Development Of Magnetic Locking Idea Shows Great Progress

November 9, 2021 by Dave Rowntree 18 Comments

No matter how its done, with whatever level of fakery, magnetic levitation just looks cool. We don’t know about you, but merely walking past the tackiest gadget shop, the displays of levitating and rotating objects always catches our eye. Superconductors aside, these devices are pretty much all operating in the same way; an object with a permanent rare-earth magnet is held in a stable position between a pair of electromagnets one above and one below, with some control electronics to adjust the field strength and close the loop.

But, there may be another way, albeit a rather special case, where a magnet can not only be levitated, but locked in place using a rotating magnetic field. The video shows a demonstration of how the mass of a magnet can be used to phase lock it against a rotating field. In essence, the magnet will want to rotate to align with the rotating magnetic field, but its mass will mean there is a time delay for the force to act and rotation to occur, which will lag the rotating magnetic field, and if it is phased just so, the rotation will be cancelled and the magnet will be locked in a stable position. Essentially the inertia of the magnet can be leveraged to counteract magnet’s tendency to rapidly rotate to find a stable position in the field.

Whilst the idea is not new, Turkish experimenter [Hamdi Ucar] has been working on this subject for some time (checkout his YouTube channel for a LOT of content on it), even going as far as to publish a very detailed academic paper on the subject. With our explanation here we’re trying to simplify the subject for the sake of brevity, but since the paper has a lot of gory details for the physicists among you, if you can handle the maths, you can come to your own conclusions.

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Adafruit AVRProg Grows UPDI Interface Support

November 8, 2021 by Dave Rowntree 11 Comments

Making a small number of things with an embedded application is pretty straightforward, you usually simply plug in a programmer or debugger dongle (such as an AVRISP2) into your board with an appropriate adaptor cable, load your code into whatever IDE tool is appropriate for the device and hit the program button. But when you scale up a bit to hundreds or thousands of units, this way of working just won’t cut it. Add in any functional or defect-oriented testing you need, and you’re going to need a custom programming rig.

Adafruit have a fair bit of experience with building embedded boards and dealing with the appropriate testing and programming, and now they’ve updated their AVR Programming library to support the latest devices which have moved to the UPDI (Unified Programming and Debug Interface) programming interface. UPDI is a single-wire bidirectional asynchronous serial interface which enables programming and debugging of embedded applications on slew of the new AVR branded devices from Microchip. An example would be the AVR128DAxx which this scribe has been tinkering with lately because it is cheap, has excellent capacitive touch support, and is available in a prototype-friendly 28-pin SOIC package, making it easy peasy to solder.

The library is intended for use with the Arduino platform, so it should run on a vast array of hardware, without any special requirements, so making a custom programming jig out of hardware lots of us have lying around is not a huge hassle.

Adafruit provide a few application examples in the project GitHub to get you going, such as this ATTiny817 example that wipes the flash memory, sets appropriate fuses and drops in a bootloader.

The UPDI code was taken from the [brandanlane’s] portaprog which is hosted on the TTGO T-Display ESP32 board from Chinese outfit LilyGo, which is also worth checking out.

A little while ago we saw how the AVR Multitool, the AVRGPP learned to speak UPDI, and since we’re on programming interfaces, its possible to get the cheap-as-chips USBasp to speak TPI as well.

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Big RGB LED Cube You Can Build Too

November 4, 2021 by Dave Rowntree 35 Comments

LED cubes are really nothing new, many of us consider the building of a good sized one almost an electronics rite of passage that not so many manage to find the time or have the skill to pull off. It’s our pleasure to draw your attention to a lovely build, showing all the processes involved, the problems and the solutions found along the way.

Building a small cube is somewhat of a trivial affair, especially without considering PWM colour mixing, however as simple maths will illustrate, as you increase the number of LEDs on each side, the total number will quickly get quite large. More LEDs need more power and increase control complexity considerably. A larger matrix like this 16 x 16 x 16 LED build, has a total of 4096. This would be a nightmare to drive with plain RGB LEDs, even with cunning multiplexing, but luckily you can buy indexable LEDs in a through-hole package similar to the ubiquitous WS2812-based SMT LEDs you see around. These are based on the PD9823 controller, which can be programmed as if they were a WS2812, at least according to this analysis. Now you can simply chain a column of LEDs, with the control signal passed from LED to nearest neighbour.

Early on in the video build log, you will note there are four power supply modules needed to feed this juice. If we assume each LED consumes 60 mA on full-white (the data for this product link shows a peak value of 100 mA) that is still a total of 246 A or around 1 kW of power. The video does shows a peak power measurement of around this figure, for the whole array on full white, so the maths seems about right.

Control is via a Teensy 4.0 using the FlexIO function of the IMXRT1060RM CPU, and a bunch of 74AHCT595 shift registers giving 32 channels of up to 1000 LEDs per channel if needed. Roughly speaking, using the DMA with FlexIO, the Teensy can drive up to 1 Million LED updates per second, which works out about 32 channels of 100 LEDs per channel updated at 330 frames/sec, so plenty of resource is available. All this is with almost no CPU intervention, freeing that up for handling the 2.4-inch LCD based UI and running the animations, which looks pretty darn slick if you ask us. You can checkout the description of the firmware in the firmware section of the GitHub project. 3D printed jigs allowed for bending and clipping the LEDs leads as well as fixing and aligning the LED column units, so there really is enough detail there to allow anyone so inclined reproduce this, so long as you can swallow the cost of all those LEDs.

For a different approach to LED cubes, checkout this sweet panel based approach, and here’s a really small 4x4x4 module for those with less space to spare.

