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580 Articles

Hackaday Prize 2023: Circuit Scout Lends A Hand (Or Two) For Troubleshooting

August 11, 2023 by 13 Comments

Troubleshooting a circuit is easy, right? All you need is a couple of hands to hold the probes, another hand to twiddle the knobs, a pair of eyes to look at the schematic, another pair to look at the circuit board, and, for fancy work, X-ray vision to see through the board so you know what pads to probe. It’s child’s play!

In the real world, most of us don’t have all the extra parts needed to do the job right, which is where something like CircuitScout would come in mighty handy. [Fangzheng Liu] and [Thomas Juldo]’s design is a little like a small pick-and-place machine, except that instead of placing components, the dual gantries place probes on whatever test points you need to look at. The stepper-controlled gantries move independently over a fixture to hold the PCB in a known position so that the servo-controlled Z-axes can drive the probes down to the right place on the board.

As cool as the hardware is, the real treat is the software. A web-based GUI parses the PCB’s KiCAD files, allowing you to pick a test point on the schematic and have the machine move a probe to the right spot on the board. The video below shows CircuitScout moving probes from a Saleae logic analyzer around, which lets you both control the test setup and see the results without ever looking away from the screen.

CircuitScout seems like a brilliant idea that has a lot of potential both for ad hoc troubleshooting and for more formal production testing. It’s just exactly what we’re looking for in an entry for the Gearing Up round of the 2023 Hackaday Prize.

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Different Etching Strokes For Different PCBs, Folks

August 8, 2023 by 44 Comments

[Sebastian] probably didn’t think he was wading into controversial waters when he posted on his experimental method for etching PCBs (in German). It’s not like etching with hydrochloric acid and peroxide is anything new, really; it was just something new to him. But is it even possible these days to post something and not find out just how wrong you are about it?

Sadly, no, or at least so it appears from a scan of [Sebastian]’s tweet on the subject (Nitter). There are a bunch of ways to etch copper off boards, including the messy old standby etchant ferric chloride, or even [Sebastian]’s preferred sodium persulfate method. Being out of that etchant, he decided to give the acid-peroxide method a go and was much pleased by the results. The traces were nice and sharp, the total etching time was low, and the etchant seemed pretty gentle when it accidentally got on his skin. Sounds like a win all around.

But Twitter wouldn’t stand for this chemical heresy, with comments suggesting that the etching process would release chlorine gas, or that ferric chloride is far safer and cleaner. It seems to us that most of the naysayers are somewhat overwrought in their criticism, especially since [Sebastian]’s method used very dilute solutions: a 30% hydrochloric acid solution added to water — like you oughta — to bring it down to 8%, and a 12% peroxide solution. Yes, that’s four times more concentrated than the drug store stuff, but it’s not likely to get you put on a terrorism watch list, as some wag suggested — a hair stylist watchlist, perhaps. And 8% HCl is about the same concentration as vinegar; true, HCl dissociates almost completely, which makes it a strong acid compared to acetic acid, but at that dilution it seems unlikely that World War I-levels of chlorine gas will be sweeping across your bench.

As with all things, one must employ caution and common sense. PPE is essential, good chemical hygiene is a must, and safe disposal of spent solutions is critical. But taking someone to task for using what he had on hand to etch a quick PCB seems foolish — we all have our ways, but that doesn’t mean everyone else is wrong if they don’t do the same.

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Nail, Meet KiCad

July 24, 2023 by 25 Comments

You know the old saying. When all you have open is KiCad, everything looks like a PCB. That was certainly true for [Evan], who needed to replace a small part recently and turned to PCBs to get the job done.

The part in question was a sheered apart detent cam from a retractable cord reel. Glue and epoxy might have worked, and [Evan] was worried about how a 3D printed PLA part would have held up. The part is an extruded 2D shape, making PCBs a non-traditional but viable choice. Using the old scanner trick, he traced the outline in KiCad 7 (which adds image references). Then with the five boards stacked up, solid core wire, solder, and a propane torch worth of heat fused it. Ultimately, this machine’s tolerances are generous, so it worked wonderfully.

Was it the “right” tool for the job? Right or wrong, it is hard to argue that in terms of durability and ease per dollar, this doesn’t come out on top. PCB files are on GitHub if you have a 5020TF-4c retractable cord reel that needs a new cam. PCBs have a fun way of adopting different use cases like enclosures, but perhaps the idea of PCBs as a mechanical part could be applied elsewhere.

DIY Laser For Ablating Metal

July 17, 2023 by 51 Comments

For those who wish to go beyond through-hole construction on perfboard for their circuit boards, a printed circuit board is usually the next step up. Allowing for things like surface-mount components, multi-layer boards, and a wider array of parts, they are much more versatile but do have a slight downside in that they are a little bit harder to make. There are lots of methods for producing them at home or makerspace, though, and although we’ve seen plenty of methods for their production like toner transfer, photoresist, and CNC milling, it’s also possible to make them using laser ablation, although you do need a special laser to get this job done.

