CC280: Analog Communications and Calibration

Are you an analog aficionado? You’re in luck. Two articles, in particular, focus on the November issue’s analog techniques theme. (Look for the issue shortly after mid-October, when it will be available on our website.)

Block Diagram

Data from the base adapter is sent by level shifting the RS-232 or CMOS serial data between 9 and 12 V. A voltage comparator at the remote adapter slices the signal to generate a 0-to-5-V logic signal. The voltage on the signal wire never goes low enough for the 5-V regulator to go out of regulation.

These adapters use a combination of tricks. A single pair of wires carries full-duplex serial data and a small amount of power to a remote device for tasks (e.g., continuous remote data collection and control). The digital signals can be simple on/off signals or more complex signals (e.g., RS-232).

These adapters use a combination of tricks. A single pair of wires carries full-duplex serial data and a small amount of power to a remote device for tasks (e.g., continuous remote data collection and control). The digital signals can be simple on/off signals or more complex signals (e.g., RS-232).

Dick Cappels, a consultant who tinkers with analog and mixed-signal projects, presents a design using a pair of cable adapters and simple analog circuits to enable full-duplex, bidirectional communications and power over more than 100 m of paired wires. Why bother when Power Over Ethernet  (PoE), Bluetooth, and Wi-Fi approaches are available?

“In some applications, using Ethernet is a disadvantage because of the higher costs and greater interface complexity,” Cappels says. “You can use a microcontroller that costs less than a dollar and a few analog parts described in this article to perform remote data gathering and control.”

The base unit including the 5-to-15-V power supply is simple for its functionality. The two eight-pin DIP ICs are a voltage comparator and the switching regulator.

The base unit including the 5-to-15-V power supply is simple for its functionality. The two eight-pin DIP ICs are a voltage comparator and the switching regulator.

Cappels’s need for data channels to monitor his inground water tank inspired his design. Because his local municipality did not always keep the tank filled, he needed to know when it was dry so his pumps wouldn’t run without water and possibly become damaged.
“Besides the mundane application of monitoring a water tank, the system would be excellent for other communication uses,” Cappels says, including computer connection to a home weather station and intrusion-detection systems. Bit rates up to 250 kHz also enable the system to be used in two-way voice communication such as intercoms, he says.

Retired engineer David Cass Tyler became interested in writing his series about calibration while working on a consulting project. “I came to realize that some people don’t really know how to approach the issue of taking an analog-to-digital value to actual engineering units, nor how to correct calibration factors after the fact,” Tyler says

In Part 1 of his article series, Tyler notes: “Digital inputs and digital outputs are pretty simple. They are either on or off. However, for ADCs and DACs to be accurate, they must first be calibrated. This article addresses linear ADCs and DACs.” Part 2, appearing in the December issue, will discuss using polynomial curve fitting to convert nonlinear data to real-world engineering values.

In addition to its analog-themed articles, the November issue includes topics ranging from a DIY solar array tracker’s software to power-capped computer systems.

Editor’s Note: Learn more about Circuit Cellar contributors Dick Cappels and David Cass Tyler by reading their posts about their workspaces and favorite DIY tools.

New Products: May 2013

iC-Haus

iC-Haus iC-TW8

The iC-TW8 is a high-resolution signal processor designed to evaluate sine/cosine sensors. Its automatic functions help minimize angular errors and jitters. The processor can be used for initial, push-button calibration and to permanently adapt signal-path parameters during operation. The angular position is calculated at a programmable resolution of up to 65,536 increments per input cycle and output as an indexed incremental signal. A 32-bit word, which includes the counted cycles, is available through the SPI.

As an application-specific DSP, the iC-TW8 has two ADCs that simultaneously sample at a 250-ksps rate, fast CORDIC algorithms, special signal filters, and an analog front end with differential programmable gate amplifier (PGA) inputs that accepts typical magnetic sensor signals from 20 mVPP and up. Signal frequencies of up to 125 kHz enable high rotary and linear speeds for position measuring devices and are processed at a 24-µs constant latency period.

The device’s 12-bit measurement accuracy works with one button press. Measuring tools are not required. The iC-TW8 independently acquires information about the signal corrections needed for offset, amplitude, and phase errors and stores them in an external EEPROM.

