September Circuit Cellar: Sneak Preview

The September issue of Circuit Cellar magazine is out next week! This 84-page publication stitches together a fine tapestry of fascinating embedded electronics articles crafted for your reading pleasure.

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Here’s a sneak preview of September 2019 Circuit Cellar:

TECHNOLOGY FOR SECURITY, SENSORS & THE IoT

Security Solutions for IoT
By Jeff Child
In this IoT era of connected devices, microcontrollers have begun taking on new roles and gaining new capabilities revolving around embedded security. MCUs are embedding ever-more sophisticated security features into their devices-both on their own and via partnerships with security specialists. Here, Circuit Cellar’s Editor-in-Chief, Jeff Child, looks at the latest technology and trends in MCU security.

Electromagnetic Fault Injection: A Closer Look
By Colin O’Flynn
Electromagnetic Fault Injection (EMFI) is a powerful method of inserting faults into embedded devices, but what does this give us? In this article, Colin dives into a little more detail of what sort of effects EMFI has on real devices, and expands upon a few previous articles to demonstrate some attacks on new devices.
 
Product Focus: IoT Gateways
By Jeff Child
IoT gateways are a smart choice to facilitate bidirectional communication between IoT field devices and the cloud. Gateways also provide local processing and storage capabilities for offline services as well as near real-time management and control of edge devices. This Product Focus section updates readers on these technology trends and provides a product gallery of representative IoT gateways.
 
Comparing Color Sensor ICs
By Kevin Jensen
Driven by demands from mobile phone, display and specialty lighting equipment manufacturers, the need for sophisticated and accurate chip-scale color and spectral sensors has become stronger than ever. In this article, ams’ Kevin Jensen describes the types of optical sensors and detectors. He also provides ideas on evaluating the suitability of each type for specific applications.

PC-BASED SOLUTIONS FOR EMBEDDED SYSTEMS
 
Mini-ITX, Pico-ITX and Nano-ITX Boards
By Jeff Child
Products based on the various small-sized versions of the ITX form factor—Mini-ITX, Pico-ITX and Nano—ITX-provide system developers with complete PC-functionality and advanced graphics. Circuit Cellar Chief Editor Jeff Child explores the latest technology trends and product developments in these three ITX architectures.
 
Using Small PCs in New Ways
By Wolfgang Matthes
Even simple MCU-based projects often require some sort of front panel interface. Traditionally such systems had to rely on LEDs and switches for such simple interfaces. These days however, you can buy small, inexpensive computing devices such as mini-PCs and notebook computers and adapt them to fill those interfacing roles. In this article, Wolfgang steps you through the options and issues involved in connecting such PC-based devices to an MCU-based environment.



FOCUS ON MICROCONTROLLERS
 
Guitar Game Uses PIC32 MCU
By Brian Dempsey, Katarina Martucci and Liam Patterson
Guitar Hero has been an extremely popular game for decades. Many college kids today who played it when they were kids still enjoy playing it today. These three Cornell students are just such fans. Learn how they used Microchip’s microcontroller and 12-bit DAC to craft their own version that lets them play any song they wish by using MIDI files.
 
Offloading Intelligence
By Jeff Bachiochi
While some embedded systems do just fine with a single microcontroller, there are situations when offloading some processing into a second processing unit, such as a second MCU, offers a lot of advantages. In this article, Jeff explores this question in the context of a robotic system project that uses Arduino and an external motor driver.
 
Building a Portable Game Console
By Juan Joel Albrecht and Leandro Dorta Duque
32-bit MCUs can do so much these days—even providing all the needed control functionality for a gaming console. Along just those lines, learn how these three Cornell students built a portable game console that combines a Microchip PIC32 MCU embedded in a custom-designed 3D-printed case, printed circuit board and in-house gameplay graphics. The device includes a 320 x 240 TFT color display.
 


… AND MORE FROM OUR EXPERT COLUMNISTS
 
Variable Frequency Drive Part 2
By Brian Millier
In Part 1 Brian started to describe the process he used to convert a 3-phase motor and OEM Variable Frequency Drive (VFD) controller—salvaged from his defunct clothes washer—into a variable speed drive for his bandsaw. In this article, he completes the discussion this tim,e covering the Cypress Semi PSoC5LP SoC he used, the software design and more.
 
Semiconductor Fundamentals Part 1
By George Novacek
Embedded systems—or even modern electronics in general—couldn’t exist without semiconductor technology. In this new article series, George delves into the fundamentals of semiconductors. In Part 1 George examines the math, chemistry and materials science that are fundamental to semiconductors with a look at the basic structures that make them work.
 

 

August Circuit Cellar: Sneak Preview

The August issue of Circuit Cellar magazine is out next week! This 84-page publication rustles up a powerful herd of compelling embedded electronics articles prepared for your reading pleasure.

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Here’s a sneak preview of August 2019 Circuit Cellar:

MCU AND EMBEDDED SYSTEM TECHNOLOGIES

MCUs for Driverless Cars
By Jeff Child
Driverless cars are steadily advancing toward becoming a mainstream phenomenon. Building toward that goal, chip vendors are evolving their driver assistance technologies into complete driver replacement solutions. These solutions make use of powerful microcontroller solutions to analyze a car’s surroundings, process the information and employ control functionality to steer cars safely. Circuit Cellar Chief Editor Jeff Child examines the MCU technology and product trends that are key to driverless vehicle evolution.

Product Focus: Small and Tiny Embedded Boards
By Jeff Child
An amazing amount of computing functionality can be squeezed on to a small form factor board these days. These small—and even tiny—board-level products meet the needs of applications where extremely low SWaP (size, weight and power) beats all other demands. This Product Focus section updates readers on this technology trend and provides a product album of representative small and tiny embedded boards.

Portable Digital Synthesizer
By T.J. Hurd and Ben Roberge
Gone are the days when even a basic music synthesizer was a bulky system requiring highly specialized design knowledge. These two Cornell students developed a portable musical synthesizer using a Microchip PIC32 MCU. The portable system performs digital audio synthesis on the fly and produces sounds that range from simple sine waves to heavily modulated waveforms.

Displays for Embedded Systems
By Jeff Child
Thanks to advances in displays and innovations in graphics ICs, embedded systems can now routinely feature sophisticated graphical user interfaces. What used to require a dedicated board-level graphics/video board, now can be integrated into a chip or just a part of a chip. Circuit Cellar Chief Editor Jeff Child dives into the latest technology trends and product developments in displays for embedded systems.

Building a Twitter Emote Robot
By Ian Kranz, Nikhil Dhawan and Sofya Calvin
Social media is so pervasive these days that it’s hard to image life without it. But digital interactions can be isolating because the physical feedback component gets lost. Using PIC32 MCU technology, these three Cornell students built an emotionally expressive robot which physically reacts to tweets in a live setting. Users can tweet to the robot’s Twitter account and receive near instant feedback as the robot shares its feelings about the tweet via physical means such as sounds, facial expressions and more.

Understanding the Role of Inference Engines in AI
By Geoff Tate, Flex Logix
Artificial Intelligence offers huge benefits for embedded systems. But implementing AI well requires making smart technology choices, especially when it comes to selected a neural inferencing engine. In this article, Flex Logix CEO Geoff Tate explains what inferencing is, how it plays into AI and how embedded system designers can make sure they are using the right solution for their AI processing.


FUN WITH LIGHT AND HEAT

Watt’s Up with LEDs?
By Jeff Bachiochi
When Jeff puts his mind to a technology topic, he goes in deep. In this article, he explores all aspects of LED lighting—including the history, math, science and technology of LEDs. He discusses everything from temperature issues to powering LEDs. After purchasing some LEDs, Jeff embarks on a series of tests and shares his results and insights.

Automating the Art of Toast
By Michael Xiao and Katie Bradford
The emergence of culinary robotics and automation has already begun to revolutionize the way we prepare our meals. In this article, learn how these two Cornell undergraduates designed an advanced toaster that’s able to toast any pattern—image, text or even today’s weather—onto a piece of bread. The project makes use of Microchip’s MIC32 MCU and a Raspberry Pi Zero W board.