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Simplify 3D Printer Wiring With CAN Bus

November 3, 2021 by Dave Rowntree 56 Comments

[mark] had an interesting idea when looking at all the wiring of a typical 3D printer; Use CAN Bus. There are a lot of wires going to the extruder assembly, and with most designs this thing is flying around at quite some speed. You’ve got connections for powering the heater, fan power, four wires for the extruder motor, thermistor sensor wires. You get the idea. Lots of wires. Worse, they’re all moving around with the axis, and if failures occur at either end due to poor strain relief, or the conductors themselves break, then all manner of interesting failures can occur. If the hot end thermistor connection goes open circuit, usually no damage occurs but the temperature control goes out the window and your print will fail.

Now if you push the electronics needed to drive and control the extruder, directly onto the moving body itself, and hook-up to the main printer electronics with CAN Bus, you can do the whole moving interconnect thing with a measly four wires. Yes, you need another PCB assembly, so it adds cost, but it does also simply the electronics at the control end, so some savings can be made. [mark] has used CAN Bus due its availability with modern microcontrollers and also its designed-in robustness, thanks to its automotive and industrial heritage. When you think about it, this is a rather obvious thing to do, and we’re not sure why we’ve not see it much before.

If you want to dig into the detail, the project GitHub has the schematics and code ready to go.

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A Builders Guide For The Perfect Solid-State Tesla Coil

October 31, 2021 by Dave Rowntree 14 Comments

[Zach Armstrong] presents for your viewing pleasure a simple guide to building a solid-state Tesla coil. The design is based around a self-resonant setup using the UCC2742x gate driver IC, which is used in a transformer-coupled full-wave configuration for delivering maximum power from the line input. The self-resonant bit is implemented by using a small antenna nearby the coil to pick up the EM field, and by suitably clamping and squaring it up, it is fed back into the gate driver to close the feedback loop. Such a setup within reason allows the circuit to oscillate with a wide range of Tesla coil designs, and track any small changes, minimizing the need for fiddly manual tuning that is the usual path you follow building these things.

Since the primary is driven with IGBTs, bigger is better. If the coil is too small, the resonant frequency would surpass the recommended 400 kHz, which could damage the IGBTs since they can’t switch much faster with the relatively large currents needed. An important part of designing Tesla coil driver circuits is matching the primary coil to the driver. You could do worse than checkout JavaTC to help with the calculations, as this is an area of the design where mistakes often result in destructive failure. The secondary coil design is simpler, where a little experimentation is needed to get the appropriate degree of coil coupling. Too much coupling is unhelpful, as you’ll just get breakdown between the two sides. Too little coupling and efficiency is compromised. This is why you often see a Tesla coil with a sizeable gap between the primary and secondary coils. There is a science to this magic!

A 555 timer wired to produce adjustable pulses feeds into the driver enable to allow easily changing the discharge properties. This enables it to produce discharges that look a bit like a Van De Graaff discharge at one extreme, and produce some lovely plasma ‘fire’ at the other.

We’ve covered Tesla coils from many angles over the years, recently this plasma tweeter made sweet sounds, and somehow we missed an insanely dangerous Tesla build by [StyroPyro] just checkout that rotary spark gap – from a distance.

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3D Printed Printing Plates Made Using Modern Tools

October 27, 2021 by Dave Rowntree 15 Comments

It’s widely accepted that the invention of the printing press by Gutenberg in the 15^th Century was the event that essentially enabled the development of the modern world, allowing access to knowledge beyond anything that came before, even if the Chinese got in on the bookmaking act some 500 years previously. Fast-forward a few centuries more and we’ve got the ability to design electronics from our arm chairs, we can print 3D objects from a machine on the coffee table, and 3D modeling can be done by your kids on a tablet computer. What a time to be alive! So we think it’s perfectly fine that [Kris Slyka] has gone full circle and used all these tools to make printing plates for a small press, in order to produce cards for her Etsy business.

Now before you scoff, yes she admits quite quickly that KiCAD wasn’t the best choice for designing the images to print, since she needed to do a lot of post-processing in Inkscape, she could have just dropped the first step and started in Inkscape anyway. You live and learn. Once the desired image was fully vectorised, it was popped into OpenSCAD in order to extrude it into 3D, thickening the contact to the base to improve the strength a little.

[Kris] demonstrates using the registration marks to align the front and rear side plates, and even (mostly) manages adding a second colour infill for a bit more pizzazz. The results look a little bit wonky and imperfect, exactly what you want for something supposed to be handmade. We think it’s a nice result, even if designing it in KiCAD was a bit bonkers.

For those interested in the OpenSCAD code, have a butchers at this gist. This project is not the first 3D-printed printing press we’ve covered, checkout the Hi-Bred for an example, and here’s the Open Press Project if you’re still interested.

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NE-2 neon lamp illuminated side-by-side with non-illuminated

The Humble NE-2 Neon Lamp Has A New Trick

October 24, 2021 by Dave Rowntree 45 Comments

Ah, the humble neon lamp. The familiar warm orange glow has graced the decks of many a DIY timepiece, sometimes in a purely indicating duty, and sometimes forming a memory element in place of a more conventional semiconductor device. Capable of many other tricks such as the ability to protect RF circuits from HV transients, its negative resistance operating region after it illuminates gives us usable hysteresis which can used to form a switching element and the way the pair of electrodes are arranged give it the ability to indicate whether a voltage source is AC or DC. Now, due to some recent research by [Johan Carlsson] and the team at Princeton University, the humble NE-2 tube has a new trick up its sleeve: acoustic transduction.

The idea is not new at all, with some previous attempts at using electric discharge in a gas to detect audio, going back to the early part of last century, but those attempts either used atmospheric pressure air or other non-sealed devices that exhibited quite a lot of electrical noise as well as producing noxious gases. Not ideal.

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