Let’s Play Spot The Fake MOSFET

Recently, the voice push to talk circuit in [Ryan]’s BITX40 radio was keyed down for a very long time. Blue smoke was released, a MOSFET was burnt out, and [Ryan] needed a new IRF510 N-channel MOSFET. Not a problem; this is a $1 in quantity one, but shipping from Mouser or Digikey will always kill you if you only buy one part at a time. Instead, [Ryan] found a supplier for five of these MOSFETs for $6 shipped. This was a good deal and a bad move because those new parts were fakes. Now we have an opportunity to play spot the fake MOSFET and learn that it’s all about the supply chain.

Spot the fake

To be fair to the counterfeit MOSFET [Ryan] acquired, it probably would have worked just fine if he were using his radio for SSB voice. [Ryan] is using this radio for digital, and that means the duty cycle for this MOSFET was 100% for two minutes straight. The fake got hot, and the magic blue smoke was released.

Through an industry contact, [Ryan] got a new, genuine IRF510 direct from Vishay Semiconductors. This is a fantastic opportunity to do a side-by-side comparison of real and counterfeit semiconductors, shown at right. Take a look: the MOSFET on the left has clear lettering, the one on the right has tinned leads and a notched heatsink. [Ryan] posed the question to a few Facebook groups, and there was a clear consensus: out of 37 votes, 21 people chose the MOSFET on the left to be genuine.

The majority of people were wrong. The real chip looked ugly, had tinned leads, and a thinner heatsink. The real chip looked like a poor imitation of the counterfeit chip.

What’s the takeaway here?  Even ‘experts’ — i.e. people who think they know what they’re talking about on the Internet — sometimes don’t have a clue when it comes to counterfeit components. How can you keep yourself from being burned by counterfeit components? Stick to reputable resellers (Mouser, Digikey, etc) and assume that too good to be true is too good to be true.

Hacked Sea Scooter Lives Another Day

The Seadoo GTI Sea Scooter is a simple conveyance, consisting of a DC motor and a big prop in a waterproof casing. By grabbing on and firing the motor, it can be used to propel oneself underwater. However, [ReSearchITEng] had problems with their unit, and did what hackers do best – cracked it open to solve the problem.

Investigation seemed to suggest there were issues with the logic of the motor controller. The original circuit had a single FET, potentially controlled through PWM.  The user interfaced with the controller through a reed switch, which operates magnetically. Using reed switches is very common in these applications as it is a cheap, effective way to make a waterproof switch.

It was decided to simplify things – the original FET was replaced with a higher-rated replacement, and it was switched hard on and off directly by the original reed switch. The logic circuitry was bypassed by cutting traces on the original board. [ReSearchITEng] also goes to the trouble of highlighting potential pitfalls of the repair – if the proper care isn’t taken during the reassembly, the water seals may leak and damage the electronics inside.

Overall it’s a solid repair that could be tackled by any experienced wielder of a soldering iron, and it keeps good hardware out of the landfill. For another take on a modified DC motor controller, check out the scooter project of yours truly.

 

Beefy 100 Amp Electronic Load uses Two MOSFETs

[Kerry Wong] had some extreme MOSFETs (IXTK90N25L2) and decided to create a high current electronic load. The result was a two-channel beast that can handle 50 A per channel. Together, they can sink 400 W and can handle a peak of 1 kW for brief periods. You can see a demo in the video below.

An electronic load is essentially a load resistor you can connect to a source and the resistance is set by an input voltage. So if the load is set to 10 A and you connect it to a 12 V source, the MOSFET should look like a 1.2 ohm resistor. Keep in mind that’s 120 watts–more power than a common incandescent light bulb. So you are going to need to carry some heat away.

The circuit is pretty simple. The FETs accept a voltage on their gates that sets them to look effectively like a resistor that varies with the voltage. A very small source resistor develops a voltage based on current (only 75 mV for a 50 A draw). That voltage feeds a comparator which generates the gate voltage after looking at the input control voltage. Each millivolt into the comparator translates to an additional 1.33 A through the load.

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The Fab Lab Next Door: DIY Semiconductors

You think you’ve got it going on because you can wire up some eBay modules and make some LEDs blink, or because you designed your own PCB, or maybe even because you’re an RF wizard. Then you see that someone is fabricating semiconductors at home, and you realize there’s always another mountain to climb.

We were mesmerized when we first saw [Sam Zeloof]’s awesome garage-turned-semiconductor fab lab. He says he’s only been acquiring equipment since October of 2016, but in that short time he’s built quite an impressive array of gear; a spin-coating centrifuge, furnaces, tons of lab supplies and toxic chemicals, a turbomolecular vacuum pump, and a vacuum chamber that looks like something from a CERN lab.