The iC-TW8 has two configuration modes. Preset functions and interpolation factors can be retrieved through pins and the device can be calibrated with a button push. No programming is required for initial operation.

The device’s functions—including an AB output divider for fractional interpolation, an advanced signal filter to reduce jitter, a table to compensate for signal distortion, and configurable monitors for errors and signal quality—can be accessed when the serial interfaces are used. Typical applications include magnetic linear displacement measuring systems, optical linear scales, programmable magnetic/optical incremental encoders, high-resolution absolute/incremental angle sensors with on-axis, Hall scanning, and the general evaluation of sine/cosine signals (e.g., PC measuring cards for 1 VPP and 11 µAPP).

The iC-TW8 operates on a 3.1-to-5.5-V single-ended supply within a –40°C-to-125°C extended operating temperature range. It comes in a 48-pin QFN package that requires 7 mm × 7 mm of board space. A ready-to-operate demo board is  available for evaluation. An optional PC operating program, in other words, a GUI, can be connected with a USB adapter.

The iC-TW8 costs $7.69 in 1,000-unit quantities.

iC-Haus GmbH

www.ichaus.com


ULTRASOUND RECEIVERS

Analog Devices AD9675

The AD9675 and the AD9674 are the latest additions to Analog Devices’s octal ultrasound receiver portfolio. The devices and are pin compatible with the AD9670/AD9671.

The AD9675 is an eight-channel ultrasound analog front end (AFE) with an on-chip radio frequency (RF) decimator and Analog Devices’s JESD204B serial interface. It is designed for mid- to high-end portable and cart-based medical and industrial ultrasound systems. The device integrates eight channels of a low-noise amplifier, a variable-gain amplifier, an anti-aliasing filter, and a 14-bit ADC with a 125-MSPS sample rate and a 75-dB signal-to-noise ratio (SNR) performance for enhanced ultrasound image quality. The on-chip RF decimator enables the ADC to be oversampled, providing increased SNR for improved image quality while maintaining lower data I/O rates. The 5-Gbps JESD204B serial interface reduces ultrasound system I/O data routing.

The AD9674 offers similar functionality, but includes a standard low-voltage differential signaling (LVDS) interface. Both devices are available in a 144-ball, 10-mm × 10-mm ball grid array (BGA) package.

The AD9674 and the AD9675 cost $62 and $68, respectively.

Analog Devices, Inc.

www.analog.com


LOW-VOLTAGE DIGITAL OUTPUT HALL-EFFECT SENSORS

Melexis MLX92212

Melexis MLX92212

MLX92212 digital output Hall-effect sensors are AEC-Q100-qualified devices that deliver robust, automotive-level performance. The MLX92212LSE-AAA low-hysteresis bipolar latch and the MLX92212LSE-ABA high-hysteresis unipolar switch are optimized for 2.5-to-5.5-V operation. They pair well with many low-power microcontrollers in embedded systems. The sensor and specified microcontroller can share the same power rail. The sensors’ open-drain outputs enable simple connectivity with CMOS/TTL. They exhibit minimal magnetic switch point drift over temperature (up to 150°C) or lifetime and can withstand 8 kV electrostatic discharge.

The MLX92212LSE-AAA is designed for use with multipole ring magnets or alternating magnetic fields. It is well suited for brushless DC electric motor commutation, speed sensing, and magnetic encoder applications. Typical automotive uses include anti-trap/anti-pinch window lift controls, automatic door/hatch systems, and automatic power seat positioning. The MLX92212LSE-ABA enables the use of generic/weak magnets or larger air gaps. It can be used in simple magnetic proximity sensing and interlocks in covers/hatches or ferrous-vane interrupt sensors for precise position and timing applications.

Both MLX92212 devices utilize chopper-stabilized amplifiers with switched capacitors. The CMOS technology makes this technique possible and contributes to the sensors’ low current consumption and small chip size.

The MLX92212 sensors cost $0.35 each in 5,000-unit quantities and $0.30 in 10,000-unit quantities.

Melexis Microelectronic Integrated Systems

www.melexis.com


POWERFUL SPI ADAPTERS

Byte SPI Storm

Byte SPI Storm

The SPI Storm 50 and the SPI Storm 10 are the latest versions of Byte Paradigm’s SPI Storm serial protocol host adapter. The adapters support serial peripheral interface (SPI), Quad-SPI, and custom serial protocols in the same USB device.

