, The transistor is illustrated as a sandwich of P silicon in between two symmetric layers of N silicon; the N-P-N layers make an NPN transistor. It turns out that transistors on a chip look nothing like this, and the base often isn't even in the middle!

Schematic symbol for an NPN transistor, along with an oversimplified diagram of its internal structure.

Schematic symbol for an NPN transistor, along with an oversimplified diagram of its internal structure.

The photo below shows one of the transistors in the 555 as it appears on the chip. The slightly different tints in the silicon indicate regions that has been doped to form N and P regions. The whitish-yellow areas are the metal layer of the chip on top of the silicon - these form the wires connecting to the collector, emitter, and base. You can spot an emitter on the chip by its "bullseye" structure, while the base rectangle surrounds the emitter.

An NPN transistor in the 555 timer chip. The collector (C), emitter (E) and base (B) are labeled, along with N and P doped silicon.

An NPN transistor in the 555 timer chip. The collector (C), emitter (E) and base (B) are labeled, along with N and P doped silicon.

Underneath the photo is a cross-section drawing illustrating how the transistor is constructed. There's a lot more than just the N-P-N sandwich you see in books, but if you look carefully at the vertical cross section below the 'E', you can find the N-P-N that forms the transistor. The emitter (E) wire is connected to N+ silicon. Below that is a P layer connected to the base contact (B). And below that is an N+ layer connected (indirectly) to the collector (C).[5] The transistor is surrounded by a P+ ring that isolates it from neighboring components.

PNP transistors inside the IC

You might expect PNP transistors to be similar to NPN transistors, just swapping the roles of N and P silicon. But for a variety of reasons, PNP transistors have an entirely different construction. They consist of a small circular emitter (P), surrounded by a ring shaped base (N), which is surrounded by the collector (P). This forms a P-N-P sandwich horizontally (laterally), unlike the vertical structure of the NPN transistors.

The diagram below shows one of the PNP transistors in the 555, along with a cross-section showing the silicon structure. Note that although the metal contact for the base is on the edge of the transistor, it is electrically connected through the N and N+ regions to its active ring in between the collector and emitter. A metal line is routed between the collector and base, but is not part of the transistor.

A PNP transistor in the 555 timer chip. Connections for the collector (C), emitter (E) and base (B) are labeled, along with N and P doped silicon. The base forms a ring around the emitter, and the collector forms a ring around the base.

A PNP transistor in the 555 timer chip. Connections for the collector (C), emitter (E) and base (B) are labeled, along with N and P doped silicon. The base forms a ring around the emitter, and the collector forms a ring around the base.

The output transistors in the 555 are much larger than the other transistors and have a different structure in order to produce the high-current output. The photo below shows one of the output transistors. Note the multiple interlocking "fingers" of the emitter and base, surrounded by the large collector.

A large, high-current NPN output transistor in the 555 timer chip. The collector (C), base (B) and emitter (E) are labeled.

A large, high-current NPN output transistor in the 555 timer chip. The collector (C), base (B) and emitter (E) are labeled.

How resistors are implemented in silicon

Resistors are a key component of analog chips. Unfortunately, resistors in ICs are large and inaccurate; the resistances can vary by 50% from chip to chip. Thus, analog ICs are designed so only the ratio of resistors matters, not the absolute values, since the ratios remain nearly constant.

A resistor inside the 555 timer. The resistor is a strip of P silicon between two metal contacts.

A resistor inside the 555 timer. The resistor is a strip of P silicon between two metal contacts.

The photo above shows a 1KΩ resistor in the 555, formed from a strip of P silicon (visible as an outline). Note that the resistor connects two metal wires and another metal wire crosses it. The resistor below is an L-shaped 100KΩ pinch resistor. A layer of N silicon on top of the pinch resistor makes the conductive region much thinner (i.e. pinches it), forming a much higher but less accurate resistance.

A pinch resistor inside the 555 timer. The resistor is a strip of P silicon between two metal contacts. An N layer on top pinches the resistor and increases the resistance.

A pinch resistor inside the 555 timer. The resistor is a strip of P silicon between two metal contacts. An N layer on top pinches the resistor and increases the resistance.

