About Circuit Cellar Staff

Circuit Cellar is the only publication that provides intensive, exploratory articles about hardware and software methods for embedded-control systems.

Q&A: Michael Hamilton (Engineering and Entrepreneurship)

Michael Hamilton

Michael Hamilton has been designing microcontroller-based systems for 25 years. Over the past 10 years, he has spearheaded two companies: A&D Technologies, which supplies wireless temperature and humidity controllers, and Point & Track, which provides data-gathering apps and other business intelligence tools. In January, I interviewed Michael about his longtime interest in electronics, his first microcontroller design, his award-winning Renesas Electronics RL78 project, and his praise for 3-D printers.—Nan Price, Associate Editor

NAN: Where are you located?

MICHAEL: Lewisville, TX.

NAN: Give us some background information. Did anything specific spark your interest in engineering?

Timer

MICHAEL: My dad was an instrument repairman for Ashland Refinery in Canton, OH. As part of his training, he brought home his electronics trainer along with the instruction manuals.

When I was 13, I was interested in explosives and I needed an electronic timer for safety reasons. I studied his coursework and figured out how to build a timer using the famous 555 timer chip.

My family had a Christmas tree farm, where I spent many hours working. This led me to the decision that I needed to go to college instead of doing hard labor. I ended up going to Ohio University in Athens, OH, to study chemical engineering.

The reason I chose chemical engineering was, during high school I entered the science fair with a project called the “Distillation of Crude Oil.” This project was very successful as I made it to the state science fair and won lots of prizes.

Tektronix 485 oscilloscope

After I graduated from college, my interest turned back to electrical engineering and I started reading every book I could find on electronics. I remember my first big electronics purchase was a Tektronix 485 oscilloscope.

While working for Ashland Chemical in clean room environments, I realized there was a need for an accurate humidity controller. This led me to design my own temperature and humidity controller and form my first company, A&D Technologies (www.a-dtechnologies.com) in 2003.

NAN: What types of products and services does your company provide?

HTC100

MICHAEL: A&D Technologies supplies wireless temperature and humidity controllers (e.g., HTC100) along with custom control panels. Using the latest technology, the control panels communicate to the outside world using SMS texting via cellular modems and e-mail via Ethernet.

Along with another partner, we created a new company, Point & Track (www.pointandtrack.com), which provides custom data-gathering apps for mobile devices such as iPhone and Android, secure database management, and business intelligence tools used to analyze collected data. The company also provides the ability to export geographic information system (GIS) data directly to customer-owned databases.

NAN: What type of work did you do prior to A&D Technologies and Point & Track?

MICHAEL: I was a project engineer who designed and installed automated equipment such as a fully automatic coiling systems using an ABB robot.

NAN: How long have you been designing microcontroller-based systems?

MICHAEL: Twenty-five years.

NAN: What was the first microcontroller you worked with?

MICHAEL: It was Microchip Technology’s PIC18F84. I designed a laser viscometer that was used to determine the viscosity of plastic resins while working for Ashland Chemical in Los Angeles, CA. I learned how easy it was to provide precise timing and work with digital I/O. It was so much easier than trying to work with individual integrated circuit (IC) chips.

NAN: What is the worst problem you have encountered with embedded microcontrollers?

MICHAEL: By far, the worst issue has to do with electromagnetic interference (EMI) from nearby devices, such as switching of solenoids or transformers. An extensive amount of time is spent designing PCBs so they will be immune to the external environment. Things like ground planes, metal oxide varistor (MOVs), transient voltage suppressors (TVSes), and capacitor/resistor networks are used to minimize the susceptibility of the microcontrollers, but it seems like you can never predict the environment for these kinds of issues. Maybe someone will write an article discussing these issues and how to prevent them.

NAN: Any recent tech purchases?

MICHAEL: I recently purchased a Rigol Technologies DSA-815-TG spectrum analyzer. This device is a must have, right behind the oscilloscope. It enables you to see all the noise/interference present in a PCB design and also test it for EMI issues.

NAN: Do you have any other unique tools on your workbench?

CNC Machine

MakerBot 3-D Printer

MICHAEL: I have a three-axis CNC machine and a MakerBot 3-D printer. I use the CNC machine to cut out enclosures and the 3-D printer to create bezels for LCDs and also to create 3-D prototypes. These machines are extremely useful if you need to make any precise cuts or if you want to create 3-D models of future products.

