MC33035 BRUSHLESS MOTOR DRIVER BREAKOUT BOARD

The board shown here is a breakout board for MC33035 brushless motor controller. It requires an output buffer IPM module or Mosfets to complete the closed loop brushless motor driver. MC33035 IC is the heart of the project; the project provides 6 PWM pulses as well 6 Inverse pulses outputs. On board Jumpers helps to change the Direction, Enable, Brake, and 60/120 phasing  Header connector provided to connect the Hall sensors and supply, on board LED for Power and fault, P1 potentiometer helps to change the speed.

The MC33035 is a high performance second generation monolithic brushless DC motor controller containing all of the active functions required to implement a full featured open loop, three or four phase motor control system. This device consists of a rotor position decoder for proper commutation sequencing, temperature compensated reference capable of supplying sensor power, frequency programmable saw tooth oscillator, three open collector top drivers, and three high current totem pole bottom drivers ideally suited for driving power MOSFETs. Also included are protective features consisting of under voltage lockout, cycle−by−cycle current limiting with a selectable time delayed latched shutdown mode, internal thermal shutdown, and a unique fault output that can be interfaced into microprocessor controlled systems. Typical motor control functions include open loop speed, forward or reverse direction, run enable, and dynamic braking. The MC33035 is designed to operate with electrical sensor phasings of 60°/300° or 120°/240°, and can also efficiently control brush DC motors.

An internal rotor position decoder monitors the three sensor inputs (Pins 4, 5, 6) to provide the proper sequencing of the top and bottom drive outputs. The sensor inputs are designed to interface directly with open collector type Hall Effect switches or opto slotted couplers. Internal pull−up resistors are included to minimize the required number of external components. The inputs are TTL compatible, with their thresholds typically at 2.2 V. The MC33035 series is designed to control three phase motors and operate with four of the most common conventions of sensor phasing. A 60°/120° Select (Pin 22) is conveniently provided and affords the MC33035 to configure itself to control motors having either 60°, 120°, 240° or 300° electrical sensor phasing. With three sensor inputs there are eight possible input code combinations, six of which are valid rotor positions. The remaining two codes are invalid and are usually caused by an open or shorted sensor line. With six valid input codes, the decoder can resolve the motor rotor position to within a window of 60 electrical degrees. The Forward/Reverse input (Pin 3) is used to change the direction of motor rotation by reversing the voltage across the stator winding. When the input changes state, from high to low with a given sensor input code (for example 100), the enabled top and bottom drive outputs with the same alpha designation are exchanged (AT to AB, BT to BB, CT to CB). In effect, the commutation sequence is reversed and the motor changes directional rotation. Motor on/off control is accomplished by the Output Enable (Pin 7). When left disconnected, an internal 25 Μa current source enables sequencing of the top and bottom

drive outputs. When grounded, the top drive outputs turn off and the bottom drives are forced low, causing the motor to coast and the Fault output to activate. Dynamic motor braking allows an additional margin of safety to be designed into the final product. Braking is accomplished by placing the Brake Input (Pin 23) in a high state. This causes the top drive outputs to turn off and the bottom drives to turn on, shorting the motor−generated back EMF. The brake input has unconditional priority over all other inputs. The internal 40 kΩ pull−up resistor simplifies interfacing with the system safety−switch by insuring brake activation if opened or disconnected. The commutation logic truth table is shown in Figure 20. A four input NOR gate is used to monitor the brake input and the inputs to the three top drive output transistors. Its purpose is to disable braking until the top drive outputs attain a high state. This helps to prevent simultaneous conduction of the the top and bottom power switches. In half wave motor drive applications, the top drive outputs are not required and are normally left disconnected. Under these conditions braking will still be accomplished since the NOR gate senses the base voltage to the top drive output transistors.

Continuous operation of a motor that is severely over−loaded results in overheating and eventual failure. This destructive condition can best be prevented with the use of cycle−by−cycle current limiting. That is, each on−cycle is treated as a separate event. Cycle−by−cycle current limiting is accomplished by monitoring the stator current build−up each time an output switch conducts, and upon sensing an over current condition, immediately turning off the switch and holding it off for the remaining duration of oscillator ramp−up period. The stator current is converted to a voltage by inserting a ground−referenced sense resistor. The voltage developed across the sense resistor is monitored by the Current Sense Input (Pins 9 and 15), and compared to the internal 100 mV reference. The current sense comparator inputs have an input common mode range of approximately 3.0 V. If the 100 mV current sense threshold is exceeded, the comparator resets the lower sense latch and terminates output switch conduction. The value for the current sense resistor is:

RS=0.1/ I stator(max)

The Fault output activates during an over current condition. The dual−latch PWM configuration ensures that only one single output conduction pulse occurs during any given oscillator cycle, whether terminated by the output of the error amp or the current limit comparator.

