How To Make A Larger Air-Cored Inductor

March 8, 2023 by Jenny List 20 Comments

Radio amateurs often have a love-hate relationship with home-made inductors, sharing all kinds of tips and tricks as to how the most stable nanohenry inductor can be wound. But there’s another group in the world of electronics with an interest in high-quality inductors, namely the audio enthusiasts. They need good quality inductors with a values in the millihenries, to use in loudspeaker crossover networks. [Homemade Audio] takes us through their manufacturing process for these coils, and the result is a watchable video resulting in some very well-made components.

The adjustable former is a machined aluminium affair of which we’re treated to the full manufacture. It’s likely the same results could be achieved with a 3D printed reel. The free-as-in-beer Coil64 on Windows is used to calculate the dimensions and number of turns, and it’s set up on a jig with a cordless screwdriver doing the winding. The best technique for flat layers of turns is explained, and a coat of varnish is put on each completed layer. We’re guessing this is to stop the coil “singing” at audio frequencies.

With a set of cable ties holding it together the result is a very tidy component. It’s adjusted a few turns to get the right value with an LCR meter, however experience tells us that a tiny percentage either way won’t harm the resulting network too much. If you make your own speakers, the video below the break could be extremely useful.

Need a loudspeaker primer? We have just the article for you.

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A Hackaday.io page screenshot, showing all the numerous CH552 projects from [Stefan].

All The USB You Can Do With A CH552

March 3, 2023 by Arya Voronova 12 Comments

Recently, you might have noticed a flurry of CH552 projects on Hackaday.io – all of them with professionally taken photos of neatly assembled PCBs, typically with a USB connector or two. You might also have noticed that they’re all built by one person, [Stefan “wagiminator” Wagner], who is a prolific hacker – his Hackaday.io page lists over a hundred projects, most of them proudly marked “Completed”. Today, with all these CH552 mentions in the Hackaday.io’s “Newest” category, we’ve decided to take a peek.

The CH552 is an 8-bit MCU with a USB peripheral, with a CH554 sibling that supports USB host, and [Stefan] seriously puts this microcontroller to the test. There’s a nRF24L01+ transceiver turned USB dongle, a rotary encoder peripheral with a 3D-printed case and knob, a mouse wiggler, an interface for our beloved I2C OLED displays, a general-purpose CH55x devboard, and a flurry of AVR programmers – regular AVRISP, an ISP+UPDI programmer, and a UPDI programmer with HV support. Plus, if USB host is your interest, there’s a CH554 USB host development board specifically. Every single one of these is open-source, with PCBs designed in EasyEDA, the firmware already written (!) and available on GitHub, and a lovingly crafted documentation page for each.

[Stefan]’s seriously put the CH552 to the test, and given that all of these projects got firmware, having these projects as examples is a serious incentive for more hackers to try these chips out, especially considering that the CH552 and CH554 go for about 50 cents a piece at websites like LCSC, and mostly in friendly packages. We did cover these two chips back in 2018, together with a programming guide, and we’ve seen things like badges built with its help, but having all these devices to follow is a step up in availability – plus, it’s undeniable that all the widgets built are quite useful by themselves!

A Milliwatt Of DOOM

February 26, 2023 by Jenny List 36 Comments

The seminal 1993 first-person shooter from id Software, DOOM, has become well-known as a test of small computer platforms. We’ve seen it on embedded systems far and wide, but we doubt we’ve ever seen it consume as little power as it does on a specialized neural network processor. The chip in question is a Syntiant NDP200, and it’s designed to be the always-on component listening for the wake word or other trigger in an AI-enabled IoT device.

DOOM running on as little as a milliwatt of power makes for an impressive PR stunt at a trade show, but perhaps more interesting is that the chip isn’t simply running the game, it’s also playing it. As a neural network processor it contains the required smarts to learn how to play the game, and in the simple circular level it’s soon picking off the targets with ease.

We’ve not seen any projects using these chips as yet, which is hardly surprising given their niche marketplace. It is however worth noting that there is a development board for the lower-range sibling chip NDP101, which sells for around $35 USD. Super-low-power AI is within reach.