Build an RGB LED Controller
By Dirceu R. Rodrigues Jr.
There are a lot of fun and interesting things you can do with LEDs and different ways to control them. In this article, Dirceu describes an alternative approach to control RGB LEDs using the parallel FET dimming technique. He steps through his efforts to design and build an alternative lightning system based on power RGB LEDs. To control them he goes very old school and uses an 8-bit MCU and the BASIC programming language.


… AND MORE FROM OUR EXPERT COLUMNISTS

Energy Monitoring Part 3
By George Novacek
This is the final installment of George’s energy monitoring article series. He discussed the solar power supply in Part 1 and the utility power data acquisition in Part 2. In Part 3, he wraps up the series by looking at the remaining modules that comprise his home energy monitoring setup, including the sensors, the natural gas monitor and the real-time clock.

The Fundamentals of Fuseology
By Robert Lacoste
Just because an electronic device is simple you shouldn’t relegate it to an afterthought in your embedded system design. Such is the case with fuses. Robert explores the fundamentals of this seemingly simple device. In this article, he dives into the history, key specifications and technology of fuses. He also steps you through an experiment to analyze the performance of fuses and shares his results.

Bluetooth Mesh (Part 4)
By Bob Japenga
In this next part of his article series on Bluetooth mesh, Bob looks at how models are defined in the Bluetooth Mesh specification and how practical it is to use them. He looks at the models defined by the Bluetooth SIG and discusses creating your own models for Bluetooth Mesh.

 

 

 

July Circuit Cellar: Sneak Preview

The July issue of Circuit Cellar magazine is out next week! This 84-page publication will make a satisfying thud sound when it lands on your desk and it’s crammed full of excellent embedded electronics articles prepared for you.

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Here’s a sneak preview of July 2019 Circuit Cellar:

CONNECTED SYSTEMS IN ACTION

Embedded Computing
in Railway Systems
Railway systems keep getting more advanced. On both the control side and passenger entertainment side, embedded computers and power supplies play critical roles. Railway systems need sophisticated networking, data collection and real-time control, all while meeting safety standards. Circuit Cellar Chief Editor Jeff Child looks at the latest technology trends and products relevant to railway applications.

Product Focus:
IoT Interface Modules
The fast growing IoT phenomenon is driving demand for highly integrated modules designed for the IoT edge. Feeding those needs, a new crop of IoT modules have emerged that offer pre-certified solutions that are ready to use. This Product Focus section updates readers on this technology trend and provides a product album of representative IoT modules.

TECHNOLOGIES AND TECHNIQUES FOR ENGINEERS

FPGA Signal Processing
Offering the dual benefits of powerful signal processing and system-level integration, FPGAs have become a key technology for embedded system developers. Makers of chip and board-level FPGA products are providing complete solutions to enable developers to meet their application needs. Circuit Cellar Chief Editor Jeff Child explores the latest technology trends and product developments in FPGA signal processing.

Macros for AVR Assembler Programming
The AVR microcontroller instruction set provides a simplicity that makes it good for learning the root principles of machine programming. There’s also a rich set of macros available for the AVR that ease assembler-level programming. In this article, Wolfgang Matthes steps you through these principles, with the goal of helping programmers “think low-level, write high-level” when they approach embedded systems software development.

Inrush Current Limiters in Action
At the moment a high-power system is switched on, high loads can result in serious damage—even when the extra load is only for short time. Inrush current limiters (ICLs) can help prevent these issues. In this article, TDK Electronics’ Matt Reynolds examines ICLs based on NTC and PTC thermistors, discussing the underlying technology and the device options.

A Look at Cores with TrustZone-M
It’s not so easy to keep up with all the new security features on the latest and greatest embedded processors—especially while you’re busy focusing on the more fundamental and unique aspects of your design. In this article, Colin O’Flynn helps out by examining the new processor cores using TrustZone-M, a feature that helps you secure even low-cost and lower power system designs.

PROJECTS THAT REUSE & RECYCLE

Energy Monitoring Part 2
In Part 1 of this article series, George Novacek began describing an MCU-based system he built to monitor his household energy. Here, he continues that discussion, this time focusing on the electrical power tracking module. As the story shows, he stuck to a design challenge of building the system with as many components he already had in his component bins.

Variable Frequency Drive Part 1
Modern appliances claim to be more efficient, but they’re certainly not designed to last as long as older models. In this project article, Brian Millier describes how he reused subsystems from a defunct modern washing machine to power his bandsaw. The effort provides valuable insights on how to make use of the complete 3-phase Variable Frequency Drive (VFD) borrowed from the washing machine.

FUN PROJECT ARTICLES WITH ALL THE DETAILS

Windless Wind Chimes (Part 2)
In part 1 of this article series, Jeff Bachiochi built a system to simulate breezes randomly playing the sounds of suspended wind chimes. In part 2 the effort evolves into a less random, more orchestrated project. Jeff decided this time to craft a string of chromatically tuned chimes, similar to what an orchestra might use so the project could be used to play music. The project relies on MIDI, an industry standard music technology protocol designed to create and share music and artistic works.

Building a Smart Frying Pan
There’s almost no limit to what an MCU can be used for—-including objects that previously had no electronics at all. In this article, learn how Cornell University graduate Joseph Dwyer build a Microchip PIC32 MCU-based system that wirelessly measures and controls the temperature of a pan on a stove. The system improves both the safety and reliability of cooking on the stove, and has potentially interesting commercial applications.

EOG-Controlled Video Game
There’s much be to learned about how electronics can interact with biological signals—not only to record, but also to see how they can be used as inputs for control applications. With ongoing research in fields such as virtual reality and prosthetics, new systems are being developed to interpret different types of signals for practical applications. Learn how Cornell graduates  Eric Cole, Evan Mok and Alex Huang use electrooculography (EOG) to control a simple video game by measuring eye movement.

GPS Guides Robotic Car

Arduino UNO in Action

In this project article, Raul builds a robotic car that navigates to a series of GPS waypoints. Using the Arduino UNO for a controller, the design is aimed at robotics beginners that want to step things up a notch. In the article, Raul discusses the math, programming and electronics hardware choices that went into this project design.

By Raul Alvarez-Torrico

In this article I lay out a basic differential drive robotic car for waypoint autonomous navigation using the Global Positioning System (GPS). The robotic car receives a list of GPS coordinates, and navigates to waypoints in their given order. To understand how it works, I will discuss concepts about GPS, a simple approach to implement autonomous navigation using GPS, the hardware required for the task, how to calculate navigation vectors using the “Haversine Formula” and the “Forward Azimuth Formula” and a simple implementation of a moving average filter for filtering the GPS coordinate readings. I also discuss a simple approach to navigation control by minimizing the robotic car’s distance and heading error with respect to the goal.

This project is aimed at beginners with basic robotic car experience—that is, line followers, ultrasonic obstacle avoiders and others who now want to try something a little more complex—or anyone who is interested in the subject.

Figure 1 shows the main components of the system. The GPS receiver helps to calculate the distance from the robotic car to the goal. With the aid of a digital compass, the GPS also helps to determine in which direction the goal is located. Those two parameters—distance and direction—give us the navigation vector required to control the robotic car toward the goal. I used a four-wheel differential drive configuration for the car, which behaves almost the same as a two-wheel differential drive. The code provided with the project should work well with both configurations.

Figure 1
GPS Robotic Car block diagram

To calculate the distance to the goal, I used the Haversine Formula, which gives great-circle distances between two points on a sphere from their longitudes and latitudes. The Forward Azimuth Formula was used to calculate the direction or heading. This formula is for the initial bearing which, if followed in a straight line along a great-circle arc, will take you from the start point to the end point. Both parameters can be calculated using the following known data: The goal’s GPS coordinate, the robotic car’s coordinate obtained from the GPS receiver and the car’s heading with respect to North obtained from the digital compass.

The robotic car constantly recalculates the navigation vector and uses the obtained distance and heading to control the motors to approach the goal. I also put a buzzer in the robotic car to give audible feedback when the robotic car reaches the waypoints.

