capacitor

124 Articles

Building A Spot Welder From 500 Junk Capacitors

August 20, 2022 by 5 Comments

[Kasyan TV] over on YouTube was given a pile of spare parts in reasonably large quantities, some of which were useful and allocated to specific projects, but given the given the kind of electronics they’re interested in, they couldn’t find a use for a bag of 500 or so low specification 470uF capacitors. These were not low ESR types, nor high capacitance, so unsuitable for power supply use individually. But, what about stacking them all in parallel? (video, embedded below) After a few quick calculations [Kasyan] determined that the total capacitance of all 500 should be around 0.23 Farads with an ESR of around 0.4 to 0.5 mΩ at 16V and packing a theoretical energy total of about 30 joules. That is enough to pack a punch in the right situation.

A PCB was constructed to wire 168 of the little cans in parallel, with hefty wide traces, reinforced with multiple strands of 1.8mm diameter copper wire and a big thick layer of solder over the top. Three such PCBs were wired in parallel with the same copper wire, in order to keep the total resistance as low as possible. Such a thing has a few practical uses, since the super low measured ESR of 0.6mΩ and large capacitance makes it ideal for smoothing power supplies in many applications, but could it be used to make a spot welder? Well, yes and no. When combined with one of the those cheap Chinese ‘spot welder’ controllers, it does indeed produce some welds on a LiPo cell with a thin nickel plated battery strip, but blows straight through it with little penetration. [Kasyan] found that the capacitor bank could be used in parallel with a decent LiPo cell giving a potentially ideal combination — a huge initial punch from the capacitors to blow through the strip and get the weld started and the LiPo following through with a lower (but still huge) current for a little longer to assist with the penetration into the battery terminal, finishing off the weld.

[Kaysan] goes into some measurements of the peak current delivery and the profile thereof, showing that even a pile of pretty mundane parts can, with a little care, be turned into something useful. How does such an assembly compare with a single supercapacitor? We talked about supercaps and LiPo batteries a little while ago, which was an interesting discussion, and in case you’re still interested, graphene-based hybrid supercapacitors are a thing too!

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Condemned Precision Capacitors Find New Home, Refuse To Become Refuse

July 24, 2022 by 12 Comments

Ah, the age old tradition of Dumpster diving! Sometimes we happen to spot something that’s not quite trash, but not quite perfect, either. And when [dzseki], an EEVblog.com forum user, spotted some high-precision capacitors being 86’d at their employer’s e-waste pile, [dzseki] did what any good hacker would do: took them home, tested them, and tore them down to understand and either repair or reuse them. They explain their escapades and teardown in this EEVblog.com forum post.

High-precision capacitors with RF connectors.

If you’re not familiar with capacitors, they are really just two or more plates of metal that are separated by an insulator, and in the case of these very large capacitors, that insulator is mostly air. Aluminum plates are attached with standard bolts, and plastic insulators are used as needed. There’s also discussion of an special alloy called Invar that lends to the thermal stability of the capacitors.

[dzseki] notes that these capacitors were on their way to the round file because they were out of spec, but only by a very, very small amount. They may not be usable for the precision devices they were originally in, but it’s clear that they are still quite useful otherwise. [dzseki]

Of course, Dumpster diving for cool parts is nothing new, and we’ve covered nifty projects such as this frankenmonitor bashed together from two bin finds.

Thank you [David] for the great tip, and don’t forget to leave your own in the Tip Line.

A Variable Capacitor For Not A Lot

March 7, 2022 by 35 Comments

There’s one component which used to be ubiquitous in every experimenter’s junk box, but nowadays unless you happen to be a radio amateur the chances are you may not have seen one in a long time, if ever. We’re talking of course about the air-dielectric variable capacitor, the tuning element for millions of radio receivers back in the day but now long ago replaced by much flimsier polymer-dielectric parts. There’s still a need for variable capacitors though, in particular a high-voltage variant for use in magnetic loop antennas. It’s something that [Ben] had a need for, which he solved with a clever combination of PCB material and 3D printing.

While the variable capacitors of yore invariably used intersecting vanes on a rotor, this one has two large parallel plates that intersect as one is moved over the other with a lead screw. It’s cheap and effective, and best of all, the files to make it can be downloaded from Thingiverse. He claims a 34pF-164pF capacitance range, which, looking at the size of the plates we find to be believable (and which is a useful range for most HF applications). We like this solution, and believe it makes more sense than being scalped for an older example at a radio rally.

This isn’t the first variable capacitor we’ve shown you, though some previous examples have been more conventional.