SPECIFICATIONS

  • Supply 12-18V
  • Jumpers for Direction, Enable,60/120 Phasing, Brake
  • LED D1 Fault
  • LED D2 Power LED
  • Pot P1 Speed Control
  • CN1 6 PWM Outputs
  • CN3 6 Inverse PWM Outputs
  • CN4 Supply Input
  • CN2 Hall Sensor Interface
  • Frequency 18 KHz

SCHEMATIC

PARTS LIST

CONNECTIONS

INTERNAL DIAGRAM

OUTPUT VS HALL SENSOR

ROTOR POSITION PULSE SEQUENCE

PHOTOS

PCB

4A PWM CONTROLLED UNIPOLAR STEPPER MOTOR DRIVER USING STK672-740

The project published here is a high-performance Unipolar stepper motor driver that offers PWM controlled high current output. An Arduino board and the project published here can be combined to create a good Unipolar stepper motor driver with micro-stepping, supply 36v DC and load current up to 4A. This board requires a sequence of 4 phase pulses which can be feed and generated using Arduino or any other microcontrollers.  IC incorporates various functions like built in over current detection, over heat output OFF, fault output (active low) when over current or over heat detected, and also has built in power on reset. LED D2 is the power indicator, LED D1 indicates a fault. PR1 trimmer potentiometer provided to set the current. Refer to datasheet of STK672-740 for pulse sequence and timing information. The projects supports 5 Wire, 6 Wire and 8 Wire Stepper Motors in unipolar mode.

The board works perfectly with motor supply up to 36V DC, however motor power supply is possible to go up to 50V DC, in this case remove LM317 regulator, and supply 5V from external power supply.

FEATURES

  • Motor Supply 36V DC ( Up to 50V DC Possible Read Note)
  • Logic Supply 5V DC ( On Board LM317 Regulator Provides 5V)
  • Motor Load Up to 4Amps
  • Required large size heat sink for IC
  • Built-in overcurrent detection function, overheat detection function ( output current OFF)
  • Fault signal ( active low) is output when over current or overheat is detected
  • Built-in power on reset function
  • Phase signal input driver activated with an active low and incorporates a simulation ON prevention function
  • Supports Schmitt input 2.5V high level input
  • Incorporating a current detection resistor, motor current can be set using trimmer pot
  • Enable pin can be used to cut output current while maintaining the excitation mode.
  • PCB Dimensions 30.32MM x 44.04MM

SCHEMATIC

PARTS LIST

BLOCK DIAGRAM

INPUT SIGNALS

INTERFACE

CONNECTIONS

PHOTOS

PCB

15A 100V ISOLATED HALF-BRIDGE DRIVER

15 A 100V Isolated Half bridge driver project intended to be used for DC-DC converters, inverters, LED driver and motor driver applications. This projects is really helpful in industrial applications where noise is a concern since project provides optical isolation between microcontroller and high current output. ADuM4224 isolated precision Half-Bridge driver is the heart of the project. IRFR120 dual Mosfet is used as output driver. MOSFET can be replaced as per application requirement of voltage and current rating. The ADuM4224 isolators each provide two independent isolated channels. They operate with an input supply voltage ranging from 3.0 V to 5.5 V, providing compatibility with lower voltage systems. In comparison to gate drivers employing high voltage level translation methodologies, the project offers the benefit of true, galvanic isolation between the input and each output. Each output can be continuously operated up to 537 V peak relative to the input, thereby supporting low-side switching to negative voltages. The differential voltage between the high-side and low-side can be as high as 800 V peak. Refer to truth table for operation conditions. The board tested with input frequency of 100 KHz but will support frequency up to 1 MHz. CN3 connector provided for logic signal and supply input, CN1 Output drive supply , CN2 load supply input, CN4 for load connection.