HARDWARE

As shown in Figure 1, I used an Arduino UNO board as the main controller. I chose Arduino because it’s incredibly intuitive for beginners, and it has an enormous constellation of libraries. The libraries make it easy to pull off reasonably advanced projects, without excessive details about the hardware and software drivers for sensors and actuators.

The GPS receiver I chose for the task is the HiLetgo GY-GPS6MV2 module, based on the U-blox NEO-6M chip. The digital compass is the GY-271 module, based on the Honeywell HMC5883L chip. Both are low-cost and ubiquitous with readily available Arduino libraries. The U-blox NEO-6M has a UART serial communication interface, and the HMC5883L works with the I2C serial protocol. To avoid interference, the compass should be placed at least 15 cm above the rest of the electronics.

The DC motors are driven using the very popular L298N module, based on the STMicroelectronics L298N dual, full-bridge driver. It can drive two DC motors with a max current of 2 A per channel. It can also drive two DC motors in each channel if the max current specification is not surpassed—which is what I’m doing with the four-wheel drive chassis I used for my prototype. The chassis has a 30 cm × 20 cm aluminum platform, four generic 12 V DC 85 rpm motors and wheels that are 13 cm in diameter. But almost any generic two-wheel or four-wheel drive chassis can be used.

Figure 2
Circuit diagram for the Robotic Car project

For supplying power to the robotic car, I used an 11.1 V, 2,200 mA-hour (LiPo) Lithium-Polymer battery with a discharge rate of 25C. For my type of chassis, a battery half that size should also work fine. Figure 2 shows the circuit diagram for this project, and Figure 3 shows the finished car.

Figure 3
Completed GPS Robotic Car

GLOBAL POSITIONING SYSTEM

The Global Positioning System (GPS) is a global navigation satellite system owned by the United States government. It provides geolocation and time information to any GPS receiver on the surface of the Earth, whenever it has unobstructed line of sight to at least four GPS satellites—the more the better [1]. GPS receivers typically can provide latitude and longitude coordinates with an accuracy of about 2.5 m to 5 m under ideal conditions, such as good sky visibility and lots of visible satellites. My robotic car is programmed with one or more waypoints given by latitude and longitude coordinates, and the car’s GPS receiver gives its actual position in the same type of coordinates.  …

Read the full article in the June 347 issue of Circuit Cellar
(Full article word count: 3773 words; Figure count: 8 Figures.)

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June Circuit Cellar: Sneak Preview

The June issue of Circuit Cellar magazine is out next week!. We’ve been tending our technology crops to bring you a rich harvest of in-depth embedded electronics articles. We’ll have this 84-page magazine brought to your table very soon..

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Here’s a sneak preview of June 2019 Circuit Cellar:

TOOLS AND CONCEPTS FOR ENGINEERS

Integrated PCB Design Tools
After decades of evolving their PCB design tool software packages, the leading tool vendors have the basics of PCB design nailed down. In recent years, these companies have continued to come up with new enhancements to their tool suites, addressing a myriad of issues related to not just the PCB design itself, but the whole process surrounding it. Circuit Cellar Chief Editor Jeff Child looks at the latest integrated PCB design tool solutions.

dB for Dummies: Decibels Demystified
Understanding decibels—or dB for short—may seem intimidating. Frequent readers of this column know that Robert uses dB terms quite often—particularly when talking about wireless systems or filters. In this article, Robert Lacoste discusses the math underlying decibels using basic concepts. The article also covers how they are used to express values in electronics and even includes a quiz to help you hone your decibel expertise.

Understanding PID
As a means for implementing feedback control systems, PID is an important concept in electronics engineering. In this article, Stuart Ball explains how PID can be applied and explains the concept by focusing on a simple circuit design.

DESIGNING CONNECTED SYSTEMS

Sensor Connectivity Trends
While sensors have always played a key role in embedded systems, the exploding Internet of Things (IoT) phenomenon has pushed sensor technology to the forefront. Any IoT implementation depends on an array of sensors that relay input back to the cloud. Circuit Cellar Chief Editor Jeff Child dives into the latest technology trends and product developments in sensors with an emphasis on their connectivity aspects.

Bluetooth Mesh (Part 3)
In this next part of his article series on Bluetooth mesh, Bob Japenga looks at how to create secure provisioning for a Bluetooth Mesh network without requiring user intervention. He takes a special look at an attack which Bluetooth’s asymmetric key encryption is vulnerable to called Man-in-the-Middle.

PONDERING POWER AND ENERGY

Product Focus: AC-DC Converters
To their peril, embedded system developers often treat their choice of power supply as an afterthought. But choosing the right AC-DC converter is critical to the ensuring your system delivers power efficiently to all parts of your system. This Product Focus section updates readers on these trends and provides a product album of representative AC-DC converter products.

Energy Monitoring (Part 1)
The efficient use of energy is a topic moving ever more front and center these days as climate change and energy costs begin to affect our daily lives. Curious to discover how efficient his own energy consumption was, George Novacek built an MCU-based system to monitor his household energy. And, in order to make sure this new device wasn’t adding more energy use, he chose to make the energy monitoring system solar-powered.

Building a PoE Power Subsystem
Power-over-Ethernet (PoE) allows a single cable to provide both data interconnection and power to devices. In this article, Maxim Integrated’s  and Maxim Integrated’s Thong Huynh and Suhei Dhanani explore the key issues involved in implementing rugged PoE systems. Topics covered include standards compliance, interface controller selection, DC-DC converter choices and more.

Taming Your Wind Turbine
While you can buy off-the-shelf wind power generators these days, they tend to get bad reviews from users. The problem is that harnessing wind energy takes some “taming” of the downstream electronics. In this article, Alexander Pozhitkov discusses his characterization project for a small wind turbine. This provides a guide for designing your own wind energy harvesting system.

MORE PROJECT ARTICLES WITH ALL THE DETAILS

Windless Wind Chimes (Part 1)
Wind chimes make a pleasant sound during the warm months when windows are open. But wouldn’t it be nice to simulate those sounds during the winter months when your windows are shut? In part 1 of this project article, Jeff Bachiochi builds a device that simulates a breeze randomly playing suspended wind chimes. Limited to the standard 5-note pentatonic chimes, this device is based on a Microchip PIC18 low power microcontroller.

GPS Guides Robotic Car
In this project article, Raul Alvarez-Torrico builds a robotic car that navigates to a series of GPS waypoints. Using the Arduino UNO for a controller, the design is aimed at robotics beginners that want to step things up a notch. In the article, Raul discusses the math, programing and electronics hardware choices that went into this project design.

Haptic Feedback Electronic Travel Aid
Time-of-flight sensors have become small and affordable in the last couple years. In this article, learn how Cornell graduates Aaheli Chattopadhyay, Naomi Hess and Jun Ko detail creating a travel aid for the visually impaired with a few time-of-flight sensors, coin vibration motors, an Arduino Pro Mini, a Microchip PIC32 MCU, a flashlight and a sock.

High-Temp Motor Control is Target for 32-Bit MCU Offerings

Renesas Electronics has announced the expansion of its RX24T and RX24U Groups of 32-bit MCUs to include new high-temperature-tolerant models for motor-control applications that require an expanded operating temperature range. The new RX24T G Version and RX24U G Version support operating temperatures ranging from −40°C to +105°C, while maintaining the high speed, high functionality and energy efficiency of the RX24T and RX24U MCUs.
As device form factors shrink, the heat challenge is growing for motor-control applications. In industrial machinery and office equipment, as well as home appliances that handle hot air and heated water, circuit boards are increasingly being mounted in high-temperature locations. In the case of home appliances such as dishwashers or induction hotplates in particular, demand for designs with larger interior capacity or heating areas is increasing, which restricts the space available for circuit boards.

The resulting shift toward circuit board design with a smaller surface area addresses the space constraints but also reduces the board’s capacity to disperse heat, causing the circuit board itself to become quite hot. To address these application needs, Renesas is adding new high-temperature-tolerant products to its MCU lineup that can operate in high-temperature spaces and on hot circuit boards. The new devices will provide greater flexibility for designers of products that operate in high-temperature environments, enabling the trend toward more compact devices to advance.

