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August  24, 2003
I've been working on the circuits required to generate sound effects.  The sound effects are needed for the exploding targets and numerous other effects that will occur through the course of a game.  I have been experimenting with the ISD2560 analog storage device.  It can hold 1 minute of 8kHz sampled audio.  The sound quality is pretty good.  This IC has address lines so that you can record and play thousands of sound files.  These ICs can be a bit flaky in that they will appear to do some strange things like only playing part of a track, play the wrong track, generate audible hum and pops, etc..  This may prove to be more trouble than it's worth.  As such, I may change my approach so that I am using an entirely different technology.  We'll see.

My first attempt was somewhat successful.  I bread boarded a 16 track, serial controlled, player/recorder.   The circuit can be put in programming mode with a jumper or switch.  In this mode, you can record up to 16 sound effects to 16 individual addresses via the dip switch.  There is a record button and a play button which are only active in programming mode.  To record a track,  audio is fed from your sound card on your PC into the audio input jack.  Pressing the record button once initializes the record sequence. (the led flashes now) To record, press the record button and the hold it while playing the track on your PC.  Recording ends when you release the record key.  To play the track in programming mode, press the play key momentarily.  Once in run mode, the circuit is a multi-track player where the tracks are controlled via simple serial commands. 

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This is my first attempt at one of the sound modules.  This one can record and play.  It is serial controlled to play up to 16 sound tracks.  I will need at least 2 or 3  sound modules because overlapping of sounds will be required.

It works pretty well however it is not reliable at this point.  Serial data control can be tricky.  When you prototype something that uses serial communications, all of those wires start to look like antennas, capturing and generating noise.  Some of the problems are that the tracks sometimes don't play or a track kicks off before it is complete.  And then there is the inherent click and pops.  The clicks and pops can be minimized with a good PC board design but with these devices, they are always there.  I have gotten around that problems in the past by building an audio muting circuit which suppresses the output audio, just before the track ends.  The problem is that you have to know the track length.  If you record a new track, you have to reprogram the microcontroller (PIC) to mute the track.

It is quite possible that the serial communication glitches would go away once the sound modules were on PC boards, but there is no guarantee.  Given that, I have decided to use a tried and tested hardware approach where the tracks are triggered by highs and lows, hardwired from the targets for example. 

I recorded 4 tracks for testing;

  1. ground explosions (first hit)

  2. ground explosion, consecutive hit(s)

  3. building explosion with glass (hard to hear the glass but it's there

  4. possible game start up sound

Here are two poor videos (sorry) of the targets with sounds effects.  The problems I was having is that the first ground hit only plays the second track, not the first and with the building video, the target lights would sometimes extinguish early.

  1. Bombing a ground based target with sound (explosion only, no dropping sound yet)

  2. Building based hit with the laser. 

August 27, 2003
I did a little research on the Internet before I proceeded any further with my own multi-track audio system.  I'm glad I did because I found and subsequently purchased a Compact Flash Digital Audio System.  I enjoy the challenge and rewards of developing things myself however when I see an opportunity to buy an existing product with great performance specifications and a reasonable price, I jump on it.  Actually, the price and specifications are fantastic.  If it performs as the manual suggests, I doubt that I will ever custom build an interactive audio system again.  The company that manufactures and sells this product is;

Ackerman Computer Sciences
6233 East Sawgrass Road
Sarasota, Florida 34240-8922
Phone (941)377-5775 -- Fax (941)378-4226

Their website address is http://www.acscontrol.com/index_ACS.asp.  The product I purchased is called a CFSound II Compact FLASH Digital Audio System.  It is a programmable audio player that uses a flash memory card.  It can be serial controlled or contact closure/open controlled.  The base price of the unit is $119.00.  It is assembled in an enclosure and comes with an AC adapter.  The CF card is sold separately.  This unit was designed specifically for interactive displays and exhibits.  For my chopper project, it is the best "off the shelf" product of it's type that I have come across.  Especially for the money.  The detailed manual contains all of the information needed to program and operate the device.  A cleaver scheme of audio file naming determines how each audio track is controlled and played.  To find out more, you can download the manual from their web site here.

