Circuit VR: An (Almost) Practical Buck Converter

July 27, 2018 by Al Williams 9 Comments

In the last installment of Circuit VR, we walked around a simplified buck converter. The main simplification was using a constant PWM signal. The result is that the output voltage is a fixed fraction of the input voltage. For a regulator, the pulse width will need to depend on the output voltage so that any changes in the output are self-correcting. So this time, we’ll make a regulator, although we’ll still use a few Spice elements you’d have to replace in a practical design. In particular, we’ll assume you can generate a triangle wave, which is easy enough, and produce a stable 2.5 V reference.

The idea is to take a voltage reference and compare it to the output. We’ll think of the difference between the two as an error voltage, and use a comparator combined with a triangle wave generator to produce a PWM signal that is proportional to the error, and thus works to hold the output voltage constant.

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The Hot And Cold Of Balanced Audio

July 27, 2018 by Dan Maloney 45 Comments

A few summers of my misspent youth found me working at an outdoor concert venue on the local crew. The local crew helps the show’s technicians — don’t call them roadies; they hate that — put up the show. You unpack the trucks, put up the lights, fly the sound system, help run the show, and put it all back in the trucks at the end. It was grueling work, but a lot of fun, and I got to meet people with names like “Mister Dog Vomit.”

One of the things I most remember about the load-in process was running the snakes. The snakes are fat bundles of cables, one for audio and one for lighting, that run from the stage to the consoles out in the house. The bigger the snakes, the bigger the show. It always impressed me that the audio snake, something like 50 yards long, was able to carry all those low-level signals without picking up interference from the AC thrumming through the lighting snake running right alongside it, while my stereo at home would pick up hum from the three-foot long RCA cable between the turntable and the preamp.

I asked one of the audio techs about that during one show, and he held up the end of the snake where all the cables break out into separate connectors. The chunky silver plugs clinked together as he gave his two-word answer before going back to patching in the console: “Balanced audio.”

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How—And Why—To Avoid Tolerance Stacking In Your Technical Drawings

July 25, 2018 by Cameron Coward 49 Comments

If you want to have your part designs fabricated, you’re going to need to provide the manufacturer with a technical drawing. Yes, 3D printers and many modern machine tools rely on toolpaths created from 3D models. But, there is a good chance the manufacturer will be recreating the 3D model in their own system, instead of using the one you provided. Or, they may use traditional manual machining and not touch a 3D model at all. More importantly, the technical drawing gives them vital information on how closely they need to adhere to your dimensions in order for you to accept the parts.

On a technical drawing, the dimension that you want is called the nominal. But, no manufacturing is ever perfect, so you have to allow some wiggle room in what you’ll accept. That wiggle room is called tolerance. Maybe your part could be a little longer than specified and it wouldn’t affect the functionality. Maybe it could be a little shorter—or either. Specifying a tolerance is necessary, because it tells the manufacturer exactly how much wiggle room you’re giving them.

But, tolerances can introduce unforeseen consequences if you’re not careful. The wiggle room provided by tolerances is absolutely necessary, but if you don’t use them properly you can easily end up with unusable parts, even if the manufacturer followed your instructions to the letter. That usually happens because you have multiple tolerances being added together, which is called tolerance stacking.

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Edwin Armstrong’s Battle For FM Radio

July 24, 2018 by Al Williams 50 Comments

Chances are you have at least one radio that can receive FM stations. Even though FM is becoming less used now with Internet and satellite options, it still is more popular than the older AM radio bands. FM was the brainchild of an inventor you may have heard of — Edwin Armstrong — but you probably don’t know the whole story. It could make a sort of radio-themed soap opera. It is a story of innovation, but also a story of personal vanity, corporate greed, stubbornness, marital problems, and even suicide. The only thing missing is a long-lost identical twin sibling to turn it into a full telenovela.

Early Days

Armstrong grew up in New York and because of an illness that gave him a tic and caused him to be homeschooled, he was somewhat of a loner. He threw himself into his interest in electric and mechanical devices. By 1909 he was enrolled in Columbia University where professors noted he was very focused on what interested him but indifferent to other studies. He was also known as someone more interested in practical results than theory. He received an electrical engineering degree in 1913.

Unlike a lot of college graduates, Armstrong didn’t go work for a big firm. Instead, he set up a self-financed independent lab at Columbia. This sounded good because it meant that he would own the patents on anything invented there. But it would turn out to be a two-edged sword.