Software can be developed using the RX24T and RX24U CPU cards combined with the 24 V Motor Control Evaluation Kit which enables developers to create motor control applications in less time. The 32-bit RX24T and RX24U features a maximum operating frequency of 80 MHz. It is equipped with peripheral functions for motor control such as timers, A/D converter, and analog circuits that enable efficient control of two brushless DC motors by a single chip. Renesas has shipped 10 million units of the popular RX24T and RX24U Groups since their launch two years ago. With the addition of the G versions, all 32-bit RX MCU family products for motor-control applications now support operating temperature from −40°C to +105°C, extending the scalability of the RX Family and providing system manufacturers a rich and scalable lineup to choose from.

The RX24T G Version and RX24U G Version are available now in mass production. The RX24T covers 11 models with pin counts ranging from 64 to 100 pins and memory sizes from 128 KB to 512 KB. The RX24U covers six models with pin counts ranging from 100 to 144 pins and memory sizes from 256 KB to 512 KB.

Renesas Electronics | www.renesas.com

Building a Generator Control System

Three-Phase Power

Three-phase electrical power is a critical technology for heavy machinery. Learn how these two US Coast Guard Academy students built a physical generator set model capable of producing three-phase electricity. The article steps through the power sensors, master controller and DC-DC conversion design choices they faced with this project.
(Caption for lead image: From left to right: Aaron Dahlen, Caleb Stewart, Kent Altobelli and Christopher Gosvener.).

By Kent Altobelli and Caleb Stewart

Three-phase electrical power is typically used by heavy machinery due to its constant power transfer, and is used on board US Coast Guard cutters to power shipboard systems while at sea. In most applications, electrical power is generated by using a prime mover such as a diesel engine, steam turbine or water turbine to drive the shaft of a synchronous generator mechanically. The generator converts mechanical power to electrical power by using a field coil (electromagnet) on its spinning rotor to induce a changing current in its stationary stator coils. The flow of electrons in the stator coils is then distributed by conductors to energize various systems, such as lights, computers or pumps. If more electrical power is required by the facility, more mechanical power is needed to drive the generator, so more fuel, steam or water is fed to the prime mover. Together, the prime mover and the generator are referred to as a generator set “genset”.

Because the load expects a specific voltage and frequency for normal operation, the genset must regulate its output using a combination of its throttle setting and rotor field strength. When a real load, such as a light bulb, is switched on, it consumes more real power from the electrical distribution bus, and the load physically slows down the genset, reducing the output frequency and voltage. The shaft rotational speed determines the number of times per second the rotor’s magnetic field sweeps past the stator coils, and determines the frequency of the sinusoidal output. Increasing the throttle returns the frequency and voltage to their setpoints.

When a partially reactive load—for example, an induction motor—is switched on, it consumes real power, but also adds a complex component called “reactive power.” This causes a voltage change due to the way a generator produces the demanded phase offset between supplied voltage and current. An inductive load, common in industrial settings, causes the voltage output to sag, whereas a capacitive load causes the voltage to rise. Voltage induced in the stator is controlled by changing the strength of the rotor’s electromagnetic field that sweeps past the stator coils in accordance with Faraday’s Law of inductance. Increasing the voltage supply to the rotor’s electromagnet increases the magnetic field and brings the voltage back up to its setpoint.

The objective of our project was to build a physical generator set model capable of producing three-phase electricity, and maintain each “Y”-connected phase at an output voltage of 120 ±5 V RMS (AC) and frequency of 60 ±0.5 Hz. When the load on the system changes, provided the system is not pushed beyond its operating limits, the control system should be capable of returning the output to the acceptable voltage and frequency ranges within 3 seconds. When controlling multiple gensets paralleled in island operation, the distributed system should be able to meet the same voltage and frequency requirements, while simultaneously balancing the real and reactive power from all online gensets.

Two Configurations

Gensets supply power in two conceptually different configurations: “island” operation with stand-alone or paralleled (electrically connected) gensets, or gensets paralleled to an “infinite” bus.” In island operation, the entire electrical bus is relatively small—either one genset or a small number of total gensets—so any changes made by one genset directly affects the voltage and frequency of the electrical bus. When paralleled to an infinite bus such as the power grid, the bus is too powerful for a single genset to change the voltage or frequency. Coast Guard cutters use gensets in island operation, so that is the focus of this article.

When in island operation, deciding how much to compensate for a voltage or frequency change is accomplished using either droop or isochronous (iso) control. Droop control uses a proportional response to reduce error between the genset output and the desired setpoint. For example, if the frequency of the output drops, then the throttle of the prime mover is opened correspondingly to generate more power and raise the frequency back up. Since a proportional response cannot ever achieve the setpoint when loaded (a certain amount of constant error is required to keep the throttle open), the output frequency tends to decrease linearly with an increase in power output. A no-load to full-load droop of 2.4 Hz is typical for a generator in the United States, but this can usually be adjusted by the user.

Frequency control typically uses a mechanical governor to provide the proportional throttle response to meet real power demand. Voltage control typically uses an automatic voltage regulator (AVR) to manipulate the field coil strength to meet reactive power demand. Isochronous mode is more challenging, because it always works to return the genset output to the setpoint. Maintaining zero error on the output usually requires some combination of a proportional response to compensate for load fluctuation quickly, and also a long-term fine-tuning compensation to ensure the steady-state output achieves the setpoint.

If two or more gensets are paralleled, the combined load is supplied by the combined power output of the gensets. As before, maintaining the expected operating voltage and frequency is the first priority, but with multiple gensets, careful changes to the throttle and field can also redistribute the real and reactive power to meet real and reactive power demand efficiently.

If the average throttle or field setting is increased, then the overall bus frequency or voltage, respectively, also increases. If the average throttle or field setting stays the same while two gensets adjust their settings in opposite directions, the frequency or voltage stay the same, but the genset that increased their throttle or field provides a greater portion of the real or reactive power. Redistribution is important because it allows gensets to produce real power at peak efficiency and share reactive power evenly, because excessive reactive power generation derates the generator. Reactive currents flowing through the windings cause heat without producing real, useful power.

Four Conditions

Before the breaker can be closed to parallel generators, four conditions need to be met between the oncoming generators and the bus to ensure smooth load transfer:

1) The oncoming generator should have the same or a slightly higher voltage than the bus.
2) The oncoming generator should have the same or a slightly higher frequency than the bus.
3) The phase angles need to match. For example, the oncoming generator “A” phase needs to be at 0 degrees when the bus “A” phase is at 0 degrees.
4) The phase sequences need to be the same. For example, A-B-C for the oncoming generator needs to match the A-B-C phase sequence of the bus.

Meeting these conditions can be visualized using Figure 1, which shows a time vs. voltage representation of an arbitrary, balanced three-phase signal. The bus and the generator each have their own corresponding plots resembling Figure 1, and the two should only be electrically connected if both plots line up and therefore satisfy the four conditions listed above.

Figure 1
Arbitrary three phase sinusoid

If done properly, closing the breaker will be anticlimactic, and the gensets will happily find a new equilibrium. The gensets should be adjusted immediately to ensure the load is split evenly between gensets. If there is an electrical mismatch, the generator will instantly attempt to align its electrical phase with the bus, bringing the prime mover along for a wild ride and potentially causing physical damage—in addition to making a loud BANG! Idaho National Laboratories demonstrated the physical damage caused by electrical mismatch in its 2007 Aurora Generator Test.

Three primary setups for parallel genset operation are discussed here: droop-droop, isochronous-droop, and isochronous-isochronous. The simplest mode of parallel operation between two or more gensets is a droop-droop mode, where both gensets are in droop mode and collectively find a new equilibrium frequency and voltage according to the real and reactive power demands of the load.

Isochronous-droop (iso-droop) mode is slightly more complex, where one genset is in droop mode and the other is in iso mode. The iso genset always provides the power required to maintain a specific voltage and frequency, and the droop genset produces a constant real power corresponding to that one point on its droop curve. Because the iso genset works more or less depending on the load, it is also termed the “swing” generator.

