coil

90 Articles

Fail Of The Week: The SMD Crystal Radio That Wasn’t

December 3, 2024 by 18 Comments

The crystal radio is a time-honored build that sadly doesn’t get much traction anymore. Once a rite of passage for electronics hobbyists, the classic coil-on-an-oatmeal-carton and cat’s whisker design just isn’t that easy to pull off anymore, mainly because the BOM isn’t really something that you can just whistle up from DigiKey or Mouser.

Or is it? To push the crystal radio into the future a bit, [tsbrownie] tried to design a receiver around standard surface-mount inductors, and spoiler alert — it didn’t go so well. His starting point was a design using a hand-wound air-core coil, a germanium diode for a detector, and a variable capacitor that was probably scrapped from an old radio. The coil had three sections, so [tsbrownie] first estimated the inductance of each section and sourced some surface-mount inductors that were as close as possible to their values. This required putting standard value inductors in series and soldering taps into the correct places, but at best the SMD coil was only an approximation of the original air-core coil. Plugging the replacement coil into the crystal radio circuit was unsatisfying, to say the least. Only one AM station was heard, and then only barely. A few tweaks to the SMD coil improved the sensitivity of the receiver a bit, but still only brought in one very local station.

[tsbrownie] chalked up the failure to the lower efficiency of SMD inductors, but we’re not so sure about that. If memory serves, the windings in an SMD inductor are usually wrapped around a core that sits perpendicular to the PCB. If that’s true, then perhaps stacking the inductors rather than connecting them end-to-end would have worked better. We’d try that now if only we had one of those nice old variable caps. Still, hats off to [tsbrownie] for at least giving it a go.

Note: Right after we wrote this, a follow-up video popped up in our feed where [tsbrownie] tried exactly the modification we suggested, and it certainly improves performance, but in a weird way. The video is included below if you want to see the details.

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DIY Loading Coil Shortens Antenna Lengths

November 20, 2023 by 24 Comments

A newly licensed amateur radio operator’s first foray into radios is likely to be a VHF or UHF radio with a manageable antenna designed for the high frequencies in these radio bands. But these radios aren’t meant for communicating more than a double-digit number of kilometers or miles. The radios meant for long-distance communication use antennas that are anything but manageable, as dipole antennas for the lowest commonly used frequencies can often be on the order of 50 meters in length. There are some tricks to getting antenna size down like folding the dipole in all manner of ways, but the real cheat code for reducing antenna size is to build a loading coil instead.

As [VA5MUD] demonstrates, a loading coil is simply an inductor that is placed somewhere along the length of the antenna which makes a shorter antenna behave as a longer antenna. In general, though, the inductor needs to be robust enough to handle the power outputs from the radio. There are plenty of commercial offerings but since an inductor is not much more than a coil of wire, it’s entirely within the realm of possibility to build them on your own. [VA5MUD]’s design uses a piece of PVC with some plastic spacers to wind some thick wire around, and then a customized end cap with screw terminals attached to affix the antenna and feedline to. Of course you’ll need to do a bit of math to figure out exactly how many turns of wire will be best for your specific situation, but beyond that it’s fairly straightforward.

It’s worth noting that the coil doesn’t have to be attached between the feedline and the antenna. It can be placed anywhere along the antenna, with the best performance typically being at the end of the antenna. Of course this is often impractical, so a center-loaded coil is generally used as a compromise. Coils like these are not too hard to wind by hand, but for smaller, lower-current projects it might be good to pick up a machine to help wind the coils instead.

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Arduino-Controlled Coil Winder

October 21, 2023 by 13 Comments

Coil winders are a popular project because doing the deed manually can be an incredibly tedious and time consuming task. After building one such rig, [Pisces Printing] wanted to find even further time savings, and thus designed an improved, faster version.

At it’s heart, it’s a straightforward design, using a linear rail and a leadscrew driven by a stepper motor. Control is via an Arduino Nano, with a few push buttons and a 16 x 2 LCD display for user feedback.

Often, completing a first build will reveal all manner of limitations and drawbacks of a design. In this case, the original winder was improved upon with faster stepper motors to cut the time it took to wind a coil. A redesigned PCB also specified a better buck converter power supply to avoid overheating issues of the initial design. A three-jaw lathe-style chuck was also 3D printed for the build to allow easy fixing of a coil bobbin.

Designing custom tools can be highly satisfying in and of itself, beyond the productivity gains they offer. Video after the break.

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All-Mechanical Coil Winder Is A Scrap-Bin Delight

August 30, 2023 by 10 Comments

If there’s something more tedious than winding coils, we’re not sure what it is — possibly rolling and wrapping coins; that’s really a bother. But luckily, just like there are mechanical ways to count coins, there are tools to make coil production a little less of a chore, but perhaps none that have as much charm as this all-mechanical coil winder.