IC component: The current mirror

There are some subcircuits that are very common in analog ICs, but may seem mysterious at first. The current mirror is one of these. If you've looked at analog IC block diagrams, you may have seen the symbols below, indicating a current source, and wondered what a current source is and why you'd use one. The idea is you start with one known current and then you can "clone" multiple copies of the current with a simple transistor circuit, the current mirror.

Schematic symbols for a current source.

Schematic symbols for a current source.

The following circuit shows how a current mirror is implemented with two identical transistors.[6] A reference current passes through the transistor on the left. (In this case, the current is set by the resistor.) Since both transistors have the same emitter voltage and base voltage, they source the same current, so the current on the right matches the reference current on the left.

Current mirror circuit. The current on the right copies the current on the left.

Current mirror circuit. The current on the right copies the current on the left.

A common use of a current mirror is to replace resistors. As explained earlier, resistors inside ICs are both inconveniently large and inaccurate. It saves space to use a current mirror instead of a resistor whenever possible. Also, the currents produced by a current mirror are nearly identical, unlike the currents produced by two resistors.

Three transistors form a current mirror in the 555 timer chip. They all share the same base and two transistors share emitters.

Three transistors form a current mirror in the 555 timer chip. They all share the same base and two transistors share emitters.
The three transistors above form a current mirror with two outputs. Note the three transistors share the base connection, tied to the collector on the right, and the emitters on the right are tied together. The transistor on the left is a Widlar current source, a modified mirror that produces a smaller current. On the schematic, the two transistors on the right are drawn as a single two-collector transistor, Q19.

IC component: The differential pair

The second important circuit to understand is the differential pair, the most common two-transistor subcircuit used in analog ICs.[7] You may have wondered how a comparator compares two voltages, or an op amp subtracts two voltages. This is the job of the differential pair.

Schematic of a simple differential pair circuit. The current sink sends a fixed current I through the differential pair. If the two inputs are equal, the current is split equally between the two branches. Otherwise, the branch with the higher input voltage gets most of the current.

Schematic of a simple differential pair circuit. The current sink sends a fixed current I through the differential pair. If the two inputs are equal, the current is split equally between the two branches. Otherwise, the branch with the higher input voltage gets most of the current.

The schematic above shows a simple differential pair. The current sink at the bottom provides a fixed current I, which is split between the two input transistors. If the input voltages are equal, the current will be split equally into the two branches (I1 and I2). If one of the input voltages is a bit higher than the other, the corresponding transistor will conduct more current, so one branch gets more current and the other branch gets less. A small input difference is enough to direct most of the current into the "winning" branch, flipping the comparator on or off.

In the 555, the threshold comparator uses NPN transistors, while the trigger comparator uses PNP transistors. This allows the threshold comparator to work near the supply voltage and the trigger comparator to work near ground. The 555's comparators also use two transistors on each input (Darlington pair) to buffer the inputs.

The 555 schematic interactive explorer

The 555 die photo and schematic[8] below are interactive. Click on a component in the die or schematic, and a brief explanation of the component will be displayed. (For a thorough discussion of how the 555 timer works, see 555 Principles of Operation.)

For a quick overview, the large output transistors and discharge transistor are the most obvious features on the die. The threshold comparator consists of Q1 through Q8. The trigger comparator consists of Q10 through Q13, along with current mirror Q9. Q16 and Q17 form the flip flop. The three 5KΩ resistors forming the voltage divider are in the middle of the chip.[9] Urban legend says that the 555 is named after these three 5K resistors, but according to its designer 555 is just an arbitrary number in the 500 chip series

Click the die or schematic for details...

How I photographed the 555 die

Integrated circuit usually come in a black epoxy package which require inconveniently dangerous concentrated acid to open. Instead, I bought a 555 in a metal can (below). To examine the die, I used a metallurgical microscope. Unlike a standard microscope, the metallurgical microscope shines light down through the lens allowing it to work with opaque objects (such as chips). I stitched the photos together with Hugin (details).