Finally, isochronous-isochronous (iso-iso) is the most complex. In iso-iso mode, both gensets attempt to maintain the specified output voltage and frequency. While this sounds ideal, this mode has the potential for instability during transient loading, because individual genset control systems may not be able to differentiate between a change in load and a change in the other genset’s power output. Iso-iso mode usually requires direct communication or a higher level controller to monitor both gensets, so they respond to load changes without fighting each other. With no external communication, one genset could end up supplying the majority of the power to the load while the second genset is idling, seeing no need to contribute because the bus voltage and frequency are spot on! At some point one genset could even resist the other genset, consuming real power and causing the generator to “motor” the prime mover. Unchecked, this condition will damage prime movers, so a reverse power relay is usually in place to trip the genset offline, leaving only one genset to supply the entire load.

System Design

Each genset simulated on the Hampden Training Bench had a custom sensor monitoring the generator voltage, current, and frequency output, a small computer running control calculations and a pair of DC-to-DC converters to close the control loop on the generator’s rotational velocity and field strength. The genset was simulated by coupling a 330 W brushed DC motor acting as the prime mover to a four-pole 330 W synchronous generator (Figure 2).

Figure 2
Simulated genset on the Hampden Training Bench

Our power sensor was a custom-designed circuit board with an 8-bit microcontroller (MCU) employed to sample the genset output continuously and provide RMS voltage, RMS current, real power, reactive power, and frequency upon request. The control system ran on a Linux computer with custom software designed to poll the sensor for data, calculate the appropriate control response to return the system to the set point and generate corresponding pulse width modulated (PWM) outputs. Finally, the PWM outputs controlled the DC-to-DC converter to step down the DC supply voltage to drive the prime mover and energize the generator field coil. The component relationships are shown in Figure 3, where the diesel engine in a typical genset was replaced by our DC motor.

Figure 3
Genset component layout

Since this project was a continuation of a previous year of work by Elise Sako and Jasper Campbell, several lessons were learned that required the system be redesigned from the ground up. One of the largest design constraint from the previous year was the decision to use a variable frequency drive (VFD) to drive an induction motor as the prime mover. While this solution is acceptable, it introduces inherent delay in the control loop, because the VFD is designed to execute commands as smoothly but not necessarily as quickly as possible.

Another design constraint was the decision to power the generator field coil using DC regulated by an off-the-shelf silicon controller rectifier (SCR) chopper. Again, while this is an acceptable solution, the system output suffered from the SCR’s slow response time (refresh rate is limited to the AC supply frequency), and voltage output regulation was non-ideal (capacitor voltage refresh again limited by the frequency of the AC supply).

To solve these performance constraints, we selected the responsive and easily controllable DC motor as the prime mover so the DC output from our Hampden Training Bench could be used as the power supply for both the DC motor and the generator field coil. By greatly simplifying the electrical control of the genset, we reduced implementation cost and improved control system response time. …

Read the full article in the February 343 issue of Circuit Cellar
(Full article word count: 6116 words; Figure count: 14 Figures.)

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February Circuit Cellar: Sneak Preview

The February issue of Circuit Cellar magazine is coming soon. We’ve raised up a bumper crop of in-depth embedded electronics articles just for you, and packed ’em into our 84-page magazine.

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MCUs ARE EVERYWHERE, DOING EVERYTHING

Electronics for Automotive Infotainment
As automotive dashboard displays get more sophisticated, information and entertainment are merging into so-called infotainment systems. That’s driving a need for powerful MCU- and MPU-based solutions that support the connectivity, computing and interfacing needs particular to these system designs. In this article, Circuit Cellar’s Editor-in-Chief, Jeff Child, looks at the technology and trends feuling automotive infotainment.

Inductive Sensing with PSoC MCUs
Inductive sensing is shaping up to be the next big thing for touch technology. It’s suited for applications involving metal-over-touch situations in automotive, industrial and other similar systems. In his article, Nishant Mittal explores the science and technology of inductive sensing. He then describes a complete system design, along with firmware, for an inductive sensing solution based on Cypress Semiconductor’s PSoC microcontroller.

Build a Self-Correcting LED Clock
In North America, most radio-controlled clocks use WWVB’s transmissions to set the correct time. WWVB is a Colorado-based time signal radio station near. Learn how Cornell graduates Eldar Slobodyan and Jason Ben Nathan designed and built a prototype of a Digital WWVB Clock. The project’s main components include a Microchip PIC32 MCU, an external oscillator and a display.

WE’VE GOT THE POWER

Product Focus: ADCs and DACs
Analog-to-digital converters (ADCs) and digital-to-analog converters (DACs) are two of the key IC components that enable digital systems to interact with the real world. Makers of analog ICs are constantly evolving their DAC and ADC chips pushing the barriers of resolution and speeds. This new Product Focus section updates readers on this technology and provides a product album of representative ADC and DAC products.

Building a Generator Control System
Three phase electrical power is a critical technology for heavy machinery. Learn how US Coast Guard Academy students Kent Altobelli and Caleb Stewart built a physical generator set model capable of producing three phase electricity. The article steps through the power sensors, master controller and DC-DC conversion design choices they faced with this project.

EMBEDDED COMPUTING FOR YOUR SYSTEM DESIGN

Non-Standard Single Board Computers
Although standard-form factor embedded computers provide a lot of value, many applications demand that form take priority over function. That’s where non-standard boards shine. The majority of non-standard boards tend to be extremely compact, and well suited for size-constrained system designs. Circuit Cellar Chief Editor Jeff Child explores the latest technology trends and product developments in non-standard SBCs.

Thermal Management in machine learning
Artificial intelligence and machine learning continue to move toward center stage. But the powerful processing they require is tied to high power dissipation that results in a lot of heat to manage. In his article, Tom Gregory from 6SigmaET explores the alternatives available today with a special look at cooling Google’s Tensor Processor Unit 3.0 (TPUv3) which was designed with machine learning in mind.

… AND MORE FROM OUR EXPERT COLUMNISTS

Bluetooth Mesh (Part 1)
Wireless mesh networks are being widely deployed in a wide variety of settings. In this article, Bob Japenga begins his series on Bluetooth mesh. He starts with defining what a mesh network is, then looks at two alternatives available to you as embedded systems designers.

Implementing Time Technology
Many embedded systems need to make use of synchronized time information. In this article, Jeff Bachiochi explores the history of time measurement and how it’s led to NTP and other modern technologies for coordinating universal date and time. Using Arduino and the Espressif System’s ESP32, Jeff then goes through the steps needed to enable your embedded system to request, retrieve and display the synchronized date and time to a display.

Infrared Sensors
Infrared sensing technology has broad application ranging from motion detection in security systems to proximity switches in consumer devices. In this article, George Novacek looks at the science, technology and circuitry of infrared sensors. He also discusses the various types of infrared sensing technologies and how to use them.

The Art of Voltage Probing
Using the right tool for the right job is a basic tenant of electronics engineering. In this article, Robert Lacoste explores one of the most common tools on an engineer’s bench: oscilloscope probes, and in particular the voltage measurement probe. He looks and the different types of voltage probes as well as the techniques to use them effectively and safely.

Motor Driver Provides Complete Solution for Industrial Designs

Infineon Technologies has launched the IFX007T NovalithIC motor driver for industrial applications. The IFX007T smart half-bridge provides an easy and efficient way to drive brushed and brushless motors, integrating a p-channel high-side MOSFET, an n-channel low-side MOSFET and a driver IC into one package. Along with a microcontroller and power supply, no other devices are necessary to drive a motor.

For many years, Infineon has followed this NovalithIC integrated approach for automotive applications. According to Infineon, the IFX007T now allows industrial system designers to benefit from this experience. It is qualified according to JESD47I and can be used to drive motors with supplies up to 40 V and peak currents up to 55 A. The broad application range includes pumps, healthcare, home and garden appliances as well as industrial automation, fans and many more.

Ease-of-use is a key benefit of the integrated solution. System designers save layout and manufacturing effort while reducing stray inductances and external components. Additionally, only three general purpose microcontroller pins are needed to control a full H-bridge.

The IFX007T has integrated self-protection, including over-temperature and cross-current protection. Within an H-bridge configuration, the half-bridge approach provides logic redundancy—if one device fails, the other can still stop the motor.

