JohnPCAE Posted October 11, 2022 Share Posted October 11, 2022 (edited) The walls are too thin for filament printing (according to one manufacturer), so SLS is required. It's not cheap. I went with Shapeways, and the result is not disappointing. The fit is perfect. Now I have to design a circuit board for it. Edited October 11, 2022 by JohnPCAE 25 1 Quote Link to comment Share on other sites More sharing options...
+Gunoz Posted October 11, 2022 Share Posted October 11, 2022 Wow that's pretty awesome! Quote Link to comment Share on other sites More sharing options...
+cmart604 Posted October 11, 2022 Share Posted October 11, 2022 That is very cool! Quote Link to comment Share on other sites More sharing options...
+the1hatman Posted October 12, 2022 Share Posted October 12, 2022 WANT! 2 Quote Link to comment Share on other sites More sharing options...
JohnPCAE Posted October 12, 2022 Author Share Posted October 12, 2022 (edited) Here is a ZIP of the .STL model files for the case. Because of the thin walls, don't expect filament printing to work. According to JLCPCB, it will likely result in sagging and deformation. So I went with Shapeways and their selective laser sintering (SLS) process. For materials I chose their nylon plastic with no finishing. Be warned, the four pieces cost me over $400 to make. The fit, though, is absolutely perfect and I can see no layer lines. The quality is outstanding. Intellivoice_II.zip Edited October 12, 2022 by JohnPCAE 4 Quote Link to comment Share on other sites More sharing options...
+KylJoy Posted October 12, 2022 Share Posted October 12, 2022 FAN-Fing-TASTIC... Let me know where to get that circuit board! LOL I'm going to try to print the case on my 3D printer to see how it goes. Thanks very much for getting this going. 1 Quote Link to comment Share on other sites More sharing options...
+KylJoy Posted October 13, 2022 Share Posted October 13, 2022 Here goes nothin'! I'm not holding my breath for this but wish me luck! 4 Quote Link to comment Share on other sites More sharing options...
+sramirez2008 Posted October 13, 2022 Share Posted October 13, 2022 On 10/11/2022 at 5:18 PM, JohnPCAE said: The walls are too thin for filament printing (according to one manufacturer), so SLS is required. It's not cheap. I went with Shapeways, and the result is not disappointing. The fit is perfect. Now I have to design a circuit board for it. She’s beautiful! Quote Link to comment Share on other sites More sharing options...
JohnPCAE Posted October 13, 2022 Author Share Posted October 13, 2022 It's getting there. I still need to do the silkscreen. This will probably undergo a few iterations before I have a final version. The main issue is precise positioning of the volume potentiometer and the mounting holes. Once it's finalized I'll release the board design and gerber files. This will use a two-board design like the ECS and the ACC. I've already done the daughterboard that plugs into the Master Component and even ordered one. 2 Quote Link to comment Share on other sites More sharing options...
JohnPCAE Posted October 13, 2022 Author Share Posted October 13, 2022 Board is completed and ordered. In a couple of weeks (hopefully) I'll see how well it fits. 2 1 Quote Link to comment Share on other sites More sharing options...
SiLic0ne t0aD Posted October 14, 2022 Share Posted October 14, 2022 $400? Holy moley, that's insane! That's awesome though. Really wish I had a 3d printer.. I still want to do nano Intellivoice project from quite a few years back. 😎 Quote Link to comment Share on other sites More sharing options...
JohnPCAE Posted October 14, 2022 Author Share Posted October 14, 2022 59 minutes ago, SiLic0ne t0aD said: $400? Holy moley, that's insane! That's awesome though. Really wish I had a 3d printer.. I still want to do nano Intellivoice project from quite a few years back. 😎 I'm still quietly making refinements to the NanoVoice board, as well. Perhaps I'll release what I have. 1 Quote Link to comment Share on other sites More sharing options...
JohnPCAE Posted October 14, 2022 Author Share Posted October 14, 2022 (edited) Here is my latest NanoVoice revision. It has better trace routing and makes a change to the design. The original Intellivoice uses 74LS12 chips, which are pretty much made of unobtainium today. I've changed the design to use readily-available 74LS10 chips instead, which also requires removing pull-up resistors R2, R4, and R5. I'm at a loss to understand why Mattel used open-collector 74LS12 chips when push-pull 74LS10 chips result in a simpler design. My Intellivoice II board also uses the same design change. I've double- and triple-checked the schematic and I see no reason why 74LS10 chips wouldn't work, since the output still goes through resistor R1. So KylJoy, how did the print go? NanoVoice_1_5.zip Edited October 14, 2022 by JohnPCAE 3 1 Quote Link to comment Share on other sites More sharing options...
+Psycho Stormtrooper- Rog Posted October 14, 2022 Share Posted October 14, 2022 Very nice John. Quote Link to comment Share on other sites More sharing options...
SiLic0ne t0aD Posted October 15, 2022 Share Posted October 15, 2022 5 hours ago, JohnPCAE said: Here is my latest NanoVoice revision. It has better trace routing and makes a change to the design. The original Intellivoice uses 74LS12 chips, which are pretty much made of unobtainium today. I've changed the design to use readily-available 74LS10 chips instead, which also requires removing pull-up resistors R2, R4, and R5. I'm at a loss to understand why Mattel used open-collector 74LS12 chips when push-pull 74LS10 chips result in a simpler design. My Intellivoice II board also uses the same design change. I've double- and triple-checked the schematic and I see no reason why 74LS10 chips wouldn't work, since the output still goes through resistor R1. So KylJoy, how did the print go? NanoVoice_1_5.zip 380.5 kB · 1 download Thanks for posting the gerbers! Just ordered it from JLCPCB. Quote Link to comment Share on other sites More sharing options...