[Sam]’s goal is to get set up for thin-film deposition so he can make integrated circuits, but with what he has on hand he’s managed to build a few diodes, some photovoltaic cells, and a couple of MOSFETs. He’s not growing silicon crystals and making his own wafers — yet — but relies on eBay to supply his wafers. The video below is a longish intro to [Sam]’s methods, and his YouTube channel has a video tour of his fab and a few videos on making specific devices.

[Sam] credits [Jeri Ellsworth]’s DIY semiconductor efforts, which we’ve covered before, as inspiration for his fab, and we’re going to be watching to see where he takes it from here. For now, though, we’d better boost the aspiration level of our future projects.

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Ask Hackaday: Dude, Where’s My MOSFET?

(Bipolar Junction) Transistors versus MOSFETs: both have their obvious niches. FETs are great for relatively high power applications because they have such a low on-resistance, but transistors are often easier to drive from low voltage microcontrollers because all they require is a current. It’s uncanny, though, how often we find ourselves in the middle between these extremes. What we’d really love is a part that has the virtues of both.

The ask in today’s Ask Hackaday is for your favorite part that fills a particular gap: a MOSFET device that’s able to move a handful of amps of low-voltage current without losing too much to heat, that is still drivable from a 3.3 V microcontroller, with bonus points for PWM ability at a frequency above human hearing. Imagine driving a moderately robust small DC robot motor forwards with a microcontroller, all running on a LiPo — a simple application that doesn’t need a full motor driver IC, but requires a high-efficiency, moderate current, and low-voltage-logic compatible transistor. If you’ve been here and done that, what did you use?

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Faux-AI Clapper Almost Seems to be Listening

When a job can be handled with a microcontroller, [devttys0] likes to buck the trend and build a circuit that requires no coding. Such was the case with this “Clapper”-inspired faux-AI light controller, which ends up being a great lesson in analog design.

The goal was to create a poor man’s JARVIS – something to turn the workshop lights on with a free-form vocal command. Or, at least to make it look that way. This is an all-analog circuit with a couple of op amps and a pair of comparators, so it can’t actually process what’s being said. “Aziz! Light!” will work just as well as any other phrase since the circuit triggers on the amplitude and duration of the spoken command. The AI-lite effect comes from the clever use of the comparators, RC networks to control delays, and what amounts to an AND gate built of discrete MOSFETs. The end result is a circuit that waits until you finish talking to trigger the lights, making it seems like it’s actually analyzing what you say.

We always enjoy [devttys0]’s videos because they’re great lessons in circuit design. From block diagram to finished prototype, everything is presented in logical steps, and there’s always something to learn. His analog circuits that demonstrate math concepts was a real eye-opener for us. And if you want some background on the height of 1980s AI tech that inspired this build, check out the guts of the original “Clapper”.

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R/C Bot Takes Your Strawberries Away

Don’t let the friendly smile on this RC cart fool you, it will take your strawberries away — though that’s kinda the point. It’s an RC car that [transistor-man] and a few friends modified for carrying freshly picked strawberries at strawberry fields so that you don’t have to.

RC strawberry carrying robot before putting on the cooler
RC strawberry carrying robot – WIP

They started with an older Traxxas Emaxx, a 4-wheel drive RC monster truck. The team also bought a suitable sized water cooler at a local hardware store. A quick load test showed that 5lbs collapsed the springs and shock absorbers, causing the chassis to sink close to the ground. The team had two options: switching to stronger springs or locking out the springs altogether. They decided to replace one set of shocks with metal plates effectively locking them. After that it was time for some CAD work, followed by the use of a water jet to cut some aluminum plate. They soon had a mounting plate for the water cooler to sit in. This mounting plate was attached to 4 posts which originally held the vehicle’s Lexan body. A bungee cord wrapped around the cooler and posts on the mounting plate holds the cooler in place.

Thermal image of bad MOSFET
Thermal image of bad MOSFET

Some initial testing showed that the vehicle moved too fast even in low gear and tended to tip over, as you can see in the first video below. Some practice helped but a 3:1 reduction planetary gearbox brought the vehicle down to walking speed, making a big difference. A trip was arranged to go to local strawberry picking field at Red Fire Farms, but not without some excitement first. At 1AM the UNIK 320A High Voltage Speed controller emitted some magic smoke. A quick check with a thermal-camera found the culprit, one of the MOSFETs had failed, and after swapping it with one that was close enough they were back in business.

As you can see in the second video below, testing in the strawberry field went very well, though it wasn’t without some tipping. Kids also found it a fun diversion from picking strawberries, alternating between mock fright and delight.

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