Rubber Bands And O-Rings Give 3D Prints Some Stretch

February 26, 2023 by Donald Papp 9 Comments

Sometimes it would be helpful if a 3D printed object could stretch & bend. Flexible filament like TPU is one option, but [NagyBig] designed a simple bracelet to ask: how about embedding rubber bands or o-rings into the print itself?

Embedding objects into prints usually involves hardware like fasteners or magnets, but this is the first one (we can think of) that uses rubber bands. Though we have seen rubber bracelets running on printed wheels, and o-rings used to provide tension on a tool holder.

The end result is slightly reminiscent of embedding 3D printed shapes into tulle in order to create fantastic, armor-like flexible creations. But using rubber bands means the result is stretchy and compliant to a degree we haven’t previously seen. Keep it in mind the next time you’re trying to solve a tricky design problem; an embedded o-ring or rubber band might just do the trick.

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Toroid Transformers Explained

February 24, 2023 by Al Williams 34 Comments

HF radios often use toroidal transformers and winding them is a rite of passage for many RF hackers. [David Casler, KE0OG] received a question about how they work and answered it in a recent video that you can see below.

Understanding how a conventional transformer works is reasonably simple, but toroids often seem mysterious because the thing that makes them beneficial is also what makes them confusing. The magnetic field for such a transformer is almost totally inside the “doughnut,” which means there is little interaction with the rest of the circuit, and the transformer can be very efficient.

The toroid itself is made of special material. They are usually formed from powdered iron oxide mixed with other metals such as cobalt, copper, nickel, manganese, and zinc bound with some sort of non-conducting binder like an epoxy. Ferrite cores have relatively low permeability, low saturation flux density, and low Curie temperature. The powder also reduces the generation of eddy currents, a source of loss in transformers. Their biggest advantage is their high electrical resistivity, which helps reduce the generation of eddy currents.

If you haven’t worked through how these common little transformers work, [David]’s talk should help you get a grip on them. These aren’t just for RF. You sometimes see them in power supplies that need to be efficient, too. If you are too lazy to wind your own, there’s always help.

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OpenStructures Is A Modular Building System For The RepRap Age

February 21, 2023 by Navarre Bartz 24 Comments

Modular construction toys like LEGO and Meccano are great for prototyping, but they aren’t so great for large builds. OpenStructures promises to be a modular building system for projects large and small.

Originally conceived in 2007 by [Thomas Lommée], OpenStructures is a modern, more robust reinterpretation of Grid Beam, which was itself a reinterpretation of the earlier Living Structures. By using a common standard (PDF), parts can be reused project after project as they would with LEGO, meaning you can spend more time building and less time cutting or figuring out joints. OpenStructures parts need connection points, part diameters, or part dimensions at multiples of 20 mm to be compatible. To fulfill the spirit of the project, parts should be designed for disassembly, use recyclable materials when possible, and be Open Source.

The system seems like a great starting point for prototyping furniture or other large builds more quickly than building everything on a case-by-case basis. By including diameters for round objects as well as square and rectangular profiles, OpenStructures is a more flexible (and aesthetically pleasing?) option than Grid Beam.

A couple more options for furniture-scale modular construction are these big LEGO bricks or copper pipe.

(via Low Tech Magazine)

Experimenting With 20 Meters Of Outlet Adapters

February 4, 2023 by Chris Lott 100 Comments

You may have seen some of the EEVblog dumpster dive videos, where [Dave Jones] occasionally finds perfectly good equipment that’s been tossed out. But this time, rather than a large screen monitor, desktop computer, or a photocopier, he features a stash of 283 electrical outlet double adapters that he found last year. He decided to perform a test in the parking lot, connecting all 283 adapters in series.

Using a pair of power meters and a 2 kW electric heater as a test load, [Dave] and his son [Sagan] measure the loss through this wild setup. It works out to about about 300 W, or roughly 1 W per adapter. He did a follow-up experiment using a FLIR thermal camera, and confirmed that the power loss is reasonably uniform, and that no single rogue adapter consuming all the lost power. After a back of the envelope calculation, we estimate this chain of adapters is about 20 meters long, making this whole thing entirely pointless but interesting nonetheless. Stick around until the end of the video for a teardown — they’re not as cheaply made as you might think.

[Dave]’s crazy experiment aside, we do wonder why someone had so many adapters to throw away in the first place. What would you have done with 283 adapters — left them in the dumpster or rescued them?

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