Programmable Zener Is Really An IC

November 24, 2024 by Al Williams 24 Comments

[Kevin] doesn’t stock zener diodes anymore. Why? Because for everything he used to use zeners, he now uses TL431 bandgap voltage references. These look like zener diodes but have an extra terminal. That extra terminal allows you to set the threshold to any value you want (within specifications, of course). Have a look at the video below for an introduction to these devices and a practical circuit on a breadboard.

Inside, there’s a voltage reference, an op-amp, and a transistor, so these are tiny 3-terminal ICs. The chip powers itself from the load, so there are no separate power supply pins.

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Large gears on a bridge in Geneva, Switzerland

Gear Up: A 15-Minute Intro On Involute Gears

November 21, 2024 by Heidi Ulrich 10 Comments

If you’re into CNC machining, mechanical tinkering, or just love a good engineering rabbit hole, you’re in for a treat. Substack’s [lcamtuf] has written a quick yet insightful 15-minute introduction to involute gears that’s as informative as it is accessible. You can find the full article here. Compared to Hackaday’s more in-depth exploration in their Mechanisms series over the years, this piece is a beginner-friendly gateway into the fascinating world of gear design.

Involute gears aren’t just pretty spirals. Their unique geometry minimizes friction and vibration, keeps rotational speeds steady, and ensures smooth torque transfer—no snags, no skips. As [lcamtuf] points out, the secret sauce lies in their design, which can’t be eyeballed. By simulating the meshing process between a gear and a rack (think infinite gear), you can create the smooth, rolling movement we take for granted in everything from cars to coffee grinders.

From pressure angles to undercutting woes, [lcamtuf] explores why small design tweaks matter. The pièce de résistance? Profile-shifted gears—a genius hack for stronger teeth in low-tooth-count designs.

Whether you’re into the theory behind gear ratios, or in need of a nifty tool to cut them at home, Hackaday has got you covered. Inspired?

USB-C For Hackers: Reusing Cables

November 21, 2024 by Arya Voronova 82 Comments

Your project needs a cable, and since USB-C cables are omnipresent now, it’s only natural to want to reuse them for your evil schemes. Ever seen USB 3.0 cables used for PCIe link carrying duty? It’s because USB 3.0 cables are built to a reasonably high standard, both sockets and cables are easy to find, and they’re cheap. Well, USB-C cables beat USB 3.0 cables by all possible metrics.

Let’s go through USB-C cable reuse in great detail, and see just what exactly you get when you buy either a gas station C-C USB 2.0 cable, or, the fanciest all-features-supported 240 W Thunderbolt cable that money can buy. Looking for a cable to cut, or something to pass a seriously high-speed link? You’re reading the right article.

The Omnipresent Cables

USB-A to USB-C cables are the least interesting. They’re equivalent to a microUSB to USB-A cable, except there’s a resistor on the USB-C plug, connected from VBUS to one of the CC pins. That’s it. The cable contains four conductors, there’s really not much new. Save these cables for all the devices still built without the 5.1 kΩ resistors.

Now, a USB-C to USB-C cable – let’s say, 60 W max, the default USB-C cable capability. If your cable says anything less than 60 W, say, “2 A” or “15 W”, that’s a lie – it can handle 60 W no problem, all USB-C to C cables can do 60 W. This cable is also cool – for one, it has five conductors; GND, VBUS, D+, D-, and CC. Two of them (GND and VBUS) are guaranteed to be thick enough to carry 3 A without much voltage drop if any, too!

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ESP32 Hosts A USB Keyboard In This Typewriter

November 17, 2024 by Adam Fabio 12 Comments

Did you know the ESP32 can be a USB host? Well it can, and [Volos] uses host mode to build this fun little word processor.

The venerable ESP32 has a well-known USB device mode. Anyone who has programmed one has used it. A bit less known is the microcontroller’s ability to host USB devices. These days, operating as a USB device is relatively simple. But acting as a host is a much more complex task. The ESP32 has a software host that works — but only for Human Interface Devices (HID). Human interface devices generally are keyboards, mice, trackballs, and similar devices that handle data relatively slowly, forming the interface with us simple humans.

[Volos] uses the EspUsbHost Arduino library for this project. The library makes USB host mode simple to use. Another piece of the puzzle is the LCD board [Volos] picked. It has a dual-role USB Type-C port, meaning the hardware to switch roles is baked in. Other boards may require some modifications or special cables to make things work.