I purchased a 32 MB flash card, a 24 input contact sense board and a USB plug in card reader for storing the sound files.  With this purchase, most of my sound effect needs will be met with the exception of the gun firing sounds from the hostile targets and chopper and the chopper rotor sounds.  All of these sound effects require very instantaneous sound effects that cannot be accommodated under most audio systems.  Fortunately, those circuits are simple to build in that they play a very short sound file in rapid succession.  The chopper sounds will be a bit tricky because the rotor speed noises have to correspond in frequency and volume to each throttle control.  Regardless, this audio system will take care of everything else and I will be ensure very high quality sound.  Here's a list of sound effects it will manage;

  • Attract mode - This is the sounds the machine will make when not in use to attract people.  It is really one relatively long track.

  • Coin/Credit sounds

  • Start up sound

  • Ground and building explosions

  • Hook lower and retract sound

  • Bomb dropping sound

  • Score update sounds

  • Miscellaneous messages for bonus, narration, warning messages, etc.

September 9, 2003
It's going to be another week before I can refocus on this project.  I need to wrap up some contract work and until that's done, I don't have much time.  Here's the latest;  I received the CFsound II audio system last week.  It works well however it has a couple of small issues that I did not expected;

  1. Upon power up, there is a 36 second delay where the unit scans the flash card.  I wanted to generate a start-up sound when the machine powers up.  With this delay, I can't.

  2. For sounds that are logic level activated, there is a noticeable delay before the sound starts.  According to the people at Ackerman (the company that makes the CFsound II, the delay is only 160ms.  It seems longer but I could be wrong.  Regardless, when I bomb or shoot a target, there is a slight delay before the explosion sound activates.

I can work around the 36 second delay by keeping the CFsound powered up at all times.  As long as the machine is plugged in, power can be applied to the CFsound permanently.  A master switch will turn on the machine.  This is when the start-up sound will occur.

The delay in the explosion sound does not seem awkward or out of sink when hitting a target with the gun because it shoots in rapid succession.  With the bomb function however, the delay is slightly noticeable.  I think I can adjust the bomb effect to compensate for the delay.  The way is works right now is when you drop a bomb, the red Luxeon Star LED blast the ground, then fades back over a 1.5 second period.  The fade effect is managed in software within the helicopters controller.  To compensate for the delay, I'm going to tweak the software so that when the bomb is dropped (Luxeon Star LED activates), It will be activated at about 60% intensity initially, then 160ms later, at 100% intensity before fading back.  This could be a really neat effect in fact.  I'll likely put the same 160ms delay in the hostile target's explosion effect.

That's an easy change.  The only other sound effect managed by the CFsound that needs to be adjusted for would be the hook lower and hook retract sound.  I'll just delay the start of the hook movement by 160ms to compensate.

Besides recording all of the sound effects such as attract mode, narration, hook, score update, bonus and explosion sounds, I only need to build a chopper rotor sound module and a gun firing sound module for the ground targets.  The helicopter's gun sounds can be generated using DTMF tones directly from the speed controller/gun/hook/bomb controller.

My goal is to have the sound system wrapped up in a week or 2.  After that, I'll begin to work on the displays.  I believe I have the answer(s) for the displays. 

October 3, 2003
Wow!  I've been bombarded with other work that has kept me from this project for a while.  I'm eager to move things a long but it will be yet another week before I can begin.  Basically, I need to build a sound effect module for the chopper and generate DTMF tones for laser sounds.  Once that is done, I'll build the collapsing bridge mechanism and pick-up vehicle charger/controller.  Then I'll start prototyping the score and timer displays and the central game controller.  That will complete the electronics.  When I prototype each function, I will design PC boards for each.  Some are done now.  When the designs are complete, I'll have the boards produced.  Finally, I'll begin the landscaping and painting.  Look for a lot of progress bringing soon!

October 6, 2003
Just a quick update;  Here are 2 possible colour designs for the cabinet.

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Here are 2 cabinet designs that I drew in Corel Draw.  

