Lots of stuff to talk about here, some very good points raised, first
power supply:

I'm thinking of a single 5V supply, such as for the Touch, on the
standard connector. Thus a basic swither could be used or one of the
aftermarket ones if desired. I would be glad to come up with one of my
linear designs for this is which could be an option for it. At this
point I have not done any research on the best wallwart to use with such
a project, there are a lot out there, maybe after Gen1 boards go out
different people can do some experimentation and come to some
conclusions. 

The grounding and noise  issues etc are a very interesting aspect of
this, what I am planning on doing is the following: the board will have
two power domains, digital and analog. The digital domain has the
processor, memory, ethernet, USB etc. The analog domain has the DAC
chip, headphone amp, S/PDIF out, audio MCLK oscillators and reclocking
flops. Each section will have it's own separate ground plane, with the
few signals going between them going through isolators (I prefere the
GMR types, I HATE ADUMS). There is a separate plane which just has the
raw +5 and ground from the  power supply, this plane connects to the two
domains in one place for each domain. This scheme does a very good job
of prevening digital domain noise from getting into the analog domain
and still lets you power the whole thing off of a single supply. What
makes it work is that there is one and only one ground connection
between domains, this prevents any ground loops from happening. 

Since I am planning on an eight layer board I can put signal routes
between planes, which does a good job shielding, cutting down on EMI. 

Cases: Norm you are right, I was just going to screw the Gen1 board onto
a pice of plywood for my own use. I can certainly design it to fit a
case if we can find own that works well. I want to keep the edge that
has the connectors to 3" so I can get all the connectors on there. 

I like the slide into extrusion concept, I have used it many times. One
variaton I have done  is use PCBs for the end panels, the board makers
have the soldermask available in many different colors and silkscreen
can handle labels etc. One interesting technique I use is to put holes
in the soldermask so the underlying glold plating shows through, you can
do logos, model name etc with this that REALLY look nice. I did one with
blue solder mask and the gold showing through that was stunning. The
price can be less than laser cut aluminum, and they can look quite
striking. 

Board testing: the manufacturing place I use automatically does bare
board testing for multi layer boards to make sure the boards were done
right. They also automatically do X-ray testing of BGAs to make sure the
soldering came out right. They CAN do assembled board electrical
testing. Simple testing is included in the price. They can do more
extensive testing if test points are included on the board, but of
course that costs more money. The big problem is that it takes a lot of
time to come up with a good comprehensive test program. I don't think I
want to do this for Gen1, but it's probably a good idea for Gen2. They
have experts that will work with you to design a board that's easy to
test. Again, probably not for Gen1, but probably a good idea for Gen2. 

On the memory front, the AM3874 has two DDR controlers, so if we use two
256MB chips we get twice the memory throughput, it's tempting. My
original thought was to limit the design to one memory chip since
putting two chips on the same controller is MUCH more difficult. But
since this processor has two controllers I don't have to deal with that,
I can do two chips without the extra hassle. I think you guys have
convinced me that it's probably worth doing it.

On the why do this in the first place? For me the motivation is that I
can integrate quite good sound into the product for a LOT less money
than it takes to do an equivalently good USB async DAC. The processors
I'm looking at already have kernel drivers for audio over I2S and
S/PDIF. These are available free from the manufacturer in their SDK
which should make sending data to the DAC chip and S/PDIF not too
difficult. Yes it is going to take some work, but I don't envision it
being too bad.

That brings up the issue of other external interfaces (remotes, IR
blasters etc). I'm kind of leary about putting those directly on the
board. They WILL require kernel drivers to be written and frankly I'm
not convinced that is going to happen.

I think we need to crefully look at this issue and come up with a
workable solution so that separate kernel drivers  do not need to be
written for each interface. USB can be used for a large number of these,
it might be a lot easier to come up with a GPIO over USB approach to add
these. Anyway I'm not going to add these in Gen1, we as a community need
to spend some significant time coming up with how to deal with this
issue of other external world interfaces.

I hope that covered all the recent quations.

On another front, the BeagleBone is coming today, so hopefully I will
have some results of hooking up USB DACs in the next couple days. There
are SDcard images for at least 10 different distros for this board, it 
will  be interesting to see what happens. 

John S.


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