JohnPCAE Posted October 15, 2022 Author Share Posted October 15, 2022 (edited) You should know that the NanoVoice is untested. While the schematic conforms to the one in the Intellivoice service manual, I don't have a connector for the cartridge that goes onto the end of the board the way it does on the real Intellivoice. So I've been unable to build and test one. Before you try to build it you might want to wait until I've built and tested the board for my Intellivoice II case. They use the same schematic so if one works so should the other. Edited October 15, 2022 by JohnPCAE 1 Quote Link to comment Share on other sites More sharing options...
SiLic0ne t0aD Posted October 15, 2022 Share Posted October 15, 2022 Sounds like a plan. I need to source all the parts and a spare Intellivoice to rob IC's, etc. out of anyway, so I'm still a ways off before diving in this project. Quote Link to comment Share on other sites More sharing options...
+KylJoy Posted October 19, 2022 Share Posted October 19, 2022 On 10/14/2022 at 4:40 PM, JohnPCAE said: KylJoy, how did the print go? We had a power blip that nuked it. Then I had to travel and I'm out of town. Will try again soon. 1 Quote Link to comment Share on other sites More sharing options...
JohnPCAE Posted October 21, 2022 Author Share Posted October 21, 2022 (edited) I got my boards today. The circuit works, but there's a high-pitched whine that comes out in addition to the speech. I don't yet know why. I'm not yet using the correct daughterboard, though. The one I'm using is a spare ACC daughterboard that generates an MCLKx4 (14.31818 MHz) signal, whereas the correct one is simply a passthrough for all signals. The correct one hasn't arrived yet, but I don't see any reason why an ACC one wouldn't work. I checked out the test points on an oscilloscope and it looks like the speech chip is sending a PWM signal that's getting filtered into the high-pitched whine (I'm testing it with a Space Spartans cartridge). I'm not sure why it's sending data when it should be quiet, but I'll do more testing. One thing I found out through inspecting the normal Intellivoice is that there's an error in the service manual. The schematic is correct, but the bill of materials for register R9 is incorrect. It's listed as 330 ohms when the actual resistor is 180 ohms. I also found out that the eight pull-up resistors on the SPB640's data lines are unnecessary and they're omitted in my Mattel Intellivoice. Edited October 21, 2022 by JohnPCAE Quote Link to comment Share on other sites More sharing options...
JohnPCAE Posted October 21, 2022 Author Share Posted October 21, 2022 (edited) Aha. It turns out that not all LM324N chips are created equal. Transplanting the TI LM324N from the Mattel Intellivoice to my board got rid of the high-pitched whine. The one I was using before was made by National Semiconductor, and yes, it's also marked as LM324N! So I can now pronounce the circuit design as good. The chip is used in an active filter (search for Generalized Impedance Converter for more info) that most likely filters out that whine. I also verified that the PWM data that's being sent to it is the same in both the Mattel board and in mine. Two articles that helped me are linked below. They're part of a larger blog titled The Filter Wizard Remastered that I'll also link. https://www.planetanalog.com/gee-i-see-the-ins-and-outs-of-generalized-impedance-converters/ https://www.planetanalog.com/lowpass-filters-that-dont-a-tale-of-leakage-current/ https://www.planetanalog.com/category/blog/the-filter-wizard-remastered/ The result of all of this work tonight is a simpler Intellivoice circuit. In the coming days I'll probably revise my NanoVoice circuit to match what I have here and release everything. Edited October 21, 2022 by JohnPCAE 1 Quote Link to comment Share on other sites More sharing options...
walldog1 Posted October 21, 2022 Share Posted October 21, 2022 When is someone going to make power switch covers for the 2609 model? So many are missing and seem easy enough to make. I am short about 10 of these currently. Quote Link to comment Share on other sites More sharing options...
JohnPCAE Posted October 21, 2022 Author Share Posted October 21, 2022 Here are the latest NanoVoice files (version 1.6). This should be the final version. I'm going to hold off on releasing the Intellivoice II files until I get the correct daughterboards in the mail. I want to first make sure that they fit in the case. NanoVoice_1_6.zip 1 Quote Link to comment Share on other sites More sharing options...
+fdr4prez Posted October 21, 2022 Share Posted October 21, 2022 23 minutes ago, JohnPCAE said: Here are the latest NanoVoice files (version 1.6). This should be the final version. I'm going to hold off on releasing the Intellivoice II files until I get the correct daughterboards in the mail. I want to first make sure that they fit in the case. NanoVoice_1_6.zip 366.77 kB · 0 downloads If you have a 3d printer, then you can print the board out yourself and see if it fits Quote Link to comment Share on other sites More sharing options...
Intvfun Posted October 22, 2022 Share Posted October 22, 2022 Awesome job! Been wanting to do this myself just haven't had the time lately to commit to it. Thanks! Quote Link to comment Share on other sites More sharing options...
JohnPCAE Posted October 23, 2022 Author Share Posted October 23, 2022 I woke up in the middle of the night with an idea. Not all Intellivoice units have the expansion port IDC header, but all Intellivoice II boards would. Also, the Intellivoice II case has an ECS-like expansion door that's properly set up over the expansion port. So, what's stopping me from designing an add-on that gives, say, access to a USB keyboard and mouse? Connecting to USB should theoretically only need a Raspberry Pi Pico and three SN74LVC245 chips. I've even looked into such a design that would connect to the Intellivision bus directly. The question is, how does the Intellivoice expansion bus work? From the service manual it looks like it revolves around the SPB640 chip, but I don't have the datasheet for it. All I have is a die shot of the decapped chip. Does anyone have the datasheet and/or has anyone delved into how the Intellivoice expansion bus works? Quote Link to comment Share on other sites More sharing options...
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