October 20, 2003
I decided to take a break from the electronics, mainly because I have been doing so much contract work recently.  Working on the cabinet is out of step with my original plan but I really need the change.  I mucked around with a lot of different designs from ultra modern to retro.  This design is a hybrid of both.  I notice that a lot of arcade machines are using this shiny aluminum.  It gives the machine an industrial yet space age look.  I may change the colour scheme but so far, I like the blue.  I believe that in about 3 weeks (assuming the aluminum pieces are completed), I'll make a huge leap in progress.  Between now and when the aluminum arrives, I'll design the graphics and have vinyl decal made.  They will stick onto the sides and the front which will be painted.  I'll paint the legs likely this week and pick up the lights (about 30 of them), this week.  After that, I'll begin working on the landscaping.  I still have a lot of work to do on the electronics but I have experimented enough to commit to a physical design of the cabinet's inside and outside.

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This is the design I am committing to.  I generated a few dozen variations before settling on this one.  The aluminum pieces are actually shiny like chrome.

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The aluminum pieces are being manufactured now and will be completed in about  2 weeks.  I am working on the graphics now.

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I narrowed the design down to these 10 before choosing the one in the middle row, right side.  I changed the red/orange front to blue but I may still use the red/orange colour.

November 12, 2003
I've finally made some progress! This is what I've done; I completed the graphic design for the side art and settled on a production method.  I'll have the artwork produced as a vinyl cut decal.  It will be done in a vivid orange which is a good contrast against the blue.  I've slightly changed my colour scheme because I really liked the idea of having a burnt orange colour for the front of the cabinet.  I have begun painting too.  So far, I have primed everything and sprayed the first coat of blue.  I am using a 2 part lacquer for the primer and finish coats.  This stuff is $50.00 a gallon! The first coat of blue is a satin finish.  I wanted a lot of solids so that I could sand much of it off.  This will really improve the finish coat.  The finish coat will be glossy.  In addition, I will be clear coating the cabinet with a metallic clear coat.  I am hoping this gives the finish a retro-modern look much like classic automotive finishes.  

I have had some of the checker plate aluminum cut already however the rear side plates will be done in a week or two.  I was initially quoted $700 to do all the metal work however I was able to reduce this to just $250.00 by going to a water jet cutting company for the difficult parts.  The metal plates are the last things (besides the lights) to go on the cabinet.  I am thinking that I may attach them with rivets.  It will look very clean that way.  Screws may make the removal easier however there is not much wood to screw into.  

I am a little stumped on the lights.  I can find red, orange and white marker lights but I cannot find blue.  If anyone has some advice, please contact me.  Lastly, the legs have their first coat of paint in a dark hammertone grey.  I am hoping to have the cabinet painted by this weekend but I may have to complete that part when I return from vacation.  It could be a while before I find the lights I want.

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This is the latest cabinet colour scheme and the final graphics.  I wanted the graphics to look abstract like vector art.

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This is the dimensional drawing for the rear side plates.  The waterjet company (Go H2O) will program their machine to cut the checker plate aluminum based on the these dimensions.  I am also getting them to cut out three 7" circles for the feet.  This method seems to be the most cost effective for difficult shapes.

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Here, the cabinet is disassembled and ready to be primed.

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These pieces are primed.  All surfaces are sanded and small imperfections are filed with putty before the finish coats.

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The bottom of the main base needed some Bondo to fill some imperfections.  The bottom and inside were painted a satin blue.  This finish is really just a stabilizer for the areas that will not be visible.

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These are the audio plates for the 2 speakers and subwoofer/amplifier.

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The base will be painted burnt orange on all vertical outside surfaces.  I'll paint the perimeter of the top with a 4 inch blue edge so that the edges bleed into the landscaping.

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A sanded corner piece upside down.  These were painted satin blue.  The finish coat will be glossy blue with a final metallic clear coat.  I've never seen the results of the clear coat metallic finish.  It's a relatively new product.  