NAN: What is the fastest way to learn about programming and electronics?

MICHAEL: In the last six months, I have learned the following languages: Arduino, PHP, HTML 5, CSS, MySQL, Android, JavaScript, and jQuery. This was done by watching YouTube videos while exercising at the gym.

NAN: Your project, the Cloud Electrofusion Machine, recently won second prize in the 2012 RL78 Green Energy Challenge. Tell us about your project and your contest-entry process.

Cloud Electrofusion

MICHAEL: The project created an in-expensive and energy-efficient way to weld polyethylene pipe together. Commercial machines cost around $4,000. This machine can be built for less than $200. It utilizes a light dimmer to drop the voltage from 110 to 40 VAC and controls the amount of time that the power is applied to a coil inside an electrofusion fitting. By incorporating a barcode scanner, all the specific properties of the fitting can be easily entered into the microcontroller. Then, after the fusion is complete, all the data is sent to a cloud server via a wireless cellular modem.

The RL78 was very easy to use and program. I really didn’t have many problems with the design.

NAN: Your article “Infrared Radiation Measurement: FFT Double-Beam Infrared Spectrophotometer” (Circuit Cellar 229, 2009) describes a spectrophotometer built around a Microchip Technology dsPIC30F4012 digital signal controller. How does the microcontroller work in the design?

MICHAEL: The project created an instrument to identify chemical substances by using infrared spectroscopy. The dsPIC30F4012 uses a 10-bit ADC to measure the infrared radiation signal that passes through a chemical substance. Then the microcontroller computes the fast Fourier transform (FFT) of the signal. This creates a table of amplitude versus frequency. The amplitude is then scaled to provide a relative transmittance. This information is serially transmitted over USB to a computer for plotting. This USB interface is accomplished using a PIC18F2450.

NAN: Are you currently working on or planning any microprocessor-based projects?

MICHAEL: We are currently working on a cloud fusion logger. This device reads all the data from the welding process in the field and transmits it to a cloud server. Later, the data can be analyzed and reports can be generated. A Raspberry Pi is used as the embedded controller. It is very fast and easy to use since it is based on Linux. We are working on getting the Android operating system loaded so existing code can be used and it will interface well with an Android smartphone, which will be used as the operator interface.

NAN: What do you consider to be the “next big thing” in the embedded design industry?

MICHAEL: One of the issues with embedded controllers is how to maintain the firmware and fix bugs after the devices are installed in the field. Using various wireless technologies, the devices will be automatically updated. Smartphones already use this technology.

SMD Stencil Reflow Soldering Tutorial

Surface-mount SMD reflow soldering doesn’t have to be difficult. All you need is a solder paste stencil, a hot air gun, and a little know-how. No reflow oven necessary!

Dave Jones, of EEVblog.com, covers everything you need to know in the following easy-to-understand SMD stencil reflow soldering tutorial.

The kit is available via Elektor’s partner, Eurocircuits.

The Eurocircuits kit includes all the essential SMT components, circuit boards, and solder stencils.

For SMT info and additional projects, refer to Vincent Himpe’s book, Mastering Surface Mount Technology (Elektor).

CircuitCellar.com is an Elektor International Media website.

New Products: March 2013

Universal PCB Test System

SaeligThe ABI BoardMaster 8000 PLUS is a versatile, self-contained, and easy-to-use PCB test system. The system, which is manufactured by ABI Electronics, comprises a comprehensive set of test instruments, including a built-in PC, for testing and faultfinding on almost any type of PCB.

The BoardMaster 8000 PLUS test system is well suited for applications including telecommunications, transportation, and automotive manufacturing. The system is used by land, air, and naval forces to provide on-site test and repair.

The BoardMaster 8000 PLUS is an integrated package of high-specification instrumentation controlled by sophisticated but easy-to-use software. The hardware is installed in a rugged transportable case that also contains a high-specification Windows PC. The BoardMaster 8000 PLUS is based on a modular, customizable system. Its software can be configured to guide users step-by-step through a test procedure with custom-annotated picture images, instructions, and attached datasheets to provide quick Pass/Fail results.