The SPI Storm 50 and the SPI Storm 10 support serial protocols and master up to 50 and 10 MHz, respectively. The SPI Storm 10 features an 8-MB memory, while the higher-end devices are equipped with a 32-MB memory.

The SPI Storm adapters enable system engineers to access, communicate, and program their digital board and digital ICs, such as field-programmable gate array (FPGA), flash memories, application-specific integrated circuit (ASIC), and

system-on-a-chip (SoC). The SPI Storm 10 is well suited for engineering schools and universities because it is a flexible, all-around access device for hands-on digital electronics. The 50- and 100-MHz versions can be used in mid- and high-end testing and debugging for telecommunications, medical electronics, and digital imaging industries.

The SPI Storm 50 and the SPI Storm 10 cost $530 and $400, respectively.

Byte Paradigm

www.byteparadigm.com


ANALOG-BASED POWER MANAGEMENT CONTROLLER WITH INTEGRATED MCU

Microchip MCP19111

Microchip MCP19111

The MCP19111 digitally enhanced power analog controller is a new hybrid, digital and analog power-management device. In combination with the expanded MCP87xxx family of low-figure-of-merit (FOM) MOSFETs, it supports configurable, high-efficiency DC/DC power-conversion designs for many consumer and industrial applications.

The MCP19111 controller, which operates at 4.5 to 32 V, integrates an analog-based PWM controller with a fully functional flash-based microcontroller. This integration offers the flexibility of a digital solution with the speed, performance, and resolution of an analog-based controller.

The MCP19111 devices have integrated MOSFET drivers configured for synchronous, step-down applications. The MCP87018, MCP87030, MCP87090, and MCP87130 are 25-V-rated, 1.8-, 3-, 9-, and 13-mΩ logic-level MOSFETs that are specifically optimized for switched-mode-power-supply (SMPS) applications.

The MCP19111 evaluation board includes Microchip’s high-speed MOSFETs. This evaluation board includes standard firmware, which is user-configurable through an MPLAB X IDE graphical user interface (GUI) plug-in. The combined evaluation board, GUI, and firmware enable power-supply designers to configure and evaluate the MCP19111’s performance for their target applications.

The MCP19111 controllers cost $2.81 each and the MCP87018/030/090/130 MOSFETs cost $0.28 each, all in 5,000-unit quantities.

Microchip Technology, Inc.

www.microchip.com


ELASTOMER SOCKET FOR HIGH-SPEED QFP ICs

Ironwood SG-QFE-7011

Ironwood SG-QFE-7011

The SG-QFE-7011 is a high-performance QFP socket for 0.4-mm pitch, 128-pin QFPs. The socket is designed for a

1.6-mm × 14-mm × 14-mm package size with a 16-mm × 16-mm lead tip to tip. It operates at bandwidths up to 10 GHz with less than 1 dB of insertion loss and has a typical 20 mΩ per I/O contact resistance. The socket connects all pins with 10-GHz bandwidth on all connections. The small-footprint socket is mounted with supplied hardware on the target PCB. No soldering is required. The small footprint enables inductors, resistors, and decoupling capacitors to be placed close to the device for impedance tuning.

The SG-QFE-7011’s swivel lid has a compression screw that enables ICs to be quickly changed out. The socket features a floating compression plate to force down the QFP leads on to elastomer. A hard-stop feature is built into the compression mechanism.

The sockets are constructed with high-performance, low-inductance gold-plated embedded wire on elastomer as interconnect material between a device and a PCB. They feature a –35°C-to-100°C temperature range, a 0.15-nH pin self inductance, a 0.025-nH mutual inductance, a 0.01-pF capacitance to ground, and a 2-A per pin current capacity.

The SG-QFE-7011 costs $474.

Ironwood Electronics

www.ironwoodelectronics.com

Retro Electronics (“Retronics”): Analog, Test, & Micrcontroller Tech

Pop quiz: What was the first microcontroller to leave the Earth? Find out the answer in Jan Buiting’s new “Retronics” webinar. Check out the video below.

The Tektronix 546B

If you read Circuit Cellar and Elektor magazines, you likely have as much passion for old-school electronics as you do for he new, cutting-edge technology you find at events such as the Embedded Systems Conference. Elektor editor Jan Buiting is well-known for his love of both new and old technology, and in his Retronics webinar series he presents some of his favorite old-school technologies.

