DIYing Huge BGA Packages

July 13, 2016 by Brian Benchoff 29 Comments

One day [Andy] was cruising around eBay and spotted something interesting. Forty Virtex-E FPGAs for two quid each. These are the big boys of the FPGA world, with 512 user IO pins, almost 200,000 logic gates, packed into a 676-ball BGA package. These are not chips designed for the hobbyist. These chips are not designed for boards with less than six layers. These chips aren’t even designed for boards with 6/6mil tolerances from the usual suspects in China. By any account, a 676-ball package is not like a big keep out sign for hobbyists. You don’t turn down a £2 class in advanced PCB design, though, leading to one of the most impressive ‘I just bought some crap on eBay’ projects we’ve seen.

The project [Andy] had in mind for these chips was a generic dev board, which meant breaking out the IO pins and connecting some SRAM, SDRAM, and Flash memory. The first issue with this project is escape routing all the balls. Xilinx published a handy application note that recommends specific design parameters for the traces of copper under the chip. Unfortunately, this was a six-layer board, and the design rules in the application note were for 5/5mil traces. [Andy]’s board house can’t do six-layer boards, and their design rules are for 6/6mil traces. To solve this problem, [Andy] just didn’t route the inner balls, and hoped the 5mil traces would work out.

With 676 tiny little pads on a PCB, the clocks routed, power supply implemented, too many decoupling caps on the back, differential pairs, static RAM, a few LEDs placed just for fun, [Andy] had to solder this thing up. Since the FPGA was oddly one of the less expensive items on the BOM, he soldered that first, just to see if it would work. It did, which meant it was time to place the RAM, Flash, and dozens of decoupling caps. Everything went relatively smoothly – the only problem was the tiny 0402 decoupling caps on the back of the board. This was, by far, the hardest part of the board to solder. [Andy] only managed to get most of the decoupling caps on with a hot air gun. That was good enough to bring the board up, but he’ll have to figure some other way of soldering those caps for the other 30 or so boards.

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Hack Your Cat’s Brain To Hunt For Food

August 8, 2015 by Rick Osgood 55 Comments

This cat feeder project by [Ben Millam] is fascinating. It all started when he read about a possible explanation for why house cats seem to needlessly explore the same areas around the home. One possibility is that the cat is practicing its mobile hunting skills. The cat is sniffing around, hoping to startle its prey and catch something for dinner. Unfortunately, house cats don’t often get to fulfill this primal desire. [Ben] thought about this problem and came up with a very interesting solution. One that involves hacking an electronic cat feeder, and also hacking his cat’s brain.

First thing’s first. Click past the break to take a look at the demo video and watch [Ben’s] cat hunt for prey. Then watch in amazement as the cat carries its bounty back to the cat feeder to exchange it for some real food.

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Interactive Robot: Project Naughty Ball

May 21, 2015 by Brian Benchoff 14 Comments

A month before the Bay Area Maker Faire, there were ominous predictions the entire faire would be filled with BB-8 droids, the cute astromech ball bot we’ll be seeing more of when The Force Awakens this December. This prediction proved to be premature. There were plenty of R2 units droiding around the faire, but not a single BB-8. Perhaps at the NYC Maker Faire this September.

Regarding ball bots, we did have one friendly rolling companion at Maker Faire this year. It was a project by UC Davis students [Henjiu Kang], [Yi Lu], and [Yunan Song] that rolls around, seeking out whoever is wearing an infrared ankle strap. They team is calling it Project Naughty Ball, but we’re going to call it the first step towards a miniature BB-8 droid.

The design of the Naughty Ball is somewhat ingenious; it’s set up as a two-wheel balancing bot inside a clear plasic sphere. A ton of batteries work well enough as the ballast, stepper motors and machined plastic wheels balance and steer the ball bot, and the structure on the top hemisphere of the ball houses all the interesting electronics.

There is a BeagleBone Black with WiFi adapter, a few motor drivers, an IMU, and a very interesting 3D printed mount that spins the robot’s eyes – infrared cameras that spin around inside the ball and track whoever is wearing that IR transmitting ankle band.

As far as robotics project go, you really can’t do better at Maker Faire than a semi-autonomous ball bot that follows its owner, and the amount of work these guys have put into this project sends it to the next level. You can check out a video description of their project below.