Mystery Effect Causing LEDs To Glow During Reflow

February 9, 2022 by 34 Comments

Sometimes you notice something small that nevertheless you can’t explain. [Greg Davill] found himself in just such a situation this week when he noticed some green LEDs glowing dimly when reflowing some boards. Naturally, [Greg] set out to investigate.

The green LEDs were wired up as power indicators, and [Greg] suspected that the polymer caps on the board might be generating a small current somehow that was causing the LEDs to light up ever so slightly. A simple test hooked a polymer cap directly up to a multimeter. When warmed with a heat gun, the meter showed a small current “in the 5-10 uA range.”

Going further, [Greg] soldered an LED to the cap and once again heated it up, this time to 100° C. The LED  glowed, continuing to do so for around 60 seconds with heat removed. The mystery also grew deeper – [Greg] noticed that this only happened with “fresh” capacitors. Once they’d been through one heat cycle, the caps would no longer light an LED when warmed up.

It’s a curious case, and has many speculating as to the causative mechanism on Twitter. Explanations from thermoelectric effects to chemical reactions inside the capacitor. If you’ve got the inside scoop on what’s going on here, don’t hesitate to let us know in the comments. Meanwhile, check out some of [Greg]’s best work – a glowing D20 dice featuring a whopping 2400 LEDs.

[Thanks to J Peterson for the tip!]

Build Your Own HV Capacitors

November 11, 2021 by 28 Comments

Finding high voltage capacitors can be tricky. Sure, you can buy these capacitors, but they are often expensive and hard to find exactly what you want. [RachelAnne] needed some low-value variable capacitors that would work at 100 kV. So she made some.

Instead of fabricating the plates directly, these capacitors use laminations from a scrap power transformer. These usually have two types of plates, one of which looks like a letter “E” and the other just like a straight bar. For dielectric, the capacitors use common transparency film.

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A tiny solar-powered robot that even works indoors

Tiny BEAM Robot Smiles Big At The Sun

September 25, 2021 by 14 Comments

What have you been working on during the Great Chip Shortage? [NanoRobotGeek] has been living up to their handle and building BEAM robots that are smaller than any we’ve seen before. What are BEAM robots, you say? Technically it stands for Biology Electronics Aesthetics and Mechanics, but basically the idea is to mimic the movement of bugs, usually with found components, and often with solar power. Here’s a bunch of tutorials to get you started.

The underbelly of what might be the world's smallest BEAM robot.
This was before the large, flat storage capacitor came and covered everything up.

This here is an example of a photovore or photopopper — it moves toward light using simple logic by charging up a capacitor and employing a voltage monitor to decide when there’s enough to run two tiny vibration motors that make up its legs and feet.

[NanoRobotGeek] started in a great place when they found these 25% efficient monocrystalline solar panels. They will even make the bot move indoors! If you want to build one of these, you can’t beat [NanoRobotGeek]’s guide. Be sure to watch it toddle around in the demo video after the break.

We love to see people work at all different scales. Last time we checked in with [NanoRobotGeek], they had built this solar-powered ball-flinging delight.

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Automate The Farm With Acorn

July 1, 2021 by 40 Comments

Farming has been undergoing quite a revolution in the past few years. Since World War 2, most industrial farming has relied on synthetic fertilizer, large machinery, and huge farms with single crops. Now there is a growing number of successful farmers bucking that trend with small farms growing many crops and using natural methods of fertilizing that don’t require as much industry. Of course even with these types of farms, some machinery is still nice to have, so this farmer has been developing an open-source automated farming robot.

The robot is known as Acorn and is the project of [taylor] who farms in California. The platform is powered by an 800 watt solar array feeding a set of supercapacitors for energy storage. It uses mountain bike wheels and tires fitted with electric hub motors which give it four wheel drive and four wheel steering to make it capable even in muddy fields. The farming tools, as well as any computer vision and automation hardware, can be housed under the solar panels. This prototype uses an Nvidia Jetson module to handle the heavy lifting of machine learning and automation, with a Raspberry Pi to handle the basic operation of the robot, and can navigate itself around a farm using highly precise GPS units.

While the robot’s development is currently ongoing, [taylor] hopes to develop a community that will build their own versions and help develop the platform. Farming improvements like this are certainly needed as more and more farmers shift from unsustainable monocultures to more ecologically friendly methods involving multiple simultaneous crops, carbon sequestration, and off-season cover crops. It’s certainly a long row to hoe but plenty of people are already plowing ahead.

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