In the video below, Jan explains how and where he found some of his retronics equipment. He also details how he fixed some of the systems and what he does with them. Examples include:

  • A Heathkit TC-2P Tube Checker that Jan found at lawn sale
  • Old audio equipment
  • A satellite TV receiver
  • An “Elektorscope” from 1977
  • 1980s-era test equipment
  • And more!

CircuitCellar.com is an Elektor International Media publication.

Prevent Embedded Design Errors (CC 25th Anniversary Preview)

Attention, electrical engineers and programmers! Our upcoming 25th Anniversary Issue (available in early 2013) isn’t solely a look back at the history of this publication. Sure, we cover a bit of history. But the issue also features design tips, projects, interviews, and essays on topics ranging from user interface (UI) tips for designers to the future of small RAM devices, FPGAs, and 8-bit chips.

Circuit Cellar’s 25th Anniversary issue … coming in early 2013

Circuit Cellar columnist Robert Lacoste is one of the engineers whose essay will focus on present-day design tips. He explains that electrical engineering projects such as mixed-signal designs can be tedious, tricky, and exhausting. In his essay, Lacoste details 25 errors that once made will surely complicate (at best) or ruin (at worst) an embedded design project. Below are some examples and tips.

Thinking about bringing an electronics design to market? Lacoste highlights a common error many designers make.

Error 3: Not Anticipating Regulatory Constraints

Another common error is forgetting to plan for regulatory requirements from day one. Unless you’re working on a prototype that won’t ever leave your lab, there is a high probability that you will need to comply with some regulations. FCC and CE are the most common, but you’ll also find local regulations as well as product-class requirements for a broad range of products, from toys to safety devices to motor-based machines. (Refer to my article, “CE Marking in a Nutshell,” in Circuit Cellar 257 for more information.)

Let’s say you design a wireless gizmo with the U.S. market and later find that your customers want to use it in Europe. This means you lose years of work, as well as profits, because you overlooked your customers’ needs and the regulations in place in different locals.

When designing a wireless gizmo that will be used outside the U.S., having adequate information from the start will help you make good decisions. An example would be selecting a worldwide-enabled band like the ubiquitous 2.4 GHz. Similarly, don’t forget that EMC/ESD regulations require that nearly all inputs and outputs should be protected against surge transients. If you forget this, your beautiful, expensive prototype may not survive its first day at the test lab.

Watch out for errors

Here’s another common error that could derail a project. Lacoste writes:

Error 10: You Order Only One Set of Parts Before PCB Design

I love this one because I’ve done it plenty of times even though I knew the risk.

Let’s say you design your schematic, route your PCB, manufacture or order the PCB, and then order the parts to populate it. But soon thereafter you discover one of the following situations: You find that some of the required parts aren’t available. (Perhaps no distributor has them. Or maybe they’re available but you must make a minimum order of 10,000 parts and wait six months.) You learn the parts are tagged as obsolete by its manufacturer, which may not be known in advance especially if you are a small customer.

If you are serious about efficiency, you won’t have this problem because you’ll order the required parts for your prototypes in advance. But even then you might have the same issue when you need to order components for the first production batch. This one is tricky to solve, but only two solutions work. Either use only very common parts that are widely available from several sources or early on buy enough parts for a couple of years of production. Unfortunately, the latter is the only reasonable option for certain components like LCDs.

Ok, how about one more? You’ll have to check out the Anniversary Issue for the list of the other 22 errors and tips. Lacoste writes:

Error 12: You Forget About Crosstalk Between Digital and Analog Signals

Full analog designs are rare, so you have probably some noisy digital signals around your sensor input or other low-noise analog lines. Of course, you know that you must separate them as much as possible, but you can be sure that you will forget it more than once.

Let’s consider a real-world example. Some years ago, my company designed a high-tech Hi-Fi audio device. It included an on-board I2C bus linking a remote user interface. Do you know what happened? Of course, we got some audible glitches on the loudspeaker every time there was an I2C transfer. We redesigned the PCB—moving tracks and adding plenty of grounded copper pour and vias between sensitive lines and the problem was resolved. Of course we lost some weeks in between. We knew the risk, but underestimated it because nothing is as sensitive as a pair of ears. Check twice and always put guard-grounded planes between sensitive tracks and noisy ones.