The software is the best part of this build. [Volos] implemented a simple word processor. It can save and load files from a microSD card and, of course, edit text — all controlled by a USB keyboard. He had to use a 4-bit palette to save memory. This gives the device a retro charm that reminds us of Don Lancaster’s TV Typewriter. The source for this and all of [Volos] projects can be found on GitHub. Now, all we need is a spell check that can fit in the memory constraints of the ESP32! We have to admit the chip has a lot of potential USB tricks.

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Ethernet From First Principles

November 16, 2024 by Bryan Cockfield 23 Comments

For someone programming in a high-level language like Python, or even for people who interact primarily with their operating system and the software running on it, it can seem like the computer hardware is largely divorced from the work. Yes, the computer has to be physically present to do something like write a Hackaday article, but most of us will not understand the Assembly language, machine code, or transistor layout well enough to build up to what makes a browser run. [Francis Stokes] is a different breed, though, continually probing these mysterious low-level regions of our computerized world where he was recently able to send an Ethernet packet from scratch.

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Ubiquitous Successful Bus: Hacking USB 2 Hubs

November 5, 2024 by Arya Voronova 28 Comments

We’ve been recently looking into USB 2.0 – the ubiquitous point-to-point communications standard. USB 2 is completely different from USB 3, the blue-connector next-generation USB standard. For instance, USB 2 is a full-duplex pseudo-differential bus, and it’s not AC-coupled. This makes USB2 notoriously difficult to galvanically isolate, as opposed to USB 3. On the other hand, USB 2 is a lot easier to incorporate into your projects. And perhaps the best way to do so is to implement a USB hub.

USB 2 hubs are, by now, omnipresent. it doesn’t cost much to add to your board, and you truly have tons of options. The standard option is 4-port hubs – one uplink port to your host, four downlink ports to your devices. If you only have two or three devices, you might be tempted to look for a hub IC with a lower amount of ports, but it’s not worth bothering – just use a 4-port chip, and stock up on them.

What about 7-port chips? You will see those every now and then – but take a close look at the datasheet. Some of them will be two 4-port chips inside a single package, with four of the ports bottlenecked compared to the three other ports – watch out! Desktop 7-port hubs are basically guaranteed to use two 4-port ICs, too, so, again, watch out for bottlenecks. lsusb -t will help you determine the hub’s structure in case you don’t want to crack its case open, thankfully.

Recommendations? I use SL2.1 chips – they’re available in an SO16 package, very unproblematic, to-the-point pinout and easily hand-solderable. CH334 is a close contender, but watch out because there are different variants of this chip that differ by both package and pinout, so if you’re buying a chip with a certain letter, you will want to stick to it. Not just that, be careful – different variants run out at different rates, so if you lock yourself into a CH334 variant, consider stocking up on it. Continue reading “Ubiquitous Successful Bus: Hacking USB 2 Hubs” →

Building A Discrete 14-Bit String DAC

November 3, 2024 by Maya Posch 4 Comments

The discrete 14-bit DAC under test. (Credit: Sine Lab, YouTube)

How easy is it to build your own Digital to Analog Converter (DAC)? Although you can readily purchase a wide variety of DACs these days, building your own can be very instructive, as the [Sine Lab] on YouTube explores in a recent video with the construction of a discrete 14-bit DAC. First there are the different architectures you can pick for a DAC, which range from R-2R (resistor ladder) to delta-sigma versions, each having its own level of complexity and providing different response times, accuracy and other characteristics.

The architecture that the [Sine Lab] picked was a String DAC with interpolator. The String type DAC has the advantage of having inherently monotonic output voltage and better switching-induced glitch performance than the R-2R DAC. At its core it still uses resistors and switches (transistors), with the latter summing up the input digital value. This makes adding more bits to the DAC as easy as adding more of these same resistors and switches, the only question is how many. In the case of a String DAC that’d be 2^N, which implies that you want to use multiple strings, as in the above graphic.

Scaling this up to 16-bit would thus entail 65,536 resistors/switches in the naive approach, or with 2 8-bit strings 513 switches, 512 resistors and 2 buffers. In the actual design in the video both MOSFETs and 74HCT4051 multiplexers were used, which also necessitated creating two buses per string to help with the input decoding. This is the part where things get serious in the video, but the reasoning for each change and addition is explained clearly as the full 6-bit DAC with interpolator is being designed and built.

One big issue with discrete DACs comes when you have to find matching MOSFETs and similar, which is where LSI DACs are generally significantly more precise. Even so, this discrete design came pretty close to a commercial offering, which is pretty impressive.

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