A Practical Discrete 386

November 27, 2022 by Jenny List 36 Comments

There are some chips that no matter how much the industry moves away from them still remain, exerting a hold decades after the ranges they once sat alongside have left the building. Such a chip is the 386, not the 80386 microprocessor you were expecting but the LM386, a small 8-pin DIP audio amplifier that’s as old as the Ark. the ‘386 can still be found in places where a small loudspeaker needs to be powered from a battery. SolderSmoke listener [Dave] undertook an interesting exercise with the LM386, reproducing it from discrete components. It’s a handy small discrete audio amplifier if you want one, but it’s also an interesting exercise in understanding analogue circuits even if you don’t work with them every day.

A basic circuit can be found in the LM386 data sheet (PDF), but as is always the case with such things it contains some simplifications. The discrete circuit has a few differences in the biasing arrangements particularly when it comes to replacing a pair of diodes with a transistor, and to make up for not being on the same chip it requires that the biasing transistors must be thermally coupled. Circuit configurations such as this one were once commonplace but have been replaced first by linear ICs such as the LM386 and more recently by IC-based switching amplifiers. It’s thus instructive to take a look at it and gain some understanding. If you’d like to know more, it’s a chip we’ve covered in detail.

A Hacker Walks Into A Trade Show: Electronica 2022

November 22, 2022 by Elliot Williams 24 Comments

Last week, the world’s largest electronics trade fair took place in Munich, so I had to attend. Electronica is so big that it happens only once every two years and fills up 14 airplane hangars. As the fairly generic name suggests, it covers anything and everything having to do with electronics. From the producers of your favorite MLCC capacitors to the firms that deliver them to your doorstep, from suppliers of ASIC test equipment to the little shop that’ll custom wind toroids for you, that’s a pretty wide scope. Walking around, I saw tomorrow’s technology today from the big players, but I also picked up some ideas that would be useful for the home gamer.

When I first walked in, for instance, I ran into the Elantas booth. They’re a company that makes flexible insulation and specialty industrial coatings. But what caught my eye was a thermoformed plastic sheet with circuit traces on it. To manufacture them, they cut out copper foil, glue it to a flat plastic sheet with a glue that has a little give, and then put it all together into a vacuum former. The result is a 3D circuit and organically formed substrate in one shot. Very cool, and none of the tech for doing that is outside of the reach of the determined hacker.

The Cool Stuff

All of the stands, big or small, try to lure you in with some gimmick. The big fish, firms with deep pockets, put up huge signs and open bars, and are staffed by no shortage of salespeople in suits. The little fish, on the other hand, have to resort to showing you the cool stuff that they do, and it’s more often the application engineers sitting there, ready to talk tech. You can guess which I found more interesting.

For instance when I walked up to an obviously DIY popcorn popper that was also showing 5000 FPS footage of kernels in mid-pop, I had to ask. The company in question was a small UK outfit that made custom programmable power supplies and digital acquisition gear that interfaced with it. You could plug in their box to some temperature probes, fire off the high-speed video camera, and control the heating and cooling profile without writing any code. Very sweet. Continue reading “A Hacker Walks Into A Trade Show: Electronica 2022” →

An Open Source Modular Flexure Construction Set

November 22, 2022 by Dave Rowntree 14 Comments

Flexures are one of those innocent-looking mechanisms that one finds inside practically any kind of consumer device. Providing constrained movements with small displacements, complete with controlled tension, they can be rather tricky to design. GrabCAD designer [Vyacheslav Popov] hails from Ukraine, and due to the current situation there, plans to sell a collection of flexure building blocks became difficult. In the end, [Vyacheslav] decided to generously release his work open source, for all to enjoy. This collection is quite extensive, looking like it could solve a huge variety of flexure design problems. (Links to the first three sets: Set00, Set01, Set02 but check the author’s collection page for many others)

It’s not just those super-cheap mechanisms in throw-away gadgets that leverage flexures, it’s much more. The Mars rovers use flexure-based suspension, scientific instruments (interferometers and the like) make use of them for small motions where specific axis constraints are needed, and finally, MEMS accelerometers and gyroscopes are based entirely upon them. We’re not even going to try to name examples of flexures in the natural world. They’re everywhere. And, now we’ve got some more design examples to use, so why not flex your flexure muscles and send one to the 3D printer and have a play?

We see flexures here quite a bit, like this nice demonstration of achievable accuracy. Flexures can make some delicious mechanisms, and neat 3D printable input devices.

Thanks to [Addison] for the tip!