Circuit Cellar’s Circuit Cellar 25th Anniversary Issue will be available in early 2013. Stay tuned for more updates on the issue’s content.

 

 

 

 

CC268: The History of Embedded Tech

At the end of September 2012, an enthusiastic crew of electrical engineers and journalists (and significant others) traveled to Portsmouth, NH, from locations as far apart as San Luis Obispo, CA,  and Paris, France, to celebrate Circuit Cellar’s 25th anniversary. Attendees included Don Akkermans (Director, Elektor International Media), Steve Ciarcia (Founder, Circuit Cellar), the current magazine staff, and several well-known engineers, editors, and columnists. The event marked the beginning of the next chapter in the history of this long-revered publication. As you’d expect, contributors and staffers both reminisced about the past and shared ideas about its future. And in many instances, the conversations turned to the content in this issue, which was at that time entering the final phase of production. Why? We purposely designed this issue (and next month’s) to feature a diversity of content that would represent the breadth of coverage we’ve come to deliver during the past quarter century. A quick look at this issue’s topics gives you an idea of how far embedded technology has come. The topics also point to the fact that some of the most popular ’80s-era engineering concerns are as relevant as ever. Let’s review.

In the earliest issues of Circuit Cellar, home control was one of the hottest topics. Today, inventive DIY home control projects are highly coveted by professional engineers and newbies alike. On page 16, Scott Weber presents an interesting GPS-based time server for lighting control applications. An MCU extracts time from GPS data and transmits it to networked devices.

The time-broadcasting device includes a circuit board that’s attached to a GPS module. (Source: S. Weber, CC268)

Thiadmer Riemersma’s DIY automated component dispenser is a contemporary solution to a problem that has frustrated engineers for decades (p. 26). The MCU-based design simplifies component management and will be a welcome addition to any workbench.

The DIY automated component dispenser. (Source: T. Riemersma, CC268)

USB technology started becoming relevant in the mid-to-late 1990s, and since then has become the go-to connection option for designers and end users alike. Turn to page 30 for Jan Axelson’s  tips about debugging USB firmware. Axelson covers controller architectures and details devices such as the FTDI FT232R USB UART controller and Microchip Technology’s PIC18F4550 microcontroller.

Debugging USB firmware (Source: J. Axelson, CC268)

Electrical engineers have been trying to “control time” in various ways since the earliest innovators began studying and experimenting with electric charge. Contemporary timing control systems are implemented in a amazing ways. For instance, Richard Lord built a digital camera controller that enables him to photograph the movement of high-speed objects (p. 36).

Security and product reliability are topics that have been on the minds of engineers for decades. Whether you’re working on aerospace electronics or a compact embedded system for your workbench (p. 52), you’ll want to ensure your data is protected and that you’ve gone through the necessary steps to predict your project’s likely reliability (p. 60).

The issue’s last two articles detail how to use contemporary electronics to improve older mechanical systems. On page 64 George Martin presents a tachometer design you can implement immediately in a machine shop. And lastly, on page 70, Jeff Bachiochi wraps up his series “Mechanical Gyroscope Replacement.” The goal is to transmit reliable data to motor controllers. The photo below shows the Pololu MinIMU-9.

The Pololu MinIMU-9’s sensor axes are aligned with the mechanical gyro so the x and y output pitch and roll, respectively. (Source: J. Bachiochi, CC268)

Simple Circuits: Turn a Tube Radio Into an MP3 Amp

Want to give your MP3 player vintage tube sound? You can with the proper circuits, an antique radio, and a little know-how. In addition to generating amazing sound, the design will be an eye catcher in your home or office.

Here I present excerpts from Bill Reeve’s article, “Repurposing Antique Radios as Tube Amplifiers,” in which he provides vintage radio resources, simple circuit diagrams, and essential part info. He also covers the topics of external audio mixing and audio switching. The article appeared in the May 2012 edition of audioXpress magazine.

Manufactured from the 1930s through the 1960s, vacuum tube radios often contain high-quality audio amplifiers at the end of their RF signal chain. You can repurpose these radios into vintage, low-power tube amplifiers—without marring them in any way or detracting from their original charm and functionality as working analog radios.

