In-Depth Design Of A Flyback Converter

It is tempting to think of analogue and digital domains as entirely distinct, never to touch each other except like a cold war Checkpoint Charlie, through the medium of an ADC or DAC. In reality there are plenty of analogue effects upon digital circuitry which designers must be aware of, but there is one field in which the analogue and the digital are intricately  meshed. Switch mode power supplies use digital techniques to exploit the analogue properties of components such as inductors and capacitors, and can be astoundingly clever in the way they do this to extract the last fraction of a percent efficiency from their conversion. Thus their design can be something of a Dark Art, so it’s always interesting to have a good read explaining some of the intricacies. [James Wilson] has built a flyback step-up converter to power Nixie tubes, and his write-up follows the whole process in great depth.

This type of converter seems at first glance to be a simple step-up design with a transformer that has a primary and secondary, where in fact it relies on the collapse in magnetic field during the off period of its duty cycle to provide a spike in voltage and thus a step-up beyond that you’d expect from the transformer alone. The write-up takes us through all this starting from a theoretical perspective, and then goes further into the realm of component selection and the effects of component properties on the waveforms involved. If you have ever battled ringing in a switch mode power supply you may recognise some of this.

If this field interests you, then there is probably no better place to send you for a start than Jim Williams’ 1987 app note 25 for Linear Technology: “Switching Regulators for Poets“.

So. You Bought A VNA. Now What?

It’s never too late in life for new experiences, but there’s a new experience I had a few weeks ago that I wasn’t expecting. I probably received my first piece of test equipment – a multimeter –  in the early 1980s, and since then every time I’ve received a new one, whether an oscilloscope, logic analyser, spectrum analyser or signal generator, I’ve been able to figure out how to use it. I have a good idea what it does, and I can figure out whatever its interface may be to make it do what I want it to. My new experience came when I bought a piece of test equipment, and for the first time in my life didn’t have a clue how to use it.

That instrument is a Vector Network Analyser, or VNA, and it’s worth spending a while going through the basics in case anyone else is in the same position. My VNA is not a superlative piece of high-end instrumentation that cost the GDP of a small country, it’s the popular $50 NanoVNA that has a fairly modest frequency range and performance, but is still a functional VNA that can take useful measurements. But I’m a VNA newbie, what does a VNA do? Continue reading “So. You Bought A VNA. Now What?” →

New Part Day: The MSC313E Is A Computer On A Chip

As the onward march of technology delivers ever more powerful semiconductors, it can be instructive to keep an eye on the periphery of the system-on-chip market for niche-application devices which may have an application in our sphere. Just such a chip is the Mstar MSC313E, a SoC designed for use in IP cameras that packs an ARM Cortex A7 and 64 MB of memory, 16 MB of flash, Ethernet, USB, and all the other usual interfaces you’d expect from a microprocessor. It’s available in a QFN package which makes it tantalisingly within the reach of the hardware hacker community, so naturally there is significant interest in unlocking its secrets. A cheap and accessible part with enough power to run a stripped-out GNU/Linux operating system has to be worth a second look!

QFNs are not the easiest packages to hand solder, but if you also find yourself in that position there is at least the prospect of a ready to go development board. The BreadBee is a small PCB that packs in the chip with all its interfaces including Ethernet and USB brought out for experimentation. If you don’t fancy building one, you don’t even have to: it’s soon to be crowdfunded.

One might ask what the point is of Yet Another Linux Capable Microcontroller Platform, given the plethora of Raspberry-pi and competitor boards. The answer to that is simple enough and contains within it the essence of hardware hacking: because it is there. We might never see it again save for in a few outlying projects, or perhaps it might find a niche in our world and become popular, without this early work we’ll never know. While we’re at it, this isn’t the first such SoC that’s emerged; we’ve previously seen an action cam chip give us a hand-solderable Linux single board computer.

Thanks [anonymouse] for the tip.

Right To Repair: Tractor Manufacturers Might Have Met Their Match In Australia

The simmering duel between farmers and agricultural machinery manufacturers over access to the software to unlock the DRM which excludes all but the manufacturer’s agents from performing repairs goes on. How this plays out will have implications for the right to repair for everyone on many more devices than simply tractors. Events so far have centred on the American Midwest, but there is an interesting new front opening up in Australia. The Aussie government consumer watchdog, the ACCC, is looking into the matter, and examining whether the tractor manufacturers are in breach of the country’s Competition and Consumer Act. As ABC News reports there is a dual focus, both of the DRM aspect and on the manufacturer’s harvesting and lock-in of customer farm data.

