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Worklog UltraLite

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Wasn't planning on entering until I stumbled across something (which you will find out later) that gave me the idea and motivation for this project to enter. I plan on having all the bells and whistles that one would expect in 2023.

Just started this yesterday, not much to show yet but more updates soon!
IMG_1291.jpg
 
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Motherboard Flex.jpg


This is the simplest of the custom boards that I wanted to knock out first. It will be a flex that simplifies the internals for cleaner/less wiring and connecting the two halves of the portable together via one FFC cable. It is just a simple NAND and U10 relocation flex as well as taps into the Wii's digital video/audio signals to route to the driver board on the top half of the portable. I'm not too sure how well the Wii digital signals will do on this flex and hope to not have issues with signal integrity since the top and bottom portion has trace matching that overlap due to the tight space. Probably would be fine on a rigid PCB board, but worst case I can just reroute the signals to overlap as little as possible. Updated the flex to have traces overlap as little as possible without trace matching, which will be done on the driver board itself instead of this flex due to limited space. Also added the appropriate untented vias for soldering to the motherboard. Up next, the custom driver board!

Fun fact: Pin 6 and 10 of the NAND are routed on the original Wii board to the GPU but actually do not do anything and have no connection internally on the NAND chip! So I left them out. Possibly due to Nintendo wanting to use different NAND chips with different pinouts but chose not to in the end.
 
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There's a lot going on with this board. This might be a compact portable, but there will be no compromises!

This board includes:

- RTD2660 LCD Driver
- gcvideo FPGA
- i2s audio amp
- bluetooth audio transmitter
- GC+ 2.0 button combo circuitry for controlling OSD and Backlight
- Integrated MicroSD card (accessible via USB-C port)
- FFC connectors for simple assembly/disassembly between the 2 halves of the portable and controller boards


Screenshot (44).png


Screenshot (45).png


Still need to add some ground vias here and there and debating whether or not to add a connector for the speakers or just pads to solder to...
 
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This is going to be a killer! Have you tested if the GC+2.0 works with GCVideo? It didn’t in my case but maybe I did something wrong.
 
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Thank you, and I know we spoke of it a while ago and I never got around to testing it but I definitely will once I make an order of these boards. I'm not set on it needing to work but would be a bonus if it did!
 
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In any case I’m digging the use of HDMI, FFC connectors and integrated microSD reader! The internals will be so tight!
Have you thought about adding HDMI out with a little HDMI switch? Might be a lot of work to implement it through USB-C though but an awesome feature for sure.
 
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Appreciate it! It's a cool feature, but my focus for this project is to purely be a handheld experience. I'd just emulate if I wanted to play it on the TV to be honest for that crispy 4K!
 
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I started working on the PMS board but decided to run some tests on the Wii first.
This project will be the first portable to feature a Wii Mini via an OMEGA trim to take advantage of the Hollywood-2 GPU.


For those of you who don’t know, certain revisions of the Wii Mini feature a newer die shrunk GPU (compared to the regular 4 layer Wii) called “Hollywood-2”. I go over further details in my other thread here: https://bitbuilt.net/forums/index.php?threads/project-m.5113/post-54897

Shank did some testing a while back to see the lowest voltages the Wii can go. According to the numbers Shank has reported, we can theoretically undervolt, but doesn’t seem like anybody has ever done it in a portable nor reported some concrete numbers of power consumption. I want to add to this so we have some documentation.

Keep in mind the testing has been done on a Wii Mini with 1 Wii remote connected on the Wii menu screen. The values of a regular 4 layer Wii will be different. I may be able to go lower, but probably won’t go much lower for piece of mind.

The Wii Mini draws about 4.124W (on the Wii menu screen) with custom regs and standard voltages (1V, 1.15V, 1.8V, 3.3V).
I need 3.3V for most things in the portable as well as 1.8V so I won't be messing with those.

I started with the 1.15V line which normally draws 1.62A (1.863W) and took it down to 1V (under load) which now draws 1.36A (1.36W).
According to Shanks notes, we can go down to 0.916V. Will test that later.

The 1V line normally draws 1.16A (1.16W) and took that down to 0.875V (under load) which now draws 1A (0.875W).
According to Shanks notes, we can go down to 0.867V. I'm going to leave this one as is since it is already close to the lowest it can go.

By undervolting these 2 voltage lines, I am saving an additional 0.788W, for a grand total of the Wii Mini drawing only 3.336W!!!

I will still try to undervolt the CPU more and see what happens which I will update later. I haven't grabbed the numbers in game since my multimeter is acting up now, but shouldn't be too far off. Have been running Melee with 4 CPUs on the hardest difficulty for 2 hours now, no issues. I can confirm the undervolt at these voltages at least for the Wii Mini.

EDIT: I was able to get the total power consumption to just 3W, but the system was unstable, and would not last a few minutes without crashing. The GPU did boot at 0.8V under load but I didn’t try going any further since there’s no point for stability reasons and same with the CPU, which the lowest was able to boot was 0.97V. So far the best combo I have found was my first initial test of the GPU at 0.875V and the CPU at 1V. I did a pretty crazy stress test and left Melee on overnight with four CPUs at max difficulty, and a few hours in it did crash. But let’s be honest, with portables that’s unrealistic. Just in case I will increase the GPU to 0.9V. Regardless, a great saving in power!
 
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Awesome!! You’re pushing all boundaries here! Wii mini + undervolting + FFCs + custom RTD2660 board, is there a limit to how much meme you can put in your meme?
 
