Christmas Bauble Is Neither Spherical Nor Runs Arduino

December 26, 2015 by Anool Mahidharia 11 Comments

[Jordan Wills] was tasked by his company, Silicon Labs, to build some Christmas Baubles to give away to co-workers. While the commissioned units were designed to be simple battery and LED affairs, he decided to make one of his own with bells and whistles. His Mario themed Christmas Ornament uses a Silicon Labs FM972 micro controller, capacitive sensing, PWM controlled 8 bit audio, and blinky lights.

The interesting part is some of the construction techniques that he used. The finger-joint style cube is built from circuit boards. Electrical connections between panels were routed using solder wicking copper braid. That’s a interesting trick which we’ll keep in mind along with some of our favorite creative structural uses of PCB.

The top of the cube has four LED’s which light up the Mario “Question Mark” symbols on the four sides of the cube while the base contains all of the electronics. The outside of the base piece was a large copper plane to act as the capacitive sensing element. This meant all electronics needed to be surface mounted with tracks laid out on one side – which posed some layout challenges. Adding the Capacitive sense function was a cinch thanks to support from the in-house design team. PWM output from the micro controller takes care of audio, and the output is routed through a buffer to boost the signal. A bandpass filter then cleans up the PWM output before feeding it to the speaker.

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Fail Of The Week – Steam Cleaner Fix Goes Bad

December 21, 2015 by Anool Mahidharia 40 Comments

[Sven337] was gifted a steam cleaner, and seemed pretty happy because it helped clean the floor better than a regular mop. Until it fell one day, and promptly stopped working. It would produce steam for a short while and then start spitting out cold water, flooding the floor.

Like any self-respecting hacker, he rolled up his sleeves and set about trying to fix it. The most-likely suspect looked like the thermostat — it would switch off and then wouldn’t switch on again until the water temperature fell way below the target, letting out liquid water instead of steam after the first switching cycle. A replacement thermostat was ordered out via eBay.

Meanwhile, he decided to try out his hypothesis by shorting out the thermostat contacts. That’s when things went south. The heater worked, and got over-heated due to the missing thermostat. The over-temperature fuse in the heater coil blew, so [Sven337] avoided burning down his house. But now, he had to replace the fuse as well as the thermostat.

[Sven337] bundled up all the parts and put them in cold storage. The thermostat arrived after almost 2 months. When it was time to put it all together, a piece of fibreglass tubing that slides over the heater coil was missing. Without the protective sleeve, the heater coil was shorting out with the grounded heater body, blowing out the fuses in his apartment.

That’s when [Sven337] called it a day and threw out the darn steam mop — a few dollars down the drain, a few hours lost, but at least he learnt a few things. Murphy’s Law being what it is, he found the missing insulation sleeve right after he’d thrown it away.

RGB LED Ceiling Display

December 20, 2015 by Anool Mahidharia 8 Comments

Disco Floor’s are passé. [dennis1a4] turned them upside down and built an awesome RGB LED ceiling display using some simple hardware and a lot of elbow grease. His main room ceiling was exactly 32 ft x 20 ft and using 2 sq. ft tiles, he figured he could make a nice grid using 160 WS2812B RGB LEDs. A Teensy mounted in the ceiling does all the heavy lifting, with two serial Bluetooth modules connected to it. These get connected to two Bluetooth enabled NES game controllers. Each of the NES controller is stuffed with an Arduino Pro Mini, a Bluetooth module, Li-Ion battery and a USB charge controller.

Bluetooth is in non-secure mode, allowing him to connect to the Teensy, and control the LEDs, from other devices besides the NES controllers. The Teensy is mounted at the centre of the ceiling to ensure a good Bluetooth link. Programming required a lot of thought and time but he did manage to include animations as well as popular games such as Snake and Tetris.

