GhostGuy wrote: 1. Why'd they go with a speaker instead of a piezo which would be cheaper and make the batteries last longer? It only needed to beep.
It's only a small step up from a piezo, only a speaker in the loosest sense.
GhostGuy wrote: 2. Why'd they use through hole leds on the screen, instead of surface mount?
SMT probably didn't look right. They'd have had to make a custom lightpipe setup to give it the look of rounded bulbs. Using actual LEDs was probably simpler in the long run.
GhostGuy wrote: 4. Why'd they use rectangular leds on the main circuit board when surface mount would do, given they are hidden behind light pipes anyway?
Again, probably production concerns. They may have initially intended the leds to be seen directly but changed it to a light pipe later without changing the LEDs themselves.
GhostGuy wrote: 5. Why is the main board, like the screen, so chock full of resistors? I count somewhere around 44 resistors on there, which seems to be about twice as many as should be needed for the 14 leds on the wings, 5 leds on the front panel, and the three switches.
There's probably a lot of debounce and signal cleanup from the various switches.
GhostGuy wrote: 6. The durability of the rotary switch for the speed control concerns me. It looks in the photo like the copper traces the contacts sub against is torn up. Is that the case or is it just a trick of the light?
That's mostly from the picture and the grease they put on the shaft. It's definitely weak though. When I put it back together it's a little tighter than before and doesn't turn as cleanly.
GhostGuy wrote: 7. I wonder what all those capacitors and transistors on the back are for. The motor perhaps? Why so many? Why not SMT?
Sometimes you can't get away with SMT capacitors, you need to use electrolytics.
GhostGuy wrote: 8. The design of the wings is nice. If I had the luxury of mass production so I could use flexible pcbs and surface mount leds on them and stick light pipes in the wings, I'd have gone that route with my boards.
Looking at the wings it's obvious there's a flexible strip of SMT LEDs behind the light pipes. Nice if you can do it but out of the realm of possibility for most people.
GhostGuy wrote: 9. I'll bet that mechanism that pulls the wings down has another rotary switch mounted under it. They've gotta have some way to detect how far the wings have traveled, and that board under there looks similar to the rotary switch one, and has four wires coming out of it.
It does, you can see the wires going to it in this pic:
http://www.gbfans.com/images/pb/jackdou ... G_9721.jpg. Simple design but it works.
GhostGuy wrote: 10. Are those metal threads where the screws attach the top of the shell to the bottom? I'm surprised, usually on toys they just use self threading screws. But maybe because this needs to be dissasembled to repalce the batteries they decided to go with something more durable.
They're actually regular nuts in a molded socket. They're not even glued in, I had trouble with one not letting go when I tried to remove the battery plate.