How Not To Build An RP2040 Board

October 11, 2023 by Al Williams 26 Comments

We love that these days you can buy ready-made microcontroller boards that are very capable. But sometimes you need to — or just want to — do it yourself. Unfortunately, you really should design everything twice: once to figure out where all the problems are, and the second time to do it better. If you want to create your own board for the RP2040 then you are in luck. [Jeremy] has made the first (and second) iteration or an RP2040 board and shares with us what he would not do again.

In all fairness, he also has a blog post talking about what he did, so you might want to start there. However, we think his most valuable advice was his final word: Don’t fail to get started on your design. The longest journey, after all, begins with the first step.

His other advice is good, too. For example, don’t plug your new board into a computer because an error in the power supply could take the whole computer out. He also warns you not to do like he did and forget to order the $10 solder stencil with the PCBs.

Some of it is just good advice in general. For example — buy more small components than you think you need. There’s nothing worse than needing three resistors, having three resistors, and then watching one of the three fly across the room or stick to your soldering iron and melt into a pool of slag. Buy ten and you’ll save money in the long run.

In the end, the board did work and what he learned might help you if you decide to tackle a similar project yourself. [Jeremy’s] board is fairly large, but if you have an appetite for something smaller, check out the RPDot or the RP2040 Stamp.

Pocket CO2 Sensor Doubles As SMD Proving Ground

October 10, 2023 by Tom Nardi 4 Comments

While for some of us it’s a distant memory, every serious electronics hobbyist must at some point make the leap from working with through-hole components to Surface Mount Devices (SMD). At first glance, the diminutive components can be quite intimidating — how can you possibly work with parts that are literally smaller than a grain of rice? But of course, like anything else, with practice comes proficiency.

It’s at this silicon precipice that [Larry Bank] recently found himself. While better known on these pages for his software exploits, he recently decided to add SMD electronics to his repertoire by designing and assembling a pocket-sized CO2 monitor. While the monitor itself is a neat gadget that would be worthy of these pages on its own, what’s really compelling about this write-up is how it documents the journey from SMD skeptic to convert in a very personal way.

A fine-tipped applicator will get the solder paste where it needs to go.

At first, [Larry] admits to being put off by projects using SMD parts, assuming (not unreasonably) that it would require a significant investment in time and money. But eventually he realized that he could start small and work his way up; for less than $100 USD he was able to pick up both a hot air rework station and a hotplate, which is more than enough to get started with a wide range of SMD components. He experimented with using solder stencils, but even there, ultimately found them to be an unnecessary expense for many projects.

While the bulk of the page details the process of assembling the board, [Larry] does provide some technical details on the device itself. It’s powered by the incredibly cheap CH32V003 microcontroller — they cost him less than twenty cents each for fifty of the things — paired with the ubiquitous 128×64 SSD1306 OLED, TP4057 charge controller, and a SCD40 CO2 sensor.

Whether you want to build your own portable CO2 sensor (which judging from the video below, is quite nice), or you’re just looking for some tips on how to leave those through-hole parts in the past, [Larry] has you covered. We’re particularly eager to see more of his work with the CH32V003, which is quickly becoming a must-have in the modern hardware hacker’s arsenal.

Continue reading “Pocket CO2 Sensor Doubles As SMD Proving Ground” →

An SMD Capacitor Guide

October 5, 2023 by Al Williams 5 Comments

For electronics, your knowledge probably follows a bit of a bell curve over time. When you start out, you know nothing. But you eventually learn a lot. Then you learn enough to be comfortable, and most of us don’t learn as much about new things unless we just happen to need it. Take SMD components. If you are just starting out, you might not know how to find the positive lead of an SMD capacitor. However, if you’ve been doing electronics for a long time, you might not have learned all the nuances of SMD. [Mr SolderFix] has been addressing this with a series of videos covering the basics of different SMD components, and this installment covers capacitors.

If you are dyed-in-the-wool with SMD, you might not get a lot out of the video, but we picked up a few tips, like using a zip tie for applying flux. The video starts with an examination of the different packages and markings. Then it moves on to soldering the components down.

Continue reading “An SMD Capacitor Guide” →

Using 5V Programmable Logic Here In The 2020s

October 4, 2023 by Jenny List 29 Comments

Do you speak GAL? [Peterzieba] does, and has pulled together a collection of documents and tools so that you can too. There’s a dividing line in electronic engineering education, between those who were taught about FPGAs, and those who weren’t. Blurring that line slightly is gate array logic (GAL). These devices were a preceursor to the FPGA, with a much simpler structure, and usually in those days UV-erasable in the same manner as an EPROM. And oddly enough, they, or at least their successor compatible parts, are still available, and as handy DIP devices that talk to 5 volt logic.