A typical BoardMaster 8000 PLUS configuration includes two board fault locator modules, with 128 test channels for multiple test methods for fault diagnosis and functional testing of digital ICs, IC connections status, voltage acquisition, and V-I curve testing of components on unpowered boards. The PCB test system also includes an analog IC tester for in-circuit functional testing of analog ICs and discrete components (i.e., no programming or circuit diagrams needed) and a fully configurable V-I tester for detection of faults on unpowered boards.

The BoardMaster 8000 PLUS test system features a multiple instrument station with eight high-specification test and measurement instruments in one compact module (frequency counter, digital storage oscilloscope, function generator, digital floating multimeter, auxiliary PSU, and universal I/O) and a triple-output variable power supply that provides required supply voltages to the unit under test.

Contact Saelig for pricing.

Saelig Co., Inc.
www.saelig.com

ABI Electronics, Ltd.
www.abielectronics.com


Small, Low-Cost Antenna

The compact MicroSplatch embedded antenna utilizes Linx Technologies’s simulation tools and provides performance similar to the standard Splatch antenna while only utilizing one third of the circuit board’s space.

The MicroSplatch is reflow-compatible and capable of withstanding oven temperatures up to 260°C. The antenna is available in 2.4-GHz and 403-, 418-, 433-, 868-, and 916-MHz bands. The antenna is well suited for remote controls, pagers, and compact data transmission devices.

The MicroSplatch antenna can be easily added to your design. You simply need a footprint for the antenna and an associated proximity ground plane.

The affordable MicroSplatch antenna is priced for cost-sensitive applications. Contact Linx for pricing.

Linx Technologies
www.linxtechnologies.com


FEM for Smart Energy/Advanced Metering Infrastructure & ISM Band Applications

The RFFM6403 is a highly-integrated front-end module (FEM) for smart energy/advanced metering infrastructure (AMI) applications. The single-chip RFFM6403 FEM reduces customer design time and speeds customer time-to-market for portable battery-powered equipment, general 433-/470-MHz ISM-band systems, and smart energy/AMI applications operating in the 405-to-475-MHz frequency range.

The feature-rich RFFM6403 integrates a transmit high-power path with a 30.5-dBm PA and Tx harmonic output filtering a transmit bypass through path with Tx harmonic output filtering, and a receive path with a low-noise amplifier (LNA) with bypass mode. The FEM also features a low insertion loss/high-isolation SP3T switch and separate Rx/Tx 50-Ω ports, which simplifies matching and provides input and output signals for both the Tx and Rx paths.

The RFFM6403 is designed for AMI systems operating with high-efficiency requirements and a minimum output power of 30 dBm. In the receive path, the Rx chain provides 16 dB of typical gain with only 5 mA of current and a 1.7-dB noise figure. The FEM’s small form factor (6 mm × 6 mm × 1 mm) minimizes product footprint and reduces the external component count and associated assembly costs.

Contact RF Micro Devices for pricing.

RF Micro Devices, Inc.
www.rfmd.com


Compact Buck Converter for High-Voltage Applications

The LTC3646 is a 40-V input synchronous buck converter capable of delivering up to 1 A of continuous output current from a 3-mm × 4-mm DFN-14 (or thermally enhanced MSOP16) package. The converter operates from a 4-to-40-V input voltage range. It is well suited for automotive and industrial applications requiring high-voltage input capability, high efficiency, and fast switching frequencies for small-solution footprints.

The LTC3646 utilizes controlled on-time architecture capable of stepping inputs as high as 36 V down to 3.3 V. It features switching frequencies in excess of 2 MHz, which keeps switching noise out of critical frequency bands (e.g., AM radio). The converter can deliver fast transient response, even with duty cycles less than 10%. Its internal synchronous rectification delivers efficiencies as high as 95% and requires only 140 µA of quiescent current, which maximizes battery run time.

The LTC3646’s internal switching frequency can be programmed between 200 kHz and 3 MHz or synchronized to an external clock. The combination of high efficiency and only 140 µA of quiescent current offers high efficiency over a broad load range. For noise-sensitive applications, the LTC3646 can be used in forced continuous operation to minimize voltage ripple.

The standard LTC3646 offers a 2-to-30-V output range. The LTC3646-1 offers a 0.6-to-15-V output range. Both versions feature internal soft-start, internal or external compensation, and robust short-circuit protection.