Another key benefit is the flexible motor control. The IFX007T can be used in either half-bridge, H-bridge or three-phase configurations. Furthermore, the motor speed can be adjusted via pulse width modulation (PWM) up to 25 kHz. Active freewheeling is possible from either the high side or the low side. An adjustable slew rate enables reduction of electromagnetic emissions.

Infineon Technologies | www.infineon.com

January Circuit Cellar: Sneak Preview

Happy New Years! The January issue of Circuit Cellar magazine is coming soon. Don’t miss this 1st issue of Circuit Cellar 2019. Enjoy pages and pages of great, in-depth embedded electronics articles.

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TRENDS & CHOICES IN EMBEDDED COMPUTING

Comms and Control for Drones
Consumer and commercial drones represent one of the most dynamic areas of embedded design today. Chip, board and system suppliers are offering improved ways for drones to do more processing on board the drone, while also providing solutions for implementing the control and communication subsystems in drones. This article by Circuit Cellar’s Editor-in-Chief Jeff Child looks at the technology and products available today that are advancing the capabilities of today’s drones.

Choosing an MPU/MCU for Industrial Design
By Microchip Technology’s Jacko Wilbrink
As MCU performance and functionality improve, the traditional boundaries between MCUs and microprocessor units (MPUs) have become less clear. In this article, Jacko examines the changing landscape in MPU vs. MCU capabilities, OS implications and the specifics of new SiP and SOM approaches for simplifying higher-performance computing requirements in industrial applications.

Product Focus: COM Express Boards
The COM Express architecture has found a solid and growing foothold in embedded systems. COM Express boards provide a complete computing core that can be upgraded when needed, leaving the application-specific I/O on the baseboard. This Product Focus section updates readers on this technology and provides a product album of representative COM Express products.

MICROCONTROLLERS ARE DOING EVERYTHING

Connecting USB to Simple MCUs
By Stuart Ball
Sometimes you want to connect a USB device such as a flash drive to a simple microcontroller. Problem is most MCUs cannot function as a USB host. In this article, Stuart steps through the technology and device choices that solve this challenge. He also puts the idea into action via a project that provides this functionality.

Vision System Enables Overlaid Images
By Daniel Edens and Elise Weir
In this project article, learn how these two Cornell students designed a system to overlay images from a visible light camera and an infrared camera. They use software running on a PIC32 MCU to interface the two types of cameras. The MCU does the computation to create the overlaid images, and displays them on an LCD screen.

DATA ACQUISITION AND MEASUREMENT

Data Acquisition Alternatives
By Jeff Child
While the fundamentals of data acquisition remain the same, its interfacing technology keeps evolving and changing. USB and PCI Express brought data acquisition off the rack, and onto the lab bench top. Today solutions are emerging that leverage Mini PCIe, Thunderbolt and remote web interfacing. Circuit Cellar’s Editor-in-Chief, Jeff Child, dives into the latest technology trends and product developments in data acquisition.

High-Side Current Sensing
By Jeff Bachiochi
Jeff says he likes being able to measure things—for example, being able to measure load current so he can predict how long a battery will last. With that in mind, he recently found a high-side current sensing device, Microchip’s EMC1701. In his article, Jeff takes you through the details of the device and how to make use of it in a battery-based system.

Power Analysis Capture with an MCU
By Colin O’Flynn
Low-cost microcontrollers integrate many powerful peripherals in them. You can even perform data capture directly to internal memory. In his article, Colin uses the ChipWhisperer-Nano as a case study in how you might use such features which would otherwise require external programmable logic.

TOOLS AND TECHNIQUES FOR EMBEDDED SYSTEM DESIGN

Easing into the IoT Cloud (Part 2)
By Brian Millier
In Part 1 of this article series Brian examined some of the technologies and services available today enabling you to ease into the IoT cloud. Now, in Part 2, he discusses the hardware features of the Particle IoT modules, as well as the circuitry and program code for the project. He also explores the integration of a Raspberry Pi solution with the Particle cloud infrastructure.

Hierarchical Menus for Touchscreens
By Aubrey Kagan
In his December article, Aubrey discussed his efforts to build a display subsystem and GUI for embedded use based on a Noritake touchscreen display. This time he shares how he created a menu system within the constraints of the Noritake graphical display system. He explains how he made good use of Microsoft Excel worksheets as a tool for developing the menu system.

Real Schematics (Part 2)
By George Novacek
The first part of this article series on the world of real schematics ended last month with wiring. At high frequencies PCBs suffer from the same parasitic effects as any other type of wiring. You can describe a transmission line as consisting of an infinite number of infinitesimal resistors, inductors and capacitors spread along its entire length. In this article George looks at real schematics from a transmission line perspective.

December Circuit Cellar: Sneak Preview

The December issue of Circuit Cellar magazine is coming soon. Don’t miss this last issue of Circuit Cellar in 2018. Pages and pages of great, in-depth embedded electronics articles prepared for you to enjoy.

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AI, FPGAs and EMBEDDED SUPERCOMPUTING

Embedded Supercomputing
Gone are the days when supercomputing levels of processing required a huge, rack-based systems in an air-conditioned room. Today, embedded processors, FPGAs and GPUs are able to do AI and machine learning kinds of operation, enable new types of local decision making in embedded systems. In this article, Circuit Cellar’s Editor-in-Chief, Jeff Child, looks at these technology and trends driving embedded supercomputing.

Convolutional Neural Networks in FPGAs
Deep learning using convolutional neural networks (CNNs) can offer a robust solution across a wide range of applications and market segments. In this article written for Microsemi, Ted Marena illustrates that, while GPUs can be used to implement CNNs, a better approach, especially in edge applications, is to use FPGAs that are aligned with the application’s specific accuracy and performance requirements as well as the available size, cost and power budget.

NOT-TO-BE-OVERLOOKED ENGINEERING ISSUES AND CHOICES

DC-DC Converters
DC-DC conversion products must juggle a lot of masters to push the limits in power density, voltage range and advanced filtering. Issues like the need to accommodate multi-voltage electronics, operate at wide temperature ranges and serve distributed system requirements all add up to some daunting design challenges. This Product Focus section updates readers on these technology trends and provides a product gallery of representative DC-DC converters.

Real Schematics (Part 1)
Our magazine readers know that each issue of Circuit Cellar has several circuit schematics replete with lots of resistors, capacitors, inductors and wiring. But those passive components don’t behave as expected under all circumstances. In this article, George Novacek takes a deep look at the way these components behave with respect to their operating frequency.

Do you speak JTAG?
While most engineers have heard of JTAG or have even used JTAG, there’s some interesting background and capabilities that are so well know. Robert Lacoste examines the history of JTAG and looks at clever ways to use it, for example, using a cheap JTAG probe to toggle pins on your design, or to read the status of a given I/O without writing a single line of code.

PUTTING THE INTERNET-OF-THINGS TO WORK

Industrial IoT Systems
The Industrial Internet-of-Things (IIoT) is a segment of IoT technology where more severe conditions change the game. Rugged gateways and IIoT edge modules comprise these systems where the extreme temperatures and high vibrations of the factory floor make for a demanding environment. Here, Circuit Cellar’s Editor-in-Chief, Jeff Child, looks at key technology and product drives in the IIoT space.

Internet of Things Security (Part 6)
Continuing on with his article series on IoT security, this time Bob Japenga returns to his efforts to craft a checklist to help us create more secure IoT devices. This time he looks at developing a checklist to evaluate the threats to an IoT device.

Applying WebRTC to the IoT
Web Real-time Communications (WebRTC) is an open-source project created by Google that facilitates peer-to-peer communication directly in the web browser and through mobile applications using application programming interfaces. In her article, Callstats.io’s Allie Mellen shows how IoT device communication can be made easy by using WebRTC. With WebRTC, developers can easily enable devices to communicate securely and reliably through video, audio or data transfer.

WI-FI AND BLUETOOTH IN ACTION

IoT Door Security System Uses Wi-Fi
Learn how three Cornell students, Norman Chen, Ram Vellanki and Giacomo Di Liberto, built an Internet connected door security system that grants the user wireless monitoring and control over the system through a web and mobile application. The article discusses the interfacing of a Microchip PIC32 MCU with the Internet and the application of IoT to a door security system.