The problem with cutting copper is that it reflects infra-red, so a higher-wavelength blue green laser is used instead. And because you want to ablate the copper, but not melt the surrounding areas or cut straight through the board, extremely short, high-power pulses are the way to go. Here, the [Munich Fab Lab] is using 9 kW pulses of around 30 microseconds each.  With these specifications the copper is ablated from the surface of the board allowing for fine details in the range of about 20 µm, which is fine enough for just about any circuit board. The design of the laser head itself is worth a look.

Aside from the laser, the rest is standard CNC machine fodder, but with an emphasis on safety that’s appropriate for a tool in a shared workspace, and the whole project is published under an open license and offers an affordable solution for larger-scale PCB production with extremely fine resolution and without the need for any amounts of chemicals for the more common PCB production methods. There is a lot more information available on the project’s webpage and its GitHub page as well.

Of course, there are other methods of producing PCBs by laser if you happen to have a 20 W fiber laser just kicking around.

Reverse Engineering A Classic ThinkPad Battery

July 15, 2023 by 14 Comments

The ThinkPad 701 is an iconic laptop series from the mid-90s and is still highly sought after today because of its famous butterfly keybaord. The laptop itself is tiny even by the standards of the time, so in order to fit a full-size keyboard IBM devised a mechanism where the keyboard splits and slides over itself to hide away as the screen is closed. But, like most 30-year-old laptops, the original batteries for these computers are well past their prime. [polymatt] takes us through all of the steps needed in order to recreate a battery from this era down to the last detail.

He starts by disassembling an old battery with extensive damage from the old, leaky batteries. The first part of the recreation is to measure the battery casing so a new one can be modeled and printed. The control boards for the batteries of these computers were not too sophisticated, so [polymatt] is able to use a logic analyzer with a working unit to duplicate its behavior on an ATtiny microcontroller. With that out of the way, a new PCB is created to host the cloned chip and a new battery pack, made out of 9 NiMH cells is put together.

[polymatt] wanted this build to be as authentic as possible, so he even goes as far as replicating the label on the underside of the battery. With everything put together he has a faithful recreation of this decades-old battery for a famous retro laptop. ThinkPads are popular laptops in general, too, due to their fairly high build quality (at least for their enterprise lineups) and comprehensive driver support especially for Linux and other open-source software projects like coreboot and libreboot.

Thanks to [Roman UA] for the tip!

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Proper Decoupling Capacitors

July 12, 2023 by 37 Comments

If you’ve been building circuits for any length of time, you probably know you need decoupling capacitors to keep your circuits stable. But even though it’s a favorite technique of ours, just scattering some around your PCB and hoping for the best isn’t necessarily the best approach. If you want to dig deeper into the why and how of decoupling, check out [Stephen Fleeman’s] post on the topic.

It is easy to think of capacitors as open circuits at DC and short circuits at high frequencies, shunting noise to ground. But the truth is more complex than that. Stray resistance and inductance mean that your simple decoupling capacitor will have a resonant frequency. This limits the high frequency protection so you often see multiple values used in parallel to respond to different frequencies.

Because the stray resistance and inductance plays a part, you may want to use fatter traces — less resistance — and shorter runs for less inductance. Of course, you can also use power and ground planes on the PCB as a form of decoupling. At the end of the post, [Stephen] talks a little about the importance of digital and analog ground that interact in a specific way.

If you want to do some empirical testing, you can build a test rig and do the work. Or check with [Bil Herd] about PCB inductance.

Importing EAGLE Projects Into KiCad 7, And How To Fix Them

July 1, 2023 by 10 Comments

Migrating a PCB design from one CAD software package to another is no one’s favorite task. It almost never works cleanly. Often there are missing schematic symbols, scrambled PCB footprints, and plenty of other problems. Thankfully [shabaz] shows how to import EAGLE projects into KiCad 7 and fix the most common problems one is likely to encounter in the process. Frankly, the information couldn’t come at a better time.

This is very timely now that EAGLE has gone the way of the dodo. CadSoft EAGLE used to be a big shot when it came to PCB design for small organizations or individual designers, but six years after being purchased by Autodesk they are no more. KiCad 7 is a staggeringly capable open-source software package containing some fantastic features for beginner and advanced designers alike.

Of course, these kinds of tutorials tend to be perishable because software changes over time. So if you’re staring down a migration from EAGLE to KiCad and could use some guidance, there’s no better time than the present. [shabaz]’s video showing the process is embedded below.

Thanks to [problemchild68] for the tip!

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