November 14, 2003
I completed painting all of the pieces that are blue.  This includes the inner part of the base, the 2 corner pieces, the audio and speaker plates, the electronics slide panel, the large access door and the top and sides of the top piece.  So far, the finish has turned out immaculate.  I'm very happy with the results.  I have never used 2 part, colored lacquer before but I have had plenty of experience with clear catalyzed lacquer while restoring lots of antique radios and other antiques.  The 2 part colored lacquer has the same characteristics as the 1 part type.  I'm not sure if one is better than the other with respect to hardness and durability.  Amazingly, I used almost an entire gallon of the blue.  I have just enough for some future touch-ups that might arise.  

The next step is to spray the orange.  The parts that will be orange are the base (about 3/4 of the outside vertical surfaces) and the inside of the top piece.  I decided to do the inside of the top piece orange because I feel it will enhance the lighting that will reside in that area.  I will likely use low voltage halogen lighting.  The glossy orange lacquer should help create a nice warm downward glow.  Once the orange painting is complete and fully cured, I will finish 2 areas with metallic clear coat to hopefully give those surfaces a retro-automotive look.  I will experiment beforehand however.  Those surfaces will include the vertical, outside surfaces of the corner pieces and the outside vertical surfaces of the base.  I may wait till I return from my upcoming vacation to apply that last step because the best finish for lacquer is achieved after letting the previous coats cure for several days.  That's my opinion anyway.  So really, I am not far off from being able to assemble the painted cabinet.  Once re-assembled, I'll mount the checker plate aluminum and install the yet to be found lights.

Ideally, I wish I could have built virtually everything before I even began painting the cabinet.  That way, all of the holes for routing wires and all of the other mounting parts would have been painted.  However, I decided to paint now as a means to commit to a cabinet colour and cosmetic design but most importantly, to inspire me to get this project done.  I have worked on this for about 11 months and I believe I'll be another 6 months before it is complete.  Originally, I simply wanted to build a helicopter arcade machine that was retro in design but performed much better than anything ever built.  It was going to be simple but powerful.  As things evolved (as they often do), I began to add lots of advanced functions like a laser, retractable hook, bomb function, hit detection, targets, collapsing bridge, fuel, ammunition and repair functions, etc, etc.  Even developing a system that  would allow the helicopter to pick up a vehicle and drop it off so that it could be picked up again and again; although it seems simple now, it took a long time to develop the scheme to make that happen and to make it work reliably.  Along with the huge increase in functionality came higher quality materials and construction techniques.  Of course this added lots of time and much more costs.  I am guessing that my costs will land me at about $4,000 to $5,000 plus hundreds of hours of labor.  I do lots of work for a company that manufactures interactive displays and exhibits for museums and companies profiling a product.  They would sell this machine for $30,000 to $50,000.  I am not kidding.  I have built several control systems for them for working models where the model was contracted for over $50,000. Yet, my machine will be more sophisticated than anything they have every built.  At this point, money is no object.  I'll sink whatever I have to, to make this machine the best one ever built.  

Given all that I said, this next while will be an exciting phase for the project.  Really, I am in the finishing stages.  Although not all of the electronics have been built and some things like the building and collapsing bridge scheme need to be developed, I feel I am entering the finishing stage where all of this experimenting and pondering is coming together. 

November 15, 2003
I completed the painting of the orange parts.  This includes the underside of the top piece and the wraparound part of the base.  They look really good.  I picked up a liter of clear coat metallic lacquer and the fellow at Days Paints in Edmonton generated a sample of the finish using colors watches.  It looks very sharp.  (Thanks for your help Bob!) It is precisely the look I wanted.  I am nervous about applying this  however.  I am concerned about getting an even distribution when spraying.  The lacquer is embedded with small metallic particles and when you spray, you have to ensure that you lay it on as evenly as possible or you could see streaks and patches.  In any case, I will wait till I return from my vacation before applying the metallic finish.  I also completed the legs.  Hopefully, shortly after I get back, I can begin to assemble the cabinet.  Depending on my choice of how the side art will be applied, I may have to bring the corner pieces into a company, for example, if the side art is silk screened. I'll return in a couple of weeks!

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The wrap-around part of the base looks great.  I'm praying I can apply the metallic lacquer evenly.  If I am successful, the cabinet will have a retro look to it.  very cool!