New Part Day: The Smallest Batteries You Have Ever Seen

November 15, 2022 by Jenny List 18 Comments

We’re used to some pretty small batteries in miniaturized electronics, thanks to the manufacture of lithium-polymer pouch cells. But they’re still pretty big, and they’re hardly the most stable power storage solution. The French company ITEN may have an answer for designers of micro-power devices though, in the form of a range of tiny surface-mount solid-state rechargeable lithium batteries. These come in a range of capacities from 0.1 mAh to 0.5 mAh, and in a 3.2 by 2.5 mm package look very much like any other slightly larger SMD chip component.

These devices are most likely to be found in applications such as remote wireless sensors, where they can store the energy from a small solar cell or similar to produce the burst of power required to transmit a packet of data as well as the tiny current required to keep things ticking over. The solid state chemistry should provide a long life and lack of leaks. For now they have some evaluation kits on offer, and unless we missed something, no full data sheet. We’d be particularly interested to learn about their temperature sensitivity when it comes to soldering, as we’ve taken to heart the warnings about soldering to more traditional lithium cells.

Via CNX Software.

Several shelf boxes of various widths are held together by brightly-colored plus-sign-shaped connectors.

3D Printed Shelf Connector

November 8, 2022 by Navarre Bartz 15 Comments

Sometimes, you really need a custom shelf. Whether you have a weird-shaped space, weird-shaped stuff, or just want something different, making your own shelving can make your place more like home. The Plus Shelf by [shurly] aims to make building your own shelves a little easier with a 3D printed bracket.

These connectors aren’t just sitting flush against the wood of the shelf. Each end of the + sign actually sits in a 3/8″ drilled recess, giving a more secure fit. The pieces were printed on an Objet and then dyed in various bright shades to really make the shelving pop. The cubbies were assembled with biscuits after cutting down a sheet of plywood to the appropriate sizes. The 45˚ angles around the edges of the cubbies make the whole shelf system that much nicer.

The final shelf has a little wobble, but that’s probably because dying the shelf connectors made them “bendy.” Because of the instability with the friction fit, the shelf connectors were super glued into the shelf boxes. [shurly] hopes that a metal version of the connectors might be able to eliminate these problems in the future.

This shelving system not your cup of tea? Maybe you’d prefer this Vintage Adjustable Shelving Method or this MP3 Player Shelf.

When Only A TO92 Will Do

November 5, 2022 by Jenny List 17 Comments

As through-hole components are supplanted by their surface-mount equivalents, we’re beginning to see the departure of once-common component form factors. Many such as the metal can transistors became rare years ago, while others still hang on albeit in fewer and fewer places. One of these is the once-ubiquitous TO92 moulded plastic transistor, which we don’t see very much of at all in 2022. [Sam Ettinger] is a fan of the D-shaped plastic blobs, and has gone as far as to recreate them for a new generation to enjoy.

Though a TO92 was a relatively miniature package in its day, it’s still large enough to easily fit a SOT23 or similar SMD packaged device on a small PCB. So the tiny board with just enough space for the part and the three wires was fabricated, ready for encapsulating. Epoxy moulding a TO92 gave very poor results, so instead an SLA print of a T092 shell was made. It fits neatly over the PCB, producing a perfect TO92 package. We’re sure a translucent pink package would have raised a few eyebrows back in the 1960s though.

There will come a time when restorers of old electronics will use and refine this technique to replace dead components. We’ve seen the technique before, after all.

Scripting Coils For PCB Motors

October 25, 2022 by Jenny List 12 Comments

PCB inductors are a subject that has appeared here at Hackaday many times, perhaps most notably in the electromagnetic exploits of [Carl Bugeja]. But there is still much to be learned in the creation of the inductors themselves, and [atomic14] has recently been investigating their automatic creation through scripting.

A simple spiral trace is easy enough to create, but when for example creating a circular array of coils for an electric motor there’s a need for more complex shapes. Drawing a trapezoidal spiral is a surprisingly difficult task for a script, and we’re treated to a variety of algorithms in the path to achieving a usable design.

Having perfected the algorithm, how to bring it into KiCAD? The PCB CAD package has its own Python environment built-in, but it’s not the most flexible in which to develop. The solution is to write a simple JSON interpreter in KiCAD, and leave the spiral generation to an external script that passes a JSON. This also leaves the possibility of using the same code in other PCB packages.

You can watch the whole video below the break. Meanwhile for more PCB electromagnetics, watch [Carl Bugeja]’s 2019 Supercon interview.

Continue reading “Scripting Coils For PCB Motors” →