The hard part was wiring up all of the 160 LED pixels. Instead of mounting the 5050 SMD LED’s on PCBs, [dennis1a4] wired them all up “dead bug” style. Each pixel has one LED, a 100nF decoupling capacitor, and 91 ohm resistors in series with the Data In and Data Out pins – these apparently help prevent ‘ringing’ on the data bus. Check the video for his radical soldering method. Each SMD LED was clamped in a machine shop vice, and the other three parts with their leads preformed were soldered directly to the LED pins.

The other tedious task was planning and laying out the wiring harness. Sets of 10 LEDs were first wired up on the shop bench. He then tacked them up to the ceiling and soldered them to the 14 gauge main harness. The final part was to put up the suspended ceiling and close the 2 sq. ft. grids with opaque plastic.

[dennis1a4] did some trials to figure out the right distance between each LED and the panel to make sure they were illuminated fully without a lot of light bleeding in to adjacent panels. This allowed him to get away without using baffles between the tiles.

Check out the video to see a cool time-lapse of the whole build.

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OSWatch, An Open Source Watch

December 13, 2015 by Anool Mahidharia 18 Comments

If you are a soldering ninja with a flair for working with tiny parts and modules, check out the Open Source Watch a.k.a. OSWatch built by [Jonathan Cook]. His goals when starting out the project were to make it Arduino compatible, have enough memory for future applications, last a full day on one charge, use BLE as Central or Peripheral and be small in size. With some ingenuity, 3d printing and hacker skills, he was able to accomplish all of that.

OSWatch is still a work in progress and with detailed build instructions available, it is open for others to dig in and create their own versions with modifications – you just need to bring in a lot of patience to the build. The watch is built around a Microdunio Core+ board, an OLED screen, BLE112A module, Vibration motor, a couple of LEDs and Buttons, and a bunch of other parts. Take a look at the schematics here. The watch requires a 3V3, 8MHz version of the Microdunio Core+ (to ensure lower power consumption), and if that isn’t readily available, [Jonathan] shows how to modify a 5V, 16MHz version.

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KiCad Utilities Generate Parts; Track Costs

December 5, 2015 by Anool Mahidharia 48 Comments

The popularity of KiCad keeps increasing, and not only are more people converting to it and using it for their projects, but there’s also a growing number of folks actively contributing to the project in the form of libraries, scripts and utilities to improve the work flow.

KiPart

[Dave Vandenbout] a.k.a [xesscorp] has written a couple of utilities for KiCad. When working with large multi pin parts such as micro-controllers, creating a schematic symbol from scratch using the traditional KiCad schematic library editor can be quite tedious. KiPart is a python script that uses a CSV table as its input to generate the KiCad schematic symbol and is able to create multi-part symbols too. Usage is quite simple. The csv file needs a part name on its first row. The next row contains the headers. ‘Pin’ number and Pin ‘Name’ are the minimum required. Additionally, you can add in ‘Unit’, ‘Side’, ‘Type’, and ‘Style’. Unit is used when defining multi-unit parts. Side decides the location of the pin, Type its function, and Style is its graphic representation. Running the KiPart python script then results in a nice KiCad schematic symbol. Besides, KiPart can specifically generate schematic symbols for the Xilinx 7-Series FPGAs and the Cypress PSoC5LP. There are a whole host of options to customize the final output, for example ordering pin placement based on pin number, or pin name or pin function. Source files can be obtained from the [xesscorp] Github repository.

KiCost

Another useful utility from [xesscorp] is KiCost. It is intended to be run as a script for generating part-cost spreadsheets for circuit boards developed with KiCad. The one piece of information you need to add to your schematic parts is a manufacturers part number. The KiCost Python script then processes the BOM XML file, reading the manufacturer part number, scraping the web sites of several popular distributors for price and inventory data, and creating a costing spreadsheet. You can grab the source files from the KiCost Github repository.

Check the two videos below where [Dave] walks through the two utilities.