Wood-cased radios have especially good sound quality, and the battery compartments in antique “portable” radios (like the Philco 48-360 or the Zenith Transoceanics) provide perfect locations for additional circuitry. When restored properly, large furniture-style radios that were built for “high fidelity” (like the late 1930s and early 1940s Philco console radios) can fill a room with rich beautiful sound.

Simple Circuits

The simple circuits described in this article perform two functions. They mix an external line-level stereo signal (typically from an MP3 player or computer) and reference it to the radio’s circuit. They also use the radio’s on/off knob to switch this external signal to the radio’s audio amplifier.

There is not one circuit that will work for every antique radio. (Original schematics for antique tube radios are available on the web www.justradios.com). But the circuits described here can be adapted to any radio topology. All the parts can be ordered from an electronics supplier like Digi-Key, and the circuit can be soldered on a prototyping printed circuit board (such as RadioShack P/N 276-168B).

External audio mixing

Figure 1 and Figure 2 show some examples of circuit schematics that mix the line-level stereo audio signals together (almost all tube radios are monophonic), while providing galvanic isolation from high voltages within the radio. Figure 1 shows an inexpensive solution suitable for most table-top radios.

Figure 1: An inexpensive circuit for mixing an MP3 player’s stereo audio signals safely into an antique radio. None of the component values are critical. (Source: B. Reeve, AX 5/12)

These radios have relatively small speakers that are unable to reproduce deep bass, so an inexpensive audio transformer (available from on-line distributors) does the job. I picked up a bucket of Tamura TY-300PR transformers for $0.50 each at an electronics surplus store, and similar transformers are commercially available. Alternatively, the Hammond 560G shown in Figure 2 is an expensive, highquality audio transformer suitable to high-fidelity radios (like the furniture-sized Philco consoles). A less expensive (and fine-sounding) alternative is the Hammond 148A.

Figure 2: A high-fidelity circuit for mixing external stereo audio signals safely into an antique radio. (Source: B. Reeve, AX 5/12)

I use Belden 9154 twisted, shielded audio cable for wiring internal to the radio, but twisted, 24-gauge wire will work well. An 8′ long audio cable with a 3.5-mm stereo jack on each end can be cut in half to make input cables for two radios, or you can use the cord from trashed ear-buds. You can route the audio cable out the back of the chassis. Photo 1 is a photograph of a 1948 Philco portable tube radio restored and used as an MP3 player amplifier.

Photo 1: A 1948 Philco portable tube radio restored and repurposed as an MP3 amplifier. (Source: B. Reeve, AX 5/12)

Audio switching using the radio’s on/off knob

After creating the mixed, radio-referenced signal, the next step is to build a circuit that switches the voltage driving the radio’s audio amplifier between its own internal broadcast and the external audio signal.

Figure 3 illustrates this audio routing control using the radio’s existing front panel power knob. Turn the radio on, and it behaves like the old analog radio it was designed to be (after the tubes warm up). However, if you turn the radio off, then on again within a few of seconds, the external audio signal is routed to the radio’s tube amplifier and speaker.

The circuit shown in Figure 3 uses a transformer to create the low voltage used by the switching circuit. There are many alternative power transformers available, and many methods of creating a transformerless power supply. Use your favorite….

The next photos (see Photo 2a and Photo 2b) show our additional circuit mounted in the lower (battery) compartment of a Zenith Transoceanic AM/shortwave receiver. Note the new high-voltage (B+) capacitors (part of the radio’s restoration) attached to a transformer housing with blue tie wraps.

Photo 2a: The inside view of a Zenith Transoceanic AM/shortwave radio restored and augmented as an MP3 audio amplifier. b: This is an outside view of the repurposed Zenith Transoceanic AM/shortwave radio. (Source: B. Reeve, AX 5/12)

The added circuit board that performs the audio re-routing is mounting to a 0.125″ maple plywood base, using screws countersunk from underneath. The plywood is securely screwed to the inside base of the radio housing. Rubber grommets are added wherever cables pass through the radio’s steel frame.—Bill Reeve

Click here to view the entire article. The article is password protected. To access it, “ax” and the author’s last name (no spaces).

CircuitCellar.com and audioXpress are Elektor International Media publications.