The BB-8 Builds Begin

May 1, 2015 by Brian Benchoff 13 Comments

Yes, the new Star Wars film coming out in December has x-wings, dogfights through the engines of star destroyers, space battles, a dead Jar Jar, and [R2D2]. It will also have the coolest droid yet, [BB-8], the rolling sphere protagonist that will surely be sold as a remote control toy by Christmas 2016.

[James] of XRobots doesn’t want to wait until the [BB-8] toys arrive, so he’s building his own. Right now, it’s just a prototype, but it’s the beginnings of the mechanics and control system of a very, very cool droid.

We’ve seen the first BB-8 droid that was basically putting some magnets on a Sphero robot, but this bot doesn’t exactly have the same functionality of the real-life [BB-8]. The real [BB-8] is actually two parts, a remote control ball-body, and a separate remote-controlled head. [James] is focusing on the head for his prototype, replacing the remote-controlled body with a dummy stand in, a big styrofoam ball.

The head of [James]’ [BB-8] is 3D printed, with some especially clever design features. The electronics are just four DC motors, an Arduino, and some motor drivers. In the future [James] will probably be looking at either steppers or servo motors, but for now his [BB-8] bot can stand up straight and serves as a great platform for testing out control schemes.

All the code and parts are available on Github, with some videos below.

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IcosaLEDron: A 20-Sided Light Up Ball

November 23, 2014 by Brian Benchoff 5 Comments

Tired of balls that are just balls, and not glowing geometric constructions of electronics and wonderment? Get yourself an IcosaLEDron, the latest in Platonic solids loaded up with RGB LEDs.

The folks at Afrit Labs wanted a fun, glowy device that would show off the capabilities of IMUs and MEMS accelerometers. They came up with a ball with a circuit board inside and twenty WS2812B RGB LEDs studded around its circumference

The frame of the ball is simply a set of twenty tessellated triangles that can be folded up during assembly. The outer shell of the ball is again printed in one piece, but fabricated out of transparent NinjaFlex, an extraordinarily odd, squishy, and likely indestructible material.

Inside the IcosaLEDron is a PCB loaded up with an ATMega328p, an accelerometer, a LiPo battery charger, and quite a bit of wiring. Once the ball is assembled and locked down, the squishy outer exterior is installed and turned into a throwable plaything.

If 20 sides and 20 LEDs aren’t enough, how about a an astonishing 386-LED ball that’s animated and knows its orientation? That’s a project from Null Space Labs, and looking at it in person is hypnotic.

via Makezine

Dyson Engineers’ Hacks Traverse Robot Obstacle Course

December 3, 2012 by Mike Szczys 9 Comments

2012-dyson-challenge

These guys are all engineers who are employed by Dyson. They’re holding remote control creations made from Dyson parts. This time around the object of the challenge was to build a bot based on a the Dyson ball and race it through an obstacle course.

This sort of thing is right up our alley, but unlike the last time Dyson engineers shrugged off the daily grind to hack their own hardware, this doesn’t show off nearly enough of the festivities. Sure the pair of videos embedded after the break make a great trailer for the event, but we would love to have seen 90 seconds devoted to each of the entries. Alas, you do get to see most of the winning unit’s obstacle course run which includes a distance route, navigating through rough terrain, and negotiating a high path where falling off the edge is a real threat.

Maybe the engineers themselves will post details about their own builds like the contestants in Sparkfun’s autonomous vehicle contest do.

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17-stage Great Ball Contraption Must Use All The LEGO Pieces

September 19, 2012 by Mike Szczys 31 Comments

Looking at this 17-stage Great Ball Contraption makes us think that [Skiyuky] should be working in industrial automation. The build, which has been assembled from an untold volume of LEGO parts, moves a reservoir of round plastic balls around a circuit. Each module exhibits a different mechanical way of handling the parts. It’s certainly not the first GBC we’ve seen, but the previous offering combined stages from many different makers. [Skiyuky] built this one all himself over the last two years.

The video after the break starts off at the main depository of tiny soccer and basketballs. To help illustrate how long it takes to move around the entire circuit [Skiyuky] adds a red and blue ball which are both easy to spot. From there it’s a Willy Wonky type of ride through all manner of contraptions. We’re struck by accuracy and efficiency with which all of the stages operate.

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