The ADuM42241 is 4 A isolated, half-bridge gate driver that employ the Analog Devices, Inc., iCoupler® technology to provide independent and isolated high-side and low-side outputs. The ADuM4224 provides 5000 V rms isolation in the wide-body, 16-lead SOIC package. Combining high speed CMOS and monolithic transformer technology, these isolation components provide outstanding performance characteristics superior to the alternatives, such as the combination of pulse transformers and gate drivers.

Note : Output MOSFETs can be used as per application requirement of voltage and load current, supply input will be depend on MOSFET.

 Features

  • Supply Output Side 12V DC ( 5V-18V Possible Refer Note)
  • Supply VDD1 5V-12V DC
  • Input Signal VIA/VIB 3V to 5V
  • Frequency Up to 1Mhz
  • PCB Dimensions 57.04mm X 48.12 mm

SCHEMATIC

PARTS LIST

CONNECTIONS

ADUM4224 TRUTH TABLE

PHOTOS

PCB

3V TO 5V BOOST DC-DC CONVERTER USING MAX711

The circuit shown here is a compact and high-efficiency boost converter that has been designed for hand-held equipment. This boost converter converts 2 cells (3V) DC power into 5V DC with output load current up to 500mA. Typical efficiency when boosting battery inputs is 85%. The circuit is based on MAX711 which integrates a step-up DC-DC converter with a linear regulator to provide step-up voltage conversion. The circuit is optimized for battery applications where the input varies above and below the regulated output voltage. The project has an input range from +1.8V to +11V. The circuit is set for 5V output but it has an adjustable output that can be set from +2.7V to +5.5V with the help of two R3, R4 resistors. The IC contains a comparator for low battery detection. If the voltage at LBI+ falls below that at LBI- (typically connected to REF), LBO goes low. Hysteresis is typically 50mV. You can set the low-battery monitor’s threshold with two resistors, R1 and R2.

The MAX711 integrate a step-up DC-DC converter with a linear regulator to provide step-up/down voltage conversion. The step-up switch-mode regulator contains an N-channel power MOSFET switch. It also shares a precision voltage reference with a linear regulator that contains a P-channel MOSFET pass element. Step-Up Operation A pulse-frequency-modulation (PFM) control scheme with a constant 1μs off-time and variable on-time controls the N-channel MOSFET switch. The N-channel switch turns off when the part reaches the peak current limit or the 4μs maximum on-time. The ripple frequency is a function of load current and input voltage.

FEATURES

  • Supply Input Two AA Cell- 3V DC (+1.8V to +11V Range)
  • Output 5V DC (Adjustable 2.5V to 5.5V)
  • Output Load 500mA Maximum
  • Efficiency for battery input is 85%

SCHEMATIC

PARTS LIST

CONNECTIONS

PHOTOS

VIDEO

PCB

50V TO 5V @7A SYNCHRONOUS BUCK (STEP-DOWN) CONVERTER

This module is a non-isolated 7A DC-DC converter. The module can convert any DC voltage between 7V to 50V to a 5V DC with load current up to 7A. The project has been designed around LM5116 Wide Range Synchronous Buck Controller IC. The design includes 6uH toroid inductor and two N channel MOSFETS. The operating frequency is 250 KHz.

The LM5116 is a synchronous buck controller intended for step-down regulator applications from a high-voltage or widely varying input supply. The control method is based upon current mode control utilizing an emulated current ramp. Current mode control provides inherent line feed-forward, cycle-by-cycle current limiting, and ease-of-loop compensation. The use of an emulated control ramp reduces noise sensitivity of the pulse-width modulation circuit, allowing reliable control of very small duty cycles necessary in high-input voltage applications.

The operating frequency is programmable from 50 kHz to 1 MHz and the LM5116 drives external high-side and low-side NMOS power switches with adaptive dead-time control. A user-selectable diode emulation mode enables discontinuous operation mode, for improved efficiency at light load conditions. A low quiescent current shutdown disables the controller and consumes less than 10 µA of total input current.

Additional features include a high-voltage bias regulator, automatic switch-over to external bias for improved efficiency, thermal shutdown, frequency synchronization, cycle-by-cycle current limit, and adjustable line under-voltage lockout. The device is available in a power enhanced HTSSOP-20 package featuring an exposed die attach PAD to aid thermal dissipation.