Thanks to [RoGeorge] for sending in this tip by commenting on the Open Source FPGA Pi Hat built by [Dave] that we featured recently.

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Increasing Cable Length In Precision Video Applications

December 4, 2015 by Anool Mahidharia 23 Comments

Transmitting video signals over long distances can be tricky. Cheap co-ax cables won’t do the job. You either need amplifiers along the path, or need to use expensive, high quality shielded co-ax cables – both of which can end up costing a lot. [Maurizio] built a low cost solution to transmit video over long distances using twisted pair cables.

The system is cheap and uses readily available parts. The idea is to convert the video signal into a differential output using a pair of op amps and transmit them over a pair of twisted pair wires, then extract the signal at the receiving end using another amplifier.

A differential amplifier usually requires a dual-polarity power supply, which may not be available when adding this upgrade to an existing system. To over come this limitation, [Maurizio] uses a bias voltage equal to half of the power supply value. This bias voltage is added to the non-inverting amplifier signal, and subtracted from the inverting amplifier signal. The resultant differential signal is then fed into the twisted pair cable through impedance matching resistors. At the receiving end, a single amplifier receives the differential signals and outputs a signal that corresponds to the original video signal.

This symmetrical configuration renders the system immune to external noise. The design was tested for transmitting video on inexpensive CAT-3 twisted pair wire. According to him, when transmitting on 300m of wire, good quality color video was displayed on a monitor with an NTSC input. He used LMH6643 op-amps for this experiment, but other devices with similar characteristics can be used. Here’s a useful PDF document that discusses signals, cables and connections.

If you want to check out more of [Maurizio]’s work, see how he figured out how to send serial data from Excel.

1Wamp, An Open Hardware Guitar Amplifier

November 30, 2015 by Anool Mahidharia 26 Comments

The folks at [ElectroSmash] recently released 1Wamp – a one watt, open hardware, Guitar amplifier packed with features. It consists of a JFET based pre-amplifier, a Big Muff Pi a.k.a BMP based Tone control and an LM386 power amplifier. The dual JFET pre-amp provides tube-like sound, the BMP provides a nice tonal range while the LM386 can drive various types of output’s ranging from headphones to speaker cabinets.

1Wamp had controls for Tone, Volume and Gain, a Speaker/Cabinet output, a headphone output with an integrated attenuator switch and an aux. input. The aux. input is handy as it adds any line level input signal to the guitar sound, allowing you to practice with metronome or MP3 backing tracks or drum bases. It runs off either a 9V battery or can be powered via an external power source. [ElectroSmash] have released all the native KiCad design files. If you’d like a quick look at the design, check out the Schematic PDF and the Bill of Materials. There’s also a handy assembly manual [PDF] that shows how to build it in five easy steps.

Their blog post provides extremely detailed circuit analysis of every part of the design, starting from the power supply filter to remove mains “hum” all the way through to PCB layout considerations for noise reduction. Oscilloscope screen shots provide signal analysis showing bias points and signal levels throughout the circuit. The choice of value for every component is explained, along with the consequences of changing those values. This makes it easy to customise the 1Wamp to suit individual tastes. We also noticed SPICE models for the recommended and alternative JFET transistors, in case you need to customise the design by changing component values.

There’s also a lot of audio amplifier trivia, references and links shared in their post. This includes a detailed analysis of the LM386 op-amp. Want to add some bling to your 1Wamp build? There are a lot of handy tips on how to add cool LED lighting to the amplifier if it is mounted in a standard metal enclosure. However, the PCB has some really nice graphics, so an acrylic-sandwich-type enclosures look best. Check out the video that walks through the features of the 1Wamp and shows off its performance. And while on the subject of Audio electronics, here’s one of their earlier projects – an open source Arduino guitar pedal.

Documentation to this level proves several things, most notably a love for this design and deep consideration for those who will use and modify this amplifier. It’s a great pattern to follow with your own Open Source designs.

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