Pricing for the LTC3646EDE/-1 and LTC3646EMSE/-1 starts at $2.85 each in 1,000-unit quantities. Pricing for the extended-temperature (I grade) versions (i.e., the LTC3646IDE/-1 and LTC3646IMSE/-1) starts at $3.14 each in 1,000-unit quantities. Pricing for the high-temperature (H grade) options (i.e., the LTC3646HDE/-1 and LTC3646HMSE/-1) starts at $3.39 each in 1,000-piece quantities.

Linear Technology Corp.
www.linear.com


Four-Quadrant PWM Servo Controller

The ESCON 36/3 EC is a four-quadrant PWM servo controller capable of controlling brushless DC motors with Hall sensors up to approximately 100 W. It features a digital current controller with a large bandwidth for optimal motor current/torque control and drift-free speed, which enables a 0-to-150,000-rpm speed range. The ESCON 36/3 EC features fully configurable digital and analog inputs and outputs and can run in various operating modes including speed controller (closed and open loop) and current controller.

The compact servo controller is controlled by an analog set value. This value can be specified by analog voltage, an external or internal potentiometer, a defined value, or a PWM signal with a variable duty cycle. The controller can enable or disable the power stage depending on the rotation’s direction, or it can use speed ramps for acceleration and deceleration. Hall sensors can be used to regulate the speed.

When the servo controller is connected to a PC via a USB port, it can be easily configured with the “ESCON Studio” graphical user interface (GUI). You can use a variety of functions during startup and while configuring the inputs and outputs, monitoring, data recording, and diagnostics. Assistance is provided by user-friendly software wizards and an automatic procedure for fine tuning the controller is also available.

The ESCON 36/3 EC features circuits that protect against overcurrent, excess temperature, under- and over-voltage, voltage transients, and short circuits in the motor cable. It is equipped with protected digital inputs and outputs and an adjustable current limitation to protect the motor and the load. The analog output voltage can be used to monitor the motor current and the motor shaft’s actual speed. The large range for the input voltage and the operating temperature enables the ESCON 36/3 EC to be used in a variety of drive applications.

Contact maxon for pricing.

maxon motor
www.maxonmotorusa.com


Modules Provide Flexible & Practical Digital I/O Functionality

The USB-7230 and USB-7250 isolated USB digital I/O modules are designed for I/O expansion or portable applications. Each module features a high-speed frequency/event counter, a digital filter, and change of state (COS) detection in a single USB module that supports high-voltage control and monitoring applications’ flexibility and reliability requirements.

The USB-7230 provides 32-channel isolated digital I/O and two-channel frequency/event counters. The USB-7250 provides eight-channel solid-state relay output (four-form C and four-form A), eight-channel isolated digital input, and two-channel frequency/

event counters. The modules feature high-voltage on/off control and monitoring and isolation voltage support up to 2,500 VRMS. They also include integrated frequency/event counting and COS detection via the built-in complex programmable logic device (CPLD). A programmable digital filter removes unexpected glitches from input channels to efficiently monitor the I/O status.

The USB-7230 and USB-7250 modules feature USB power, removable screw-down terminals for simplified connection, and multifunctional stands for fast and easy desktop-, rail-, or wall-mounting. They also include lockable USB cables to secure connectivity. The USB modules simplify device ID settings with a rotary control that identifies the active module in multiple-connection configurations.

The USB-7230 and USB-7250 modules include ADLINK’s U-Test application, which is a free, ready-to-use testing program that delivers out-of-the-box configuration and generates simple functions to get the platform up and running. With U-Test, no programming is required for full data monitoring, logging, and FFT analysis. As with all ADLINK USB digital I/O devices, the USB-7230 and USB-7250 are compatible with National Instruments’s LabVIEWTM, MathWorks’s MATLAB, and Microsoft Visual Studio and Visual Studio.NET.

Contact ADLINK for pricing.

ADLINK Technology, Inc.
www.adlinktech.com


High-Efficiency Stepper Motor Driver IC

The LV8702V is a stepper motor driver integrated circuit (IC) designed to reduce overall power consumption. The motor driver also helps reduce heat generation, vibration, and noise from motors in office automation equipment applications (e.g., copiers, scanners, and multifunction printers).

