Liquid Cooling Keeps This Electronic Load’s MOSFETs From Burning

January 7, 2020 by Dan Maloney 21 Comments

Problem: your electronic load works fine, except for the occasional MOSFET bursting into flames. Solution: do what [tbladykas] did, and build a water-cooled electronic load.

One can quibble that perhaps there are other ways to go about preventing your MOSFETs from burning, including changes to the electrical design. But he decided to take a page from [Kerry Wong]’s design book and go big. [Kerry]’s electronic load was air-cooled and capable of sinking 100 amps; [tbladykas] only needed 60 or 70 amps or so. Since he had an all-in-one liquid CPU cooler on hand, it was only natural to use that for cooling.

The IXYS linear MOSFET dangles off the end of the controller PCB, where the TO-247 device is soldered directly to the copper cold plate of the AiO cooler. This might seem sketchy as the solder could melt if things got out of hand, but then again drilling and tapping the cold plate could lead to leakage of the thermal coupling fluid. It hasn’t had any rigorous testing yet – his guesstimate is 300 Watts dissipation at this point – but as his primary endpoint was to stop the MOSFET fires, the exact details aren’t that important.

We’ve seen a fair number of liquid-cooled Raspberry Pis and Arduinos before, but we can’t find an example of a liquid-cooled electronic load. Perhaps [tbladykas] is onto something with this design.

Now Even Your Business Card Can Run Linux

December 24, 2019 by Tom Nardi 50 Comments

It takes a lot of work to get a functional PCB business card that’s thin, cheap, and robust enough to be practical. If you can even blink a few LEDs on the thing and still hand them out with a straight face, you’ve done pretty well for yourself. So you can imagine our surprise when [George Hilliard] wrote in to tell us about his $3 business card computer that boots into a functioning Linux environment. If this were a bit closer to April, we might have figured it was just a joke…

Of course it helps that, as an embedded systems engineer, [George] literally does this kind of thing for a living. Which isn’t to say it was easy, but at least he keeps close enough tabs on the industry to find a suitable ARM solution at a price that makes sense, namely the Allwinner F1C100s. This diminutive chip offers both RAM and CPU in a single package, which greatly simplifies the overall design and construction of the card.

With a root filesystem that weighs in at just 2.4 MB, the environment on the card is minimal to say the least. There’s no networking, limited I/O, and forget about running any heavy software. But it does boot in about six seconds, and [George] managed to pack in a MicroPython interpreter and a copy of the classic Unix dungeon crawler rogue.

Oh yeah, and it also has his resume and some samples of his photography onboard. It is, after all, a business card. All the user has to do is plug it into the USB port of their computer and wait for the virtual serial port to pop up that will let them log into the system running on the card. It also shows up as a USB Mass Storage device for recipients who might not be quite as adept at the command line.

In addition to the high-level documentation for this project, [George] has also prepared a deeper write-up that goes into more technical detail for anyone who might be looking to follow in his footsteps. Thanks to all of the source code that he’s made available, it should be a lot easier for the next person to get their own disposable pocket computer up and running.

We’ve seen all manner of electronic business cards over the years, but never anything quite like this. Which, of course, is quite the point. If you’re ever given a business card that doubles as a computer running a full-fledged operating system on it, you aren’t likely to forget it anytime soon.

Universal Interface Board Comes To The Rescue Of Bigger Projects

December 19, 2019 by Donald Papp 31 Comments

As soon as a project involves other assemblies, parts, or modules, things get more complicated. Devices like fans, cooling units, probes, pumps, or lighting might have simple electrical requirements, but they are rarely identical. As a result, one’s tidy project ends up having to deal with, for example, a pump that is controlled with 5 V active high logic, a sensor that outputs 5 V active low, lights that expect to be switched with 24 VDC, and a fan that needs a relay right now. But that might change in the future.

That’s exactly what led [Lukas Fässler] to design and build the Universal Interface, a board intended to be a kind of universal translator and interface for all such devices. The idea is to have one Universal Interface board for every external device. For each board, a wide variety of input combinations controls a single output. The boards are “hardware programmable” in the sense that jumpers (zero-ohm resistors) are used to spell out in black and white exactly what combinations of inputs result in which output state. In this way, some standardization and clarity of control can be enforced while still being flexible enough to accommodate changes.

Jumper-configured logic table defining with utter clarity which combination of inputs results in an OFF or ON.

Each Universal Interface board has three inputs and an enable line, each with their own indicator LED visually confirming its state. The inputs are 24 V tolerant and each can be configured with a pull-up, a pull-down, and as an active high or active low. There is one output, but it takes several forms: a sturdy relay, a powerful open-collector output, a 5 V logic output, and a 24 V logic output. Configuring which output state corresponds to what combination of inputs is set by jumpers, so the board is very much WYSIWYG.

[Lukas] is currently using four of these devices with his CNC mill project, all in different configurations, and they’re working reliably. Interested? The GitHub repository for the project has all the board design files.

Journey Through The Inner Workings Of A PCB

December 10, 2019 by Kerry Scharfglass 20 Comments

Most electronics we deal with day to day are comprised of circuit boards. No surprise there, right? But how do they work? This might seem like a simple question but we’ve all been in the place where those weird green or black sheets are little slices of magic. [Teddy Tablante] at Branch Eduction put together a lovingly crafted ~~walkthrough~~ flythrough video of how PCB(A)s work that’s definitely worth your time.

[Teddy]’s video focuses on unraveling the mysteries of the PCBA by peeling back the layers of a smartphone. Starting from the full assembly he separates components from circuit board and descends from there, highlighting the manufacturing methods and purpose behind what you see.