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Learn To Count In Seximal, A Position Above The Rest

July 20, 2018 by Tucker Ervin 42 Comments

Believe it or not, counting is not special. Quite a few animals have figured it out over the years. Tiny honeybees compare what is less and what is more, and their brains are smaller than a pinky nail. They even understand the concept of zero, which — as anyone who has had to teach a toddler knows — is rather difficult to grasp. No, counting is not special, but how we count is.

I don’t mean to toot our own horn, but humans are remarkable for having created numerous numeral systems, each specialized in their own ways. Ask almost anyone and they will at least have heard of binary. Hackaday readers are deeper into counting systems and most of us have used binary, octal, and hexadecimal, often in conjunction, but those are just the perfectly standard positional systems.

If you want to start getting weird, there’s balanced ternary and negabinary, and we still haven’t even left the positional systems. There’s a whole host of systems out there, each with their own strengths and weaknesses. I happen to think seximal is the best. To see why, we have to explore the different creations that arose throughout the ages. As long as we’ve had sheep, humans have been trying to count them, and the systems that resulted have been quite creative, if inefficient.

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Using Pad Printers To Add Color To Artistic PCBs

July 19, 2018 by Brian Benchoff 11 Comments

I’ve done a few experiments in adding color to printed circuit boards. These experiments used a process known as pad printing, and so far all indications are that pad printing is a viable process for truly multicolor artistic PCBs. For this year’s DEF CON, I’m stepping things up and taking them to their logical conclusion. I’m making true multicolor PCBs with orange and blue ink. This is, I believe, the first time this has ever been done with printed circuit board art, and it is certainly the first time it has ever been documented.

You may be wondering why I need more color on my boards. It’s that time of year again where PCB artisans all around the world are gearing up for ~~badgecon~~ DEF CON. For the last few years, independent badge makers have come together to form a demoscene of hardware creation. This year, add-ons for badges are a thing, and everyone is getting in on the game. Tindie is filled with amazing electronic badges and add-ons that will be found at this year’s DEF CON. There are badges featuring the Cromulon from Rick and Morty, baby Benders from Futurama, pikachus, and glowing tacos.

This is all about badge art, but when it comes to rendering an image in fiberglass and soldermask, everyone is working with a limited palette. Yes, you can get pink and orange soldermask, but I can’t find a place that will do it inexpensively. For any PCB, your choice of colors are only green, red, yellow, blue, purple, black, or white. No, you can’t mix them.

But I want both orange and blue, on the same board, cheaply and easily — here’s how I did it.

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Delta Clipper: A 1990s Reusable Single-Stage To Orbit Spaceship Prototype

July 19, 2018 by Steven Dufresne 50 Comments

With all the talk of SpaceX and Blue Origin sending rockets to orbit and vertically landing part or all of them back on Earth for reuse you’d think that they were the first to try it. Nothing can be further from the truth. Back in the 1990s, a small team backed by McDonnell Douglas and the US government vertically launched and landed versions of a rocket called the Delta Clipper. It didn’t go to orbit but it did perform some extraordinary feats.

Origin Of The Delta Clipper

The Delta Clipper was an unmanned demonstrator launch vehicle flown from 1993 to 1996 for testing vertical takeoff and landing (VTOL) single-stage to orbit (SSTO) technology. For anyone who watched SpaceX testing VTOL with its Grasshopper vehicle in 2012/13, the Delta Clipper’s maneuvers would look very familiar.

Initially, it was funded by the Strategic Defence Initiative Organization (SDIO). Many may remember SDI as “Star Wars”, the proposed defence system against ballistic missiles which had political traction during the 1980s up to the end of the Cold War.

Ultimately, the SDIO wanted a suborbital recoverable rocket capable of carrying a 3,000 lb payload to an altitude of 284 miles (457 km), which is around the altitude of the International Space Station. It also had to return with a soft landing to a precise location and be able to fly again in three to seven days. Part of the goal was to have a means of rapidly replacing military satellites should there be a national emergency.

The plan was to start with an “X” subscale vehicle which would demonstrate vertical takeoff and landing and do so again in three to seven days. A “Y” orbital prototype would follow that. In August 1991, McDonnell-Douglas won the contract for the “X” version and the possible future “Y” one. The following is the story of that vehicle and its amazing feats.

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