Self-Navigating Robots Use BLE
Navigating indoors is a difficult but interesting problem. Learn how these two Cornell students, Jane Du and Jacob Glueck, used Received Signal Strength Indicator (RSSI) of Bluetooth Low Energy (BLE) 4.0 chips to enable wheeled, mobile robots to navigate towards a stationary base station. The robot detects its proximity to the station based on the strength of the signal and moves towards what it believes to be the signal source.

IN-DEPTH PROJECT ARTICLES WITH ALL THE DETAILS

Sun Tracking Project
Most solar panel arrays are either fixed-position, or have a limited field of movement. In this project article, Jeff Bachiochi set out to tackle the challenge of a sun tracking system that can move your solar array to wherever the sun is coming from. Jeff’s project is a closed-loop system using severs, opto encoders and the Microchip PIC18 microcontroller.

Designing a Display System for Embedded Use
In this project article, Aubrey Kagan takes us through the process of developing an embedded system user interface subsystem—including everything from display selection to GUI development to MCU control. For the project he chose a 7” Noritake GT800 LCD color display and a Cypress Semiconductor PSoC5LP MCU.

November Circuit Cellar: Sneak Preview

The November issue of Circuit Cellar magazine is coming soon. Clear your decks for a new stack of in-depth embedded electronics articles prepared for you to enjoy.

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SOLUTIONS FOR SYSTEM DESIGNS

3D Printing for Embedded Systems
Although 3D printing for prototyping has existed for decades, it’s only in recent years that it’s become a mainstream tool for embedded systems development. Today the ease of use of these systems has reached new levels and the types of materials that can be used continues to expand. This article by Circuit Cellar’s Editor-in-Chief, Jeff Child looks at the technology and products available today that enable 3D printing for embedded systems.

Add GPS to Your Embedded System
We certainly depend on GPS technology a lot these days, and technology advances have brought fairly powerful GPS functionally into our pockets. Today’s miniaturization of GPS receivers enables you to purchase an inexpensive but capable GPS module that you can add to your embedded system designs. In this article, Stuart Ball shows how to do this and take advantage of the GPS functionality.

FCL for Servo Drives
Servo drives are a key part of many factory automation systems. Improving their precision and speed requires attention to fast-current loops and related functions. In his article, Texas Instruments’ Ramesh Ramamoorthy gives an overview of the functional behavior of the servo loops using fast current loop algorithms in terms of bandwidth and phase margin.

FOCUS ON ANALOG AND POWER

Analog and Mixed-Signal ICs
Analog and mixed-signal ICs play important roles in a variety of applications. These applications depend heavily on all kinds of interfacing between real-world analog signals and the digital realm of processing and control. Circuit Cellar’s Editor-in-Chief, Jeff Child, dives into the latest technology trends and product developments in analog and mixed-signal chips.

Sleeping Electronics
Many of today’s electronic devices are never truly “off.” Even when a device is in sleep mode, it draws some amount of power—and drains batteries. Could this power drain be reduced? In this project article, Jeff Bachiochi addresses this question by looking at more efficient ways to for a system to “play dead” and regulate power.

BUILDING CONNECTED SYSTEMS FOR THE IoT EDGE

Easing into the IoT Cloud (Part 1)
There’s a lot of advantages for the control/monitoring of devices to communicate indirectly with the user interface for those devices—using some form of “always-on” server. When this server is something beyond one in your home, it’s called the “cloud.” Today it’s not that difficult to use an external cloud service to act as the “middleman” in your system design. In this article, Brian Millier looks at the technologies and services available today enabling you to ease in to the IoT cloud.

Sensors at the Intelligent IoT Edge
A new breed of intelligent sensors has emerged aimed squarely at IoT edge subsystems. In this article, Mentor Graphics’ Greg Lebsack explores what defines a sensor as intelligent and steps through the unique design flow issues that surround these kinds of devices.

FUN AND INTERESTING PROJECT ARTICLES

MCU-Based Project Enhances Dance Game
Microcontrollers are perfect for systems that need to process analog signals such as audio and do real-time digital control in conjunction with those signals. Along just those lines, learn how two Cornell students Michael Solomentsev and Drew Dunne recreated the classic arcade game “Dance Dance Revolution” using a Microchip Technology PIC32 MCU. Their version performs wavelet transforms to detect beats from an audio signal to synthesize dance move instructions in real-time without preprocessing.

Building an Autopilot Robot (Part 2)
In part 1 of this two-part article series, Pedro Bertoleti laid the groundwork for his autopiloted four-wheeled robot project by exploring the concept of speed estimation and speed control. In part 2, he dives into the actual building of the robot. The project provides insight to the control and sensing functions of autonomous electrical vehicles.

… AND MORE FROM OUR EXPERT COLUMNISTS

Embedded System Security: Live from Las Vegas
This month Colin O’Flynn summarizes a few interesting presentations from the Black Hat conference in Las Vegas. He walks you through some attacks on bitcoin wallets, x86 backdoors and side channel analysis work—these and other interesting presentations from Black Hat.

Highly Accelerated Product Testing
It’s a fact of life that every electronic system eventually fails. Manufacturers use various methods to weed out most of the initial failures before shipping their product. In this article, George Novacek discusses engineering attempts to bring some predictability into the reliability and life expectancy of electronic systems. In particular, he focuses on Highly Accelerated Lifetime Testing (HALT) and Highly Accelerated Stress Screening (HASS).

Motor Drivers Provide Solution for Low- to Mid-Power Applications

STMicroelectronics has released the STSPIN830 and STSPIN840 single-chip drivers that simplify the design of low-to-mid-power motor controls in the 7 V to 45 V range.  The devices contain flexible control logic and low-RDS(ON) power switches for industrial applications, medical technology, and home appliances.
The STSPIN830 for driving 3-phase brushless DC motors has a mode-setting pin that lets users control the three half bridges of the integrated power stage with direct U, V, and W pulse-width modulated (PWM) inputs, or by applying signals to each gate individually for higher control flexibility. A dedicated sense pin for each inverter leg simplifies setting up three-shunt or single-shunt current sensing for Field-Oriented Control (FOC).

The STSPIN840 can drive two brushed DC motors or one larger motor leveraging ST’s well- known, market-proven paralleling concept, which allows the integrated full bridges to be configured as two separate bridges or as a single bridge using the two sets of MOSFETs in parallel for lower RDS(ON) and higher current rating.

Both drivers contain rich features, including PWM current-control circuitry with adjustable off-time, a convenient standby pin for power saving, and protection circuitry including non-dissipative overcurrent protection, short-circuit protection, undervoltage lockout, thermal shutdown, and interlocking to help create robust and reliable drives.

The integrated power stage of each device features ST-proprietary MOSFETs with low RDS(ON) of only 500 mΩ to combine high efficiency with economy. The option to use the output bridges individually or connected in parallel, in the STSPIN840, helps trim the BOM for multi-motor applications.

With their high feature integration and flexibility, the drivers enable more compact and cost-effective controls for industrial, robotic, medical, building-automation, and office-equipment applications. The STSPIN830 is ideal for factory-automation end-points, home appliances, small pumps, and fans for computer or general-purpose cooling. The STSPIN840 targets ATM and money-handling machines, multi-axis stage-lighting mechanisms, thermal printers, textile or sewing machines, and vending machines.

The STSPIN830 and STSPIN840 are both in production now, as 4 mm x 4 mm QFN devices. Pricing for both starts from $1.25 for orders of 1,000 pieces.

Two STM32 Nucleo expansion boards are provided to facilitate product evaluation and build functional prototypes using the STM32 Open Development Environment: X-NUCLEO-IHM16M1 for the STSPIN830 and X-NUCLEO-IHM15A1 for the STSPIN840, both priced at $16.

STMicroelectronics | www.st.com

September Circuit Cellar: Sneak Preview

The September issue of Circuit Cellar magazine is coming soon. Clear your decks for a new stack of in-depth embedded electronics articles prepared for you to enjoy.