We’d say that [Ralph (VK3ZZC)]’s amazing invention firmly falls under the “contraption” category, without a hint of the term being used as a pejorative. The rig was based on the MoReCo Coilmaster, a machine that was once commercially available at a fairly steep price, according to [Ralph], and still seems to command a premium even today. Never being able to afford an original, [Ralph] spun up his own from scrap metal and tooling no more sophisticated than a drill press. It’s a riot of brass and steel, with a hand crank that drives the main winding shaft while powering a cam that guides the wire along the long axis of the coil form. Cams can be changed out for different winding patterns, and various chucks adapt to hold different coil forms to the winding shaft.

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Cat Feeder Depends On RFID To Keep The Peace At Dinnertime

February 28, 2023 by 10 Comments

Anyone with more than one cat can tell you that the joy mischief they bring into your life is much more than twice that of a single cat. And if those felines have different dietary needs, you can end up where [Benjamin Krejci] found himself, which resulted in this fancy RFID cat feeder.

For a little backstory, [Ben]’s furry friends [Luna] and [Fermi] have vastly different eating styles, with the former being a grazer and the latter more of a “disordered eater,” to put it politely. [Fermi] tends to eat until she vomits, which is fun, and muscles her pickier sister away from the bowl if there’s anything left in it. [Ben]’s idea was to leverage [Luna]’s existing RFID chip, which he figured would be a breeze. But the vet-inserted chip is designed to be read by a high-power reader directly in contact with the cat’s skin, which made reliably reading the chip a challenge.

Several round of design iteration resulted in the current configuration, with a large antenna coil poised above and behind the food dispenser. [Luna] has no choice but to put the back of her neck and shoulder blades almost directly in contact with the coil, which makes it easier to read the 134.2-kHz chip with a long-distance RFID module. If [Luna]’s chip is found, the lid on the food bowl opens gently and quietly, so as not to spook the mild-mannered cat. The lid stays open as long as [Luna] is in place thanks to some IR sensors, but as soon as she backs out, the lid comes down to keep [Fermi] from gorging herself.

Hats off to [Ben] for working through the problem and coming up with what looks like a fine solution. We suppose he could have tried something easier like weighing the two cats to distinguish between them, but this seems like a cleaner solution to us.

New Possibilities From Fading Lighting Technology

February 25, 2023 by 54 Comments

Like the incandescent bulb before it, the compact fluorescent (CFL) bulb is rapidly fading into obscurity as there are fewer and fewer reasons to use them over their LED successors. But there are plenty of things to do with some of the more interesting circuitry that made these relatively efficient light bulbs work, and [mircemk] is here to show us some of them.

Fluorescent bulbs require a high voltage to work properly, and while this was easy enough for large ceiling installations, it was a while until this hardware could be placed inside a bulb-sized package. When removed, the high voltage driver from the CFL is used in this case to drive a small inductive heating coil circuit, which can then be used to rapidly heat metals and other objects. After some testing, [mircemk] found that the electronics on the CFL circuit board were able to easily handle the electrical load of its new task.

When old technology fades away, there are often a lot of interesting use cases just waiting to be found. [mircemk] reports that he was able to find these light bulbs at an extremely low price due to low demand caused by LEDs, so anyone needing a high voltage driver board for something like a small Tesla coil might want to look at a CFL first.

Internal Heating Element Makes These PCBs Self-Soldering

January 18, 2023 by 53 Comments

Surface mount components have been a game changer for the electronics hobbyist, but doing reflow soldering right requires some way to evenly heat the board. You might need to buy a commercial reflow oven — you can cobble one together from an old toaster oven, after all — but you still need something, because it’s not like a PCB is going to solder itself. Right?

Wrong. At least if you’re [Carl Bugeja], who came up with a clever way to make his PCBs self-soldering. The idea is to use one of the internal layers on a four-layer PCB, which would normally be devoted to a ground plane, as a built-in heating element. Rather than a broad, continuous layer of copper, [Carl] made a long, twisting trace covering the entire area of the PCB. Routing the trace around vias was a bit tricky, but in the end he managed a single trace with a resistance of about 3 ohms.

When connected to a bench power supply, the PCB actually heats up quickly and pretty evenly judging by the IR camera. The quality of the soldering seems very similar to what you’d see from a reflow oven. After soldering, the now-useless heating element is converted into a ground plane for the circuit by breaking off the terminals and soldering on a couple of zero ohm resistors to short the coil to ground.

The whole thing is pretty clever, but there’s more to the story. The circuit [Carl] chose for his first self-soldering board is actually a reflow controller. So once the first board was manually reflowed with a bench supply, it was used to control the reflow process for the rest of the boards in the batch, or any board with a built-in heating element. We expect there will be some limitations on the size of the self-soldering board, though.

We really like this idea, and we’re looking forward to seeing more from [Carl] on this.

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