This is an exciting turn of events for anyone with an interest in the right to repair, because it takes the manufacturers out of the comfort zone of their home legal environment into one that may be less accommodating to their needs. If Aussie farmers force them to open up their platforms then it will benefit all of us, but even if it fails, the fact that the issue has received more publicity in a different part of the world can only be a good thing. There are still tractor manufacturers that do not load their machines with DRM, how long will it be we ask before the easy repairability of their products becomes a selling point?

There are many stories relating to this issue on these pages, our most recent followed the skirmishes in Nebraska.

Thanks Stuart Longland for the tip.

Header image, John Deere under Australian skies: Bahnfrend (CC BY-SA 4.0).

A Broken Inductor As A Bike Chain Sensor

If you have ever broken the ferrite core of an inductor, you’ll probably sympathize with [Oliver Mattos]. He accidentally stood on a ferrite-cored component, breaking it and rendering it useless. But utility is in the eye of the beholder, and instead of throwing it away he’s repurposed it as a chain sensor for his electric bicycle.

The broken inductor was positioned on the rear frame of the machine such that the chain passed through the area where the broken half of its core would once have been. As each link passes through the magnetic field it causes the inductance to change, and from this the speed, direction, and tension of the chain can be read.

Adding a 180 nF capacitor in parallel with the inductor creates a tuned circuit, and measuring the inductance is as straightforward as firing a single pulse at it and measuring the time it takes to go negative. Chain speed can be read by sensing the change in inductance as each link passes, tension by sensing the change in inductance as the chain is closer or further away, and direction by whether the chain is slack or not. It’s an ingenious and simple solution to measuring a bicycle chain, and we like it.

A lot of bicycle measurement systems have passed our way over the years, but it’s fair to say they have been more concerned with displays than sensors.

A Hoverboard As An Assistive Device

Assistive devices for people with disabilities can make an inestimable difference to their lives, but with a combination of technology, complexity, and often one-off builds for individual needs, they can be eye-wateringly expensive. When the recipient is a young person who may grow out of more than one device as they mature, this cost can be prohibitive. Some way to cut down on the expense is called for, and [Phil Malone] has identified the readily available hoverboard as a possible source of motive power for devices that need it.

Aside from being a children’s toy, hoverboards have been well and truly hacked; we’ve featured them in Hacky Racers, and as hacker camp transport. But this is an application which demands controllability and finesse not needed when careering round a dusty field. He’s taken that work and built upon it to produce a firmware that he calls HUGS, designed to make the hoverboard motors precisely controllable. It’s a departure from the norm in hoverboard hacking, but perhaps it can open up new vistas in the use of these versatile components.

There is much our community can do when it comes to improving access to assistive technologies, and we hope that this project can be one of the success stories. We would however caution every reader to avoid falling into the engineer savior trap.

An FPGA And A Few Components Can Make A Radio

There was a time when making a radio receiver involved significant work, much winding of coils, and tricky alignment of circuitry. The advent of Software Defined Radio (SDR) has moved a lot of this into the domain of software, but there is of course another field in which a radio can be created via code. [Alberto Garlassi] has created a radio receiver for the AM and HF bands with a Lattice MachXO2 FPGA and minimal external components.

He describes it as an SDR, which given that it’s created from Verilog, is a term that could be applied to it. But instead of using an SDR topology of ADC and digital signal processing, it implements a surprisingly traditional direct conversion receiver.

It has a quadrature AM demodulator which has a passing similarity to an SDR with I and Q phased signals, but that’s where the similarity ends. Frequency selection is via an oscillator controlled from a serial port, and there is even a PWM amplifier on board that can drive a speaker. The result can be seen in the video below, and as you can hear the direct conversion with quadrature demodulator approach makes for a very effective AM receiver.

If this is a little much but you still fancy a radio with minimal components, you should have a look at the Silicon Labs range of receiver chips.

Continue reading “An FPGA And A Few Components Can Make A Radio” →