The stepper motor driver IC uses driver waveform monitoring to detect motor conditions. It reduces power consumption by automatically reducing the current value according to the rotation speed or motor load. The stepper motor has a 9-to-32-V operating voltage range. Protection features include output short protection, a thermal shutdown function, and a step-out detection function. The LV8702V’s advanced functions include stall detection, step-loss, and current drive optimization.

The LV8702V is available in a 5.6-mm × 15-mm SSOP44J package. The motor costs $6 per unit in 2,000-quantity units.

ON Semiconductor
www.onsemi.com


Pressure Sensors for Flow Measurement in Bypass Configuration

The SDP601 and SDP611 sensors are differential pressure sensors specifically calibrated to measure mass flow in a bypass configuration. A bypass configuration is well suited for applications where individually adapted flow channels are necessary or where small differential pressures must be measured with high precision (e.g., HVAC applications, which often involve large flow volume measurement).

Bypass configurations use an orifice or a linear-flow restrictor to generate a differential pressure in a flow channel. This pressure is measured over the orifice or the linear flow component. The difference between the pressures before and after the orifice correlates to the volumetric flow in the channel, depending on the specific characteristics of the flow restriction component. Therefore, the mass flow can be calculated from the measured pressure drop (i.e., differential pressure) over the orifice.

The SDP601 and SDP611 sensors expand Sensirion’s product range of digital differential pressure sensors in the SDP600 series. Along with the other products in this series, these sensors provide a digital I2C output and are fully calibrated and temperature compensated. Like all devices in the SDP600 series, the SDP6x1 sensors are available in two versions. The SDP601 is designed for direct threaded connection to a pressure manifold with O-ring sealing. The SDP611 is designed for tube connection.

Contact Sensirion for pricing.

Sensirion
www.sensirion.com


Single-Board Retrocomputer

The CGCOLORMAX is a single-board retrocomputer that supports add-on Arduino Shields and runs a modern implementation of the BASIC programming language. The board has connections for color video (i.e., video graphics array) output and a PS/2 keyboard input. An SD card socket on the front of the board provides the “floppy drive” for program and data storage.

A stereo music synthesizer, an Arduino Shield interface, and a battery-backed clock are included on The CGCOLORMAX. Hardware interfacing is available as 20 I/O lines on the rear connector and 20 lines on the Arduino Shield connector. This versatile design enables you to easily interface to serial, SPI, I2C, 1-wire, and other circuits.

The CGCOLORMAX also includes a bootloader that enables firmware updating and comes preloaded with BASIC. The board can be tethered to a PC/Mac via a USB cable and programmed via a serial terminal. The USB connection can also provide power to the board.

The CGCOLORMAX can operate as a stand-alone computer by supporting a keyboard and a VGA monitor. The board can be powered by any 8-to-18-V AC or DC power supply. The default BASIC program can be automatically loaded from internal or SD card memory.

Contact CircuitGizmos for pricing.

CircuitGizmos, LLC
www.circuitgizmos.com


Optimized Compiler with Advanced Debug Capabilities

A complete integration with the Eclipse IDE—IAR Systems’s integrated development environment (IDE)—is available for IAR Embedded Workbench for ARM, the high-performance development tool suite. With this integration, IAR offers Eclipse support as an alternative to the IAR Embedded Workbench IDE, which enables its customers to use its build tools and debugger within the Eclipse IDE.

While the proprietary IAR Embedded Workbench IDE is tailor-made for embedded development, intuitive, and easy-to-use, the open-source Eclipse IDE provides flexibility through its extensible framework and its ability to interoperate with a large ecosystem of supplementary tools.

The full integration of the IAR C-SPY debugger replaces the GDB-based debugger that is standard with Eclipse, and enables IAR Systems’ debug technology to be fully exploited from within the Eclipse IDE. C-SPY’s debug functionality includes a timeline window that graphically correlates visualizations of interrupt logs, data logs, power samples, and user-defined events plotted against time. C-SPY supports ARM’s Embedded Trace Macrocell (ETM) and its Embedded Trace Buffer (ETB). Power profiling enables fine-tuning of an application’s power consumption, and the C-SPY Trace window displays detailed trace data.

In addition to all standard Eclipse CDT (C/C++ development tooling) functionality, the integration enables additional features (e.g., project import functionality, stepping on function call level, and complex code and data breakpoints).