What really stands out here is the animation; at each step [Teddy] has modeled the relevant components and rendered them on the PCBA in 3D. Instead of relying solely on hard to understand blurry X-ray images and 2D scans of PCBAs he illustrates their relationships in space, an especially important element in understanding what’s going on underneath the solder mask. Even if you think you know it all we bet there’s a pearl of knowledge to discover; this writer learned that VIA is an acronym!

If you don’t like clicking links you can find the video embedded after the break. Credit to friend of the Hackaday [Mike Harrison] for acting as the best recommendation algorithm and finding this gem.

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Antique Pocket Watch Project Updates Antique Pocket Watch

December 8, 2019 by Kerry Scharfglass 54 Comments

Here at Hackaday we have a bit of a preoccupation with timepieces. Maybe it’s the deeply personal connection to an object you wear on your body, or the need for ultimate reliability. Perhaps it’s just a fascination with the notion of time itself. Whatever the case, we don’t seem to be alone as there is a constant stream of time-related projects coming through our virtual doors. For this article we’ve unearthed the LED Pocketwatch 1.0 by [Dr. Pauline Pounds] from way back in 2009 (ironically via a post about a wristwatch from last year!). Fortunately for us the Internet Archive has saved this heirloom nouveau from the internet dustbin so we can appreciate the craftsmanship involved in [Dr. Pounds]’ work.

Check out the wonderful, spiral routing!

My how far we’ve come; a decade after this project was posted a hacker might choose to 3d print a case for a new wearable, but in 2009 that would have been an entire project by itself! [Dr. Pounds] chose to use the casing from an antique Elgin pocket watch. Even through the mists of a grainy demo video we can imagine how soft the well-worn casing must be from heavy use. This particular unit was chosen because it was a hefty 50mm in diameter, leaving plenty of room inside for a 44mm double sided PCBA with 133 0603 LEDs (60 seconds, 60 minutes, 12 hours), a PIC 16F946, an ERM, and a 110mAh LiPo. But what really sets the LED Pocketwatch 1.0 apart is the user interface.

The ERM is attached directly to the rear of the case in order to best conduct vibration to the outside world. For maximum authenticity it blips on the second, to give a sense that the digital watch is mechanically ticking like the original. The original pocket watch was designed with a closing lid which is released when the stem is pressed. [Dr. Pounds] integrated a button and encoder with the end of the stem (on the PCBA) so the device can be aware of this interaction; on lid open it wakes the device to display the time on the LEDs. The real pièce de résistance is that he also integrated a minuscule rotary encoder, so when the stem is pressed you can rotate it to set the time. It’s all quite elegantly integrated and imminently usable.

At this point we’d love to link to sources, detailed drawings, or CAD files, but unfortunately we haven’t found any. If this has you inspired check out some of the other pocket watches we’ve posted about in the past. If you’re interested in a live demo of the LED Pocketwatch 1.0, check out the original video after the break.

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David Williams Is “FPGA-Curious”

December 6, 2019 by Elliot Williams 17 Comments

If you hadn’t noticed, we had a bit of an FPGA theme running at this year’s Superconference. Why? Because the open-source FPGA toolchain is ripening, and because many of the problems that hackers (and academics) are tackling these days have become complex enough to warrant using them. A case in point: David Williams is a university professor who just wanted to build a quadruped robotics project. Each leg has a complex set of motors, motor drivers, sensors, and other feedback mechanisms. Centralizing all of this data put real strains on the robot’s network, and with so many devices the microcontrollers were running out of GPIOs. This lead him to become, in his words, “FPGA-curious”.

If you’re looking for a gentle introduction to the state of the art in open-source FPGAs, this is your talk. David covers everything, from a bird’s eye view of hardware description languages, through the entire Yosys-based open-source toolchain, and even through to embedding soft-CPUs into the FPGA fabric. And that’s just the first 18 minutes. (Slides for your enjoyment, and you can watch the talk embedded below the break.)
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Creating Easy Glass Circuit Boards At Home

December 1, 2019 by Tom Nardi 41 Comments

This tip for creating glass substrate circuit boards at home might hew a bit closer to arts and crafts than the traditional Hackaday post, but the final results of the method demonstrated by [Heliox] in her recent video are simply too gorgeous to ignore. The video is in French, but between YouTube’s attempted automatic translation and the formidable mental powers of our beloved readers, we don’t think it will be too hard for you to follow along after the break.

The short version is that [Heliox] loads her Silhouette Cameo, a computer-controlled cutting machine generally used for paper and vinyl, with a thin sheet of copper adhered to a backing sheet to give it some mechanical strength. With the cutting pressure of the Cameo dialed back, the circuit is cut out of the copper but not the sheet underneath, and the excess can be carefully peeled away.

Using transfer paper, [Heliox] then lifts the copper traces off the sheet and sticks them down to a cut piece of glass. Once it’s been smoothed out and pushed down, she pulls the transfer paper off and the copper is left behind.

From there, it’s just a matter of soldering on the SMD components. To make it a little safer to handle she wet sands the edges of the glass to round them off, but it’s still glass, so we wouldn’t recommend this construction for anything heavy duty. While it might not be the ideal choice for your next build, it certainly does looks fantastic when mounted in a stand and blinking away like [Heliox] shows off at the end.

Ironically, when compared to some of the other methods of making professional looking PCBs at home that we’ve seen over the years, this one might actually be one of the easiest. Who knew?

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