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Here’s a sneak preview of September 2018 Circuit Cellar:

MOTORS, MOTION CONTROL AND MORE

Motion Control for Robotics
Motion control technology for robotic systems continues to advance, as chip- and board-level solutions evolve to meet new demands. These involve a blending of precise analog technologies to control position, torque and speed with signal processing to enable accurate, real-time motor control. Here, Circuit Cellar’s Editor-in-Chief, Jeff Child, looks the latest technology and product advances in motion control for robotics.

Electronic Speed Control (Part 3)
Radio-controlled drones are one among many applications that depend on the use of an Electronic Speed Controller (ESC) as part of its motor control design. After observing the operation of a number of ESC modules, in this part Jeff Bachiochi focuses in more closely on the interaction of the ESC with the BLDC motor.

BUILDING CONNECTED SYSTEMS

Product Focus: IoT Gateways
IoT gateways are a smart choice to facilitate bidirectional communication between IoT field devices and the cloud. Gateways also provide local processing and storage capabilities for offline services as well as near real-time management and control of edge devices. This Product Focus section updates readers on these technology trends and provides a product gallery of representative IoT gateways.

Wireless Weather Station
Integrating wireless technologies into embedded systems has become much easier these days. In this project article, Raul Alvarez Torrico describes his home-made wireless weather station that monitors ambient temperature, relative humidity, wind speed and wind direction, using Arduino and a pair of cheap Amplitude Shift Keying (ASK) radio modules.

FOCUS ON ANALOG AND POWER TECHNOLOGY

Frequency Modulated DDS
Prompted by a reader’s query, Ed became aware that you can no longer get crystal oscillator modules tuned to specific frequencies. With that in mind, Ed set out to build a “Channel Element” replacement around a Teensy 3.6 board and a DDS module. In this article, Ed Nisley explains how the Teensy’s 32-bit datapath and 180 MHz CPU clock affect the DDS frequency calculations. He then explores some detailed timings.

Power Supplies / Batteries
Sometimes power decisions are left as an afterthought in system designs. But your choice of power supply or battery strategy can have a major impact on your system’s capabilities. Circuit Cellar’s Editor-in-Chief, Jeff Child, dives into the latest technology trends and product developments in power supplies and batteries.

Murphy’s Laws in the DSP World (Part 3)
Unpredictable issues crop up when you move from the real world of analog signals and enter the world of digital signal processing (DSP). In Part 3 of this article series, Mike Smith and Mai Tanaka focuses on strategies for how to—or how to try to—avoid Murphy’s Laws when doing DSP.

SYSTEM DESIGN ISSUES IN VIDEO AND IMAGING

Virtual Emulation for Drones
Drone system designers are integrating high-definition video and other features into their SoCs. Verifying the video capture circuitry, data collection components and UHD-4K streaming video capabilities found in drones is not trivial. In his article, Mentor’s Richard Pugh explains why drone verification is a natural fit for hardware emulation because emulation is very efficient at handling large amounts of streamed data.

LIDAR 3D Imaging on a Budget
Demand is on the rise for 3D image data for use in a variety of applications, from autonomous cars to military base security. That has spurred research into high precision LIDAR systems capable of creating extremely clear 3D images to meet this demand. Learn how Cornell student Chris Graef leveraged inexpensive LIDAR sensors to build a 3D imaging system all within a budget of around $200.

AND MORE FROM OUR EXPERT COLUMNISTS

Velocity and Speed Sensors
Automatic systems require real-life physical attributes to be measured and converted to electrical quantities ready for electronic processing. Velocity is one such attribute. In this article, George Novacek steps through the math, science and technology behind measuring velocity and the sensors used for such measurements.

Recreating the LPC Code Protection Bypass
Microcontroller fuse bits are used to protect code from being read out. How well do they work in practice? Some of them have been recently broken. In this article Colin O’Flynn takes you through the details of such an attack to help you understand the realistic threat model.

August Circuit Cellar: Sneak Preview

The August issue of Circuit Cellar magazine is coming soon. Be on the lookout for a whole shipload of top-notch embedded electronics articles for you to enjoy.

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Here’s a sneak preview of August 2018 Circuit Cellar:

FPGAs REDEFINE THE DEFINITION OF “SYSTEM”

FPGA System Design
Long gone now are the days when FPGAs were thought of as simple programmable circuitry for interfacing and glue logic. Today, FPGAs are powerful system chips with on-chip processors, signal processing functionality and rich offerings or high-speed connectivity. Here, Circuit Cellar’s Editor-in-Chief, Jeff Child, looks at the latest technology and trends in FPGA system design.

Managing FPGA Design Complexity
Modern FPGAs can contain millions of logic gates and thousands of embedded DSP processors allowing FPGA hardware designers to create extremely sophisticated and complex application-specific hardware functions. In this article, Pentek’s Bob Sgandurra explores how today’s FPGA technology has revamped the roles of both hardware and software engineers as well as how dealing with on-chip IP adds new layers of complexity.

HIGH-INTEGRATION AT THE CHIP-
AND BOARD-LEVEL

Product Focus: Small and Tiny Embedded Boards
An amazing amount of computing functionality can be squeezed on to a small form factor board these days. These company—and even tiny—board-level products meet the needs of applications where extremely low SWaP (size, weight and power) beats all other demands. This Product Focus section updates readers on this technology trend and provides a product album of representative small and tiny embedded boards.

Microcontrollers and Processors
Today’s crop of microcontrollers and embedded processors provide a rich continuum of features, functions and capabilities. It’s hard to tell anymore where the dividing line is, especially when a lot of them use the same CPU cores. Circuit Cellar’s Editor-in-Chief, Jeff Child, delves into the technology and product trends of MCUs and embedded processors.

CAN’T STOP THE SIGNAL

Murphy’s Laws in the DSP World (Part 2)
Many unexpected issues come into play when you move from the real world of analog signals and enter the world of digital signal processing (DSP). Part 2 of this article series by Michael Smith, Mai Tanaka and Ehsan Shahrabi Farahani charges forward introducing “Murphy’s Laws of DSP” #7, #8 and #9 and looks at the spectral analysis of DSP signals.

Signature Analyzer Uses NXP MCU
Doing a signature analysis of a signal used to require an oscilloscope to display your results. In this article, Brian Millier shows how you can build a free-standing tester that uses mostly just the internal peripherals of an NXP ARM microcontroller. He described how the tester operates and how he implemented it using a Teensy 3.5 development module and an intelligent 4.3-inch TFT touch-screen display.

Pitfalls of Filtering Pulsed Signals
Filtering pulsed signals can be a tricky prospect. Using a recent customer implementation as an example, Robert Lacoste highlights various alternative approaches and describes the key concepts involved. Simulation results are provided to help readers understand what’s going on.

PROJECT-BASED STORIES WITH ALL THE DETAILS

Electronic Speed Control (Part 2)
In Part 1, Jeff Bachiochi discussed the mechanical differences between DC brushed and brushless DC (BLDC) motors. This time he dives into basics of an Electronic Speed Controller’s operations and its circuitry. And all this is illustrated via his ESC-based project that uses a Microchip PIC MCU.

Build an Audio Response Light Display
Light shows have been a part of entertainment situations seemingly forever, but the technology has evolved over time. These light shows have their origin in the primitive “light organs” of the 1960s in which each spectral band had its own color that pulsed in intensity with audio amplitudes within its range of frequencies. In this article, Devlin Gualtieri discusses his circuit design that implements a light organ using today’s IC and LED technologies.

AND MORE FROM OUR EXPERT COLUMNISTS

Internet of Things Security (Part 4)
In this next part of his article series on IoT security, Bob Japenga looks at how checklists and the common criteria framework can help us create more secure IoT devices. He covers how to create a list of security assets and to establish threat checklists that identify all the threats to your security assets.

Thermoelectric Cooling (Part 2)
In Part 1 George Novacek described how he built a test chamber using some electronics combined with components salvaged from his thermoelectric water cooler. To confirm his test results, he purchased another thermoelectric cooler and repeated the tests. In Part 2 he covers the results of these tests along with some theoretical performance calculations.