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It has been quite some time, but started working on this again in the last month.
I think the spirit of the summer competition motivated me to pick this project back up since this was last years submission. Not entering this year but in good faith would like to finish this project this summer.

Here was the assembled all in one driver board from last year:
IMG_1536.jpeg


While it looked nice, it didn’t work properly. Got the video to display one time only with artifacts with a weird error, then never again.
IMG_1554.jpeg


I always post about my failures, I’ve got nothing to hide lol. I’m just a humble hobbyist.

I redesigned the whole board using a different chipset to handle the video (MST703 instead of RTD2660) as I discovered it used less than half the power and didn’t get warm at all. It used VGA with the AVE integrated on board.
IMG_2150.jpeg


While it worked, I soon realized running power and video all through one unshielded FFC cable was no good and the video had issues. At least you can see my flex in the background worked just fine. Ignore the FFC cable, I cut it to fit properly just for testing haha.

I’m working on a new driver board that should fix all the issues I have discovered from all of this trial and error. I also went over many various layout guidelines for various circuits like HDMI, USB, etc to properly design everything again from scratch. It pays to make mistakes!

Huge shoutout to YveltalGriffin for my many questions that he has answered through the years!

On the bright side, last year I did successfully trim a Wii Mini OMEGA:
IMG_3272.jpeg

IMG_3273.jpeg


Sorry, couldn't find the photo showing it actually booting...
The flex did not look so good on a trimmed board but that’s okay because I’m scrapping it anyway for something else.

I made a couple discoveries along the way that I forgot to post about so might as well now.

1) You can see a red wire in the trim, and that is because Nintendo changed the design slightly where they repositioned the feed through capacitor and while cutting an OMEGA, it cuts through the 3.3v that connects to the feed through cap on the Wii Mini that doesn’t on the Hollywood 1 boards. You can either reconnect 3.3v or cut slightly further away to not cut through that trace.

2) The digital video vias are all the same except V0, which was moved so it slightly varies from the other 4 layer Wii boards and therefore is not compatible with current video flexes unless you run a jumper or make your own compatible flex.

3) Thankfully, Nintendo moved the USB vias and they are available to solder to on an OMEGA trim whereas the regular 4 layer Wii boards require you to scratch the fine traces and solder to those.

These are only the immediate things I noticed, there may be other changes that I didn’t notice right away.

From my research, if you want a Hollywood 2 Wii Mini, just check the serial number underneath and if it starts with an “HW2” then it should be a Hollywood 2 variant. Maybe that’s what the abbreviation stands for in the first place. Confirmed this theory with about 5 Wii Minis, plus a few other members confirmed this as well.
IMG_3268.jpeg


I never shared this on here back during the 2023 Summer Contest, but the whole reason I was building this was because it was the time when Waveshare released the first QLED screen on the market for projects like this.

https://www.waveshare.com/product/43h-800480-ips.htm?sku=24773

I have already posted another portable using a 5" QLED screen (here), but was long after starting this build as this portable will feature the 4.3" 800x480 QLED screen whereas my other build used the 5" version.

And man let me tell you QLED is beautiful. Here are a few shots of the 4.3" QLED screen:
IMG_1407.jpg

IMG_1408.jpg


Even compares to OLED colors on the Switch OLED (QLED screen is definitely a warmer display as you can see):
IMG_1415.jpg


Next, I designed a funky little power board to fit in the small space left above the Wii OMEGA in the case.
Screenshot 2024-05-22 210826.png


Which fits a little snug right above the Wii Mini OMEGA trim:
IMG_3470.jpeg


The Reg board will have a thermal pad/paste that will be screwed right on top of the heatsink so I’ll never have to worry about it overheating.

This build will also feature undervolting to maximize the battery life, which should be about 4 hours.

I’ve decided I’d like to change it up with the analog sticks, so I’ll be using modified Quest 2 sticks. They are definitely thicker, so I had to add a few more mm of thickness to the case but I think it is worth it. I visited these sticks previously and didn't like them and now I know why. The Quest sticks are pretty stiff in my opinion compared to modern day sticks that have much lighter tension, so the stiffness makes them feel kind of limited in range. Easy fix, I just replaced the spring internally with one from a Joycon stick and it feels buttery smooth now with greater feeling range than Joycon sticks. And they look great too:
IMG_3433.jpg


This build I will have a proper built sealed soundbar chamber for higher quality audio as well. High quality audio really ups the experience with these projects. Here's a quick comparison from regular speakers to sealed chamber speakers:

Regular Speakers (doesn't have much bass/depth and very sharp sounding)

Speaker Soundbar Chamber (well rounded sound with a lot of bass/depth)


Last, the biggest hurdle that I need to tackle that I don't have an update on yet (still in the planning phase) is to have hall sensor triggers. They feel really nice in modern day controllers and with a click at the end of the trigger would make it feel close to the original Gamecube controller. I'm planning on have a PS5/Xbox type feel with a hinge design as opposed to the original sliding of the Gamecube controller. Luckily, StonedEdge has already done something similar and even shared his code on his github that I'll mess around with.

This was a long post, thanks for sticking around!
 
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Portables
KiWii Portable (In progress)
Amazing work on this! I love the design you approached with making an All-In-One board for the Screen, GCvideo, Audio, and GC+ controls! Hopefully I'll finish my portable some day, but great job!
 
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