The guide goes into detail about the parts, the terminology surrounding them, and the CUPL language which raises a few memories for us. There are several possible workflows, including for those not faint of heart, the possibility of writing a fusemap by hand. We’re impressed by that one.

If these devices interest you, our colleague Bil Herd wrote a two-part guide (part one, and part two) which should answer your questions.

Thanks [Bjonnh] for the tip!

Featured image: “Commodore Amiga 1000 – sub board – Texas Instruments PAL16L8ACN-0126” by Raimond Spekking

Roll Your Own Servo

October 4, 2023 by Al Williams 51 Comments

Usually, when you want a servo motor, you simply buy one already made. But if you need something unusual, you can turn any DC motor into a custom servo you can control just like [Dejan] did. You can watch a video of the process below.

The custom servo can tune the endpoints, the center point, and the sensitivity. It also can be set to handle continuous rotation. A 12-bit encoder tells the microcontroller where the motor is and the output drivers can handle over 3 A of motor current. The microprocessor is a tried-and-true ATmega328. [Dejan] wanted to make the board as small as possible, and we think 40 mm square isn’t bad at all. There is also a 3D printed gearbox and housing. Overall, a very well-done project.

The motor control uses a PID algorithm. Potentiometers set the end range and sensitivity. A push button allows resetting the center position. DIP switches control the mode. The video shows a computer and an RC controller setting the position of the motors.

We have, of course, seen many variations on this idea. We’ve also seen servos rebuilt for better performance.

Continue reading “Roll Your Own Servo” →

Chip Shortage Engineering: Misusing DIP Packages

October 3, 2023 by Tom Nardi 57 Comments

After years of seeing people showing off and trading their badge Simple Add-Ons (SAOs) at Supercon, this year I finally decided to make one myself. Now for a first attempt, it would have been enough to come up with some cool PCB art and stick a few LEDs on it. But naturally I started with a concept that was far more ambitious than necessary, and before long, had convinced myself that the only way to do the thing justice was to have an onboard microcontroller.

My first thought was to go with the venerable ATtiny85, and since I already had a considerable stock of the classic eight-pin DIP MCUs on hand, that’s what I started prototyping with. After I had something working on the breadboard, the plan was to switch over to the SOIC-8 version of the chip which would be far more appropriate for something as small as an SAO.

Unfortunately, that’s where things got tricky. I quickly found that none of the major players actually had the SMD version of the chip in stock. Both DigiKey and Mouser said they didn’t expect to get more in until early 2024, and while Arrow briefly showed around 3,000 on hand, they were all gone by the time I checked back. But that was only half the problem — even if they had them, $1.50 a piece seems a hell of a lot of money for an 8-bit MCU with 8K of flash in 2023.

The whole thing was made all the more frustrating by the pile of DIP8 ATtiny85s sitting on the bench, mocking me. Under normal circumstances, using them in an SAO wouldn’t really be a problem, but eight hand-soldered leads popping through the front artwork would screw up the look I had in mind.

While brooding over the situation my eyes happened to fall on one of the chips I had been fiddling with, it’s legs badly bent from repeated trips through the programmer. Suddenly it occurred to me that maybe there was a way to use the parts I already had…

Continue reading “Chip Shortage Engineering: Misusing DIP Packages” →

Displays We Love Hacking: The HD44780 Family

October 2, 2023 by Arya Voronova 31 Comments

There are too many different kinds of displays – some of them, you already know. I’d like to help you navigate the hobbyist-accessible display world – let’s take a journey together, technology by technology, get a high-level overview of everything you could want to know about it, and learn all the details you never knew you needed to know. In the end, I’d like you to be able to find the best displays for any project you might have in mind, whatever it could be.

There’s a HD44780 clone IC under this epoxy blob! CC0 1.0

Today, let’s take a look at a well-known LCD technology – the HD44780 displays, a type of display that we hobbyists have been working with since the 1980s. Its name comes from the HD44780 driver chip – a character display driver IC that connects to a raw display panel and provides an easy interface.

HD44780 displays are not known for power efficiency, cutting-edge technology, ultimate flexibility, or small size, for that matter. However, they’re tried and true, easy to drive, require little to no computing power on your MCU, and you will be able to buy them for the foreseeable future. They’re not about to get taken off the market, and they deserve a certain kind of place in our parts boxes, too.

If you work with HD44780 displays for a project or two, you might acquire a new useless superpower – noticing just how many HD44780 displays are still in use in all sorts of user-facing devices, public or private. Going out and about in your day-to-day life, you can encounter a familiar 16 x 2 grid of characters in cash registers, public transport ticket machines, home security panels, industrial and factory equipment, public coffee machines, and other microcontroller-assisted places of all kinds! Continue reading “Displays We Love Hacking: The HD44780 Family” →