The 555 timer in a metal can package. (Banana for scale)

The 555 timer in an eight-pin metal can package. (Banana for scale)

The failed improved 555

Given the popularity of the 555, it's surprising that it has several rookie design flaws; unbalanced comparators, large operating currents, an asymmetric output waveform, and temperature sensitivity.[10]

In 1997, Camenzind redesigned the 555 to create a much better chip that could run at much lower voltages. The improved chip was sold by Zetex as the ZSCT1555, but unfortunately was a flop. The continuing success of the original 555 and the failure of the improved successor can be viewed as an example of the worse is better principle.

Conclusion

I hope you've found this look inside the 555 timer chip interesting. Next time you're building a 555 project, you'll know exactly what's inside the chip. If you enjoyed this article, I've also reverse-engineered the 741 op amp and 7805 voltage regulator. Thanks to Eric Schlaepfer[11] for helpful comments.

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Notes and references

[1] The 555 timer is iconic enough to appear on mugs, bags, caps and t-shirts.

The 555 timer is popular enough to appear on t-shirts. Courtesy of EEVblog.

The 555 timer is popular enough to appear on t-shirts. Courtesy of EEVblog.

[2] The book Designing Analog Chips written by the 555's inventor Hans Camenzind is really interesting, and I recommend it if you want to know how analog chips work. Chapter 11 has an extensive discussion of the 555's history and operation. Page 11-3 claims the 555 has been the best-selling IC every year, although I don't know if that is still true. The free PDF is here or get the book.

[3] You can cut an IC can open with a plain hacksaw, but a jeweler's saw gives a much cleaner cut. I got a jeweler's saw on eBay for $14, and used the #2 blade. Make sure you cut near the top of the IC so you don't hit the die as I did.

[4] The brilliant part of the 555 timer is that the oscillation frequency depends only on the external resistors and capacitor and is insensitive to the supply voltage. If the supply voltage drops, the 1/3 and 2/3 references drop too, so you might expect the oscillations to be faster. But the lower voltage charges the capacitor more slowly, canceling this out and keeping the frequency constant.

This voltage insensitivity is so tricky that the chip's designer didn't figure it out until near the end of the 555's design, but it made a big difference. The original design was more complex and required nine pins, which is a terrible size for an IC since there are no packages between 8 and 14 pins. The final, simpler 555 design worked with 8 pins, making the chip's packaging much cheaper. (See page 11-3 of Designing Analog Chips for the full story.)

[5] You might have wondered why there is a distinction between the collector and emitter of a transistor, when the typical diagram of a transistor is symmetrical. As you can see from the die photo, the collector and emitter are very different in a real transistor. In addition to the very large size difference, the silicon doping is different. The result is a transistor will have poor gain if the collector and emitter are swapped.

[6] For more information about current mirrors, check wikipedia, any analog IC book, or chapter 3 of Designing Analog Chips.

[7] Differential pairs are also called long-tailed pairs. According to Analysis and Design of Analog Integrated Circuits differential pairs are "perhaps the most widely used two-transistor subcircuits in monolithic analog circuits." (p214) For more information about differential pairs, see wikipedia, any analog IC book, or chapter 4 of Designing Analog Chips.

[8] The 555 schematic used in this article is from the Philips datasheet.

[9] Note that the three resistors for the voltage divider are parallel and next to each other. This helps ensure they have the same resistance even if there are electrical variations across the silicon.

[10] I'm not criticizing the 555; Hans Camenzind points out the design flaws and attributes them to "the early period of IC design (and the inexperience of a rookie designer)"; see Designing Analog Chips, page 11-4. The design of a 555 replacement is discussed in detail in "Redesigning the old 555", IEEE Spectrum, September 1997. That article makes it clear how much much faster IC design is now than in 1970. It took months to create the layout of the 555 chip by hand and manually verify it for correctness. The new chip took two days to layout and 20 minutes to verify.

[11] Evil Mad Scientist sells a very cool discrete 555 timer kit, duplicating the 555 circuit on a larger scale with individual transistors and resistors — it actually works as a 555 replacement. Their 555 footstool is also worth a look.

Large-size 555 timer created by Evil Mad Scientist Lab.

Large-size 555 timer created by Evil Mad Scientist Lab.