Contact IAR for pricing.

IAR Systems
www.iar.com


Advanced Video Annotation Controller

The eVAC2000 is a real-time NTSC/PAL video overlay and video annotation controller for the PCI/104 bus. The controller features a high-resolution graphics accelerator, a digital NTSC/PAL TV decoder, a digital NTSC/PAL TV encoder, and a video overlay controller, which are all contained within a single PC104 card. The eVAC2000 is well suited for applications requiring titles, dynamic grids, or visible watermarking.

The eVAC2000 accepts up to four composite NTSC or PAL analog video inputs, from inputs including video cameras, digital video recording equipment, and video instrumentation. It is capable of mixing video and graphics data or mixing two separate video channels, and can provide output to drive a video graphics array (VGA) monitor, a TV monitor, or a TMDS/LVDS flat-panel display. The eVAC2000 video annotation controller features multi-format, alpha-blending, hardware-enabling graphics/video and video/video to be alpha-blended over gradations from transparent to fully opaque.

The high-throughput, low-latency controller uses a high-performance, 64-bit, 2-D graphics accelerator combined with an 8-Mb frame buffer to deliver rapid video graphics processing. It has a –40°C to 85°C operating temperature and a single 5-V power requirement.

The eVAC2000 is supported by a comprehensive software development kit (SDK) for Windows, Linux and QNX that provides a high level API to configure and control the embedded video hardware (via more than 500 internal registers). The SDK includes support libraries and drivers and a range of example applications (including source code).

Contact Advanced Micro Peripherals for pricing.

Advanced Micro Peripherals, Ltd.
www.ampltd.com

 

Electrical Engineer Crossword (Issue 272)

The answers to Circuit Cellar’s March electronics engineering crossword puzzle are now available.

Across

1.     JACOBSLADDER—Climbing arc [two words]

5.     WOZNIAK—Apple I

8.     SPARKCOIL—Uses a low-voltage DC supply to create high-voltage pulses

10.   JITTER—Creates an imperfect timing signal

11.   ERG—Energy measurement

13.   ACOUSTICOHM—Equivalent to µbar s/cm3 [two words]

15.   BUFFER—Provides electrical isolation

16.   WIFI—Provides movement to smartphones, PCs, and tablets

17.   POSIX—An IEEE operating system compatibility standard

18.   PEAKTOPEAK—Alterations between high and low values

19.   MUTEX—Capable of ensuring atomic access to any shared resource

20.   NAKAMURA—University of California, Santa Barbara professor credited with inventing the blue LED

 

Down

2.     OSCILLATOR—American physicist George W. Pierce (1872–1956); piezoelectric

3.     EIGENTONE—A pitch capable of resonance

4.     FRETSONFIRE—Open-source gameplay for music lovers [three words]

6.     NEGATIVEFEEDBACK—Type of amplifier invented in 1927 by Harold Black [two words]

7.     BAFFLE—Sound wave obstruction

9.     MORSECODE—A pre-texting means of communication [two words]

12.   COMBFILTER—Capable of causing delay [two words]

14.   CHIPSET—Intel created the first family of these

Client Profile: Parallax, Inc.

Parallax P8X32A Propeller chips

Parallax, Inc.
599 Menlo Drive
Rocklin, CA 95765

www.parallaxsemiconductor.com
www.parallax.com

Contact: Emily Kurze
ekurze@parallax.com

Embedded Products/Services: Parallax P8X32A Propeller chip (Part #P8X32A-Q44), Propeller family. The P8X32A Propeller chip is Parallax’s 8-core, 32-bit, 80-MHz microcontroller. P8X32A Quickstart (Part #40000), Quickstart family. The P8X32A Quickstart board, featuring the Propeller chip, is everything you need to begin designing Propeller-based applications.

Product Information: The P8X32A Propeller chip is a modern, easy-to-use and a powerful multicore microcontroller that has the flexibility to propel your design to the next tier of performance and reliability. With eight independent cores at your disposal, developers can easily instantiate any number of custom soft-peripherals from Parallax’s Object Exchange library to enable the chip to fill nearly any role. From generating graphics for a control system’s VGA display to managing fly-by-wire avionics equipment, the 80-MHz Propeller chip makes short work of embedded applications that require real-time execution.

Parallax Propeller QuickStart Board #40000

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