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The top of the base will be painted different colors and fitted with all kinds of things that will make up the landscaping.

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Shown are the 2 corner pieces, the access door, the electronics slide plate, 2 speaker plates and the sub-woofer/amplifier mounting plate.

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Another shot of the blue parts but with the back of the access door shown.  The corner pieces' outside surface will be sprayed with metallic lacquer like the base.  The small orbs you see was caused by dust on my camera lens.

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The top piece is painted blue on the outside and vivid burnt orange on the inside.  Checker plate aluminum will wrap around the sides.  I am hoping the orange will enhance the lighting that will reside under the top, creating a nice orange glow.

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Here are the samples of the metallic lacquer sprayed on the color swatches.

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The legs have been painted a dark hammertone.

December 3, 2003
I returned from my vacation a few days ago and now have a flu!  Before I left, I attempted to paint one of the blue corner pieces with the metallic clear coat however it did not turn out.  I could not lay it on consistently.  I only did one surface so sanding it down and repainting it was not a problem.  It is possible that I could successfully create a metallic finish by dusting the the metallic finish on from a further distance.  This normally allows you to lay it on slower and more evenly.  In doing so, you have to spray several clear coats afterwards, sanding between coats.  I decided to drop this idea because the paint looks great as it is.  Much of it will be covered in metal, silk screened graphics, lights, etc.

I now have all of the checker plate aluminum cut and all for $90.00. Another company quoted me $700.00.  I'm not kidding!   Although I have not test fitted everything, all of the pieces look really good.  Thank you "Go H20", the waterjet company that did this for me.  I'll take some pictures when I feel better.  I have thought about fastening methods for all of the metal.  I'll likely use wood screws in some areas and small bolts in others where I can.   The heads will all match.  I plan to start assembling the base this weekend.  I may not be able to attach the wrap around metal to the top until I get some lights.  I want to pre-drill as much of the metal as possible including all of the holes for the lights, lenses and wiring holes.  I still have not found suitable lights for this project.  I am looking for blue round marker lights, about 2" to 2.5" in diameter.  They may not exist.  One option is to make my own from colored pinball bumper caps.  I have sent emails to two suppliers to get exact dimensions for certain bumper caps but have not heard back from them yet.  I often go through hardware stores and toy stores looking for something I could hack for parts.  These lights have me stumped.  I am even going to look at tinted plastic drinking cups.

By Friday, a full size positive film will be generated for the corner pieces, that is, the film for the silk screen of the buildings.  I decided to use a hybrid approach where the buildings are silk screened and the white graphic helicopters are going to be precision white vinyl decals that will overlay the silk screened buildings.  This was not the most cost effective solution because of the silk screening but it should be reasonable and give professional results.  I am hoping this stuff is done in less than 2 weeks.  If I can resolve the lights in a few days and get some stuff ordered, I may meet my target of having the basic working machine in my basement by Christmas.

December 7, 2003
I managed to get the corner pieces and and all of the artwork to the graphics company last week.  I had to get a full size positive film generated for the silk screening of the buildings.  The helicopters that will be made from vinyl, will be generated directly from an EPS file.  The cost for silk screening and generating all of vinyl helicopters and 4 sets of the words "US Terrorist Hunt" (with a white outline) will be $218.00.  Not bad really.  All of this will be done by December 10th, next week.  I think I have resolved my lighting problem.  I have found a source for LED marker lights however I will have to purchase orange and clear instead of orange lights and blue lights.  The supplier is searching for blue marker lights however I doubt they exist.  I will have a set of 4 smaller lights on each side of the corner pieces near the bottom.  Of these 4 lights, 2 will be red and 2 will be blue.  These are dome lights for newer pinball machines.  So I am compromising a bit on the main lights but perhaps I will find them some day.  At this point I simply want to move forward. 

I was going to begin assembling the cabinet this weekend but instead I had to do some work on a rental property we bought.  Priorities!  In any case, I want to wait till I get the stuff back from the graphics company next week anyway.  It should start to look pretty neat.  I'll have the cabinet assembled with all of the graphics and metal pieces.  Only the lights will be missing.  For the first time, it will look like an arcade machine.

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