FEATURES

  • Wide Operating Range 7V – 50V
  • Output 5V DC
  • Load Current Up To 7Amps
  • Thermal Shutdown
  • Operating Frequency 250Khz
  • PCB Dimensions 45.04 x 22.82 mm

SCHEMATIC

PARTS LIST

CONNECTIONS

PHOTOS

PCB

SINGLE 18650 LIPO BATTERY TO 5V BOOST CONVERTER

This small board is based on the CS5171 boost converter from ON Semiconductor. The board is configured to be used with a single 18650 LiPo battery. The circuit converts single-cell 3.7V LiPo battery voltage to 5V with a load current up to 400mA. Board has been designed to fit on the backside of a single-cell battery holder with a screw. The CS5171 IC is a 280 kHz switching regulator with a high efficiency, 1.5 A integrated switch.

FEATURES

  • Supply Input 2.7V-3.7V (Single Lipo Battery)
  • Output 5V
  • Output Current 400mA
  • Operation Frequency 280 kHz
  • Very Tiny Board Designed to Fit On Back Side Of LIPO Battery Holder
  • PCB Dimensions 44.27 x 11.01 mm

SCHEMATIC

PARTS LIST

CONNECTIONS

PHOTOS

PCB

USB (5V) TO DUAL OUTPUT +/-15V OR +/-12V STEP-UP DC-DC CONVERTER

This USB to dual output step-up DC-DC converter has been designed to be used in industrial automation control equipment, sensors, isolated operational amplifiers and test & measurement equipment that require bipolar supply voltages. The module provides +/-15V or +/-12V DC load current up-to +/-100mA. An onboard PCB solder jumper is provided to set the output voltage 15V or 12V DC. The project typically provides 75 to 82% efficiency over most of the load range. It operates with current-mode feedback at 200Khz.

The MAX743 DC-DC converter IC contains all the active circuitry needed to build small, dual-output power supplies. Relying on simple two-terminal inductors rather than a transformer, the MAX743 regulates both outputs independently to within +/-4% overall conditions of line voltage, temperature, and load current.

FEATURES

  • DC Input USB Power Or 5V DC
  • Output Dual 15V Or 12V DC Load Up-to +/-100mA
  • Easy to Use USB Connector
  • J1 PCB Jumper To Set 15V or 12V Output
  • Header Connector for Output
  • Efficiency 75 to 82%
  • Operation Frequency 200 kHz
  • On-Board Power LED
  • PCB Dimensions 56.37 x 19.19mm

SCHEMATIC

PARTS LIST

CONNECTIONS

PHOTOS

VIDEO

PCB

200W LAMP FLASHER

200W Lamp Flasher kit is used to flash lamps, bulbs and halogen lamp to give your product that attracting look.

  • Input supply – 6 ~ 12 VDC
  • Output – upto 200 W lamp / bulb load
  • Optically isolated Mains supply
  • Onboard preset to adjust the frequency (speed) of flashing (1 Hz to 5 Hz)
  • Power Battery Terminal (PBT) for easy input 230 VAC mains and load connection
  • Terminal pins for connecting DC power supply
  • Four mounting holes of 3.2 mm each
  • PCB dimensions 36 mm x 68 mm

SCHEMATIC

schematic

specsPARTS

parts

 

PCB

555 STEPPER PULSE GENERATOR

The 555 Stepper Pulse Generator kit will help you with the pulse required to drive your favorite DC Servo Motor application.  This kit uses the famous 555 timer IC for generating the Stepping Pulse.

  • Input – 5 – 12 VDC @ 25 mA
  • TTL/CMOS interfaceable
  • Jumper selectable two speed operation
  • Onboard preset to vary the duty cycle
  • Power-On LED indicator
  • Terminal pins for easy interfacing of the kit
  • Four mounting holes of 3.2 mm each
  • PCB dimensions 39 mm x 37 mm

SCHEMATIC

schematic

 

DOWNLOADS

10 factors that affect the transmission range of DIY FM Transmitters

BuildCircuit sells several types of FM transmitters for electronics beginners and hobbyists. Some are for short-range and some for long-range transmission. Sometimes, customers complain that they didn’t get the mentioned quality or the required range of transmission. In this article, I am explaining 10 factors that affect the transmission range as well as the transmitted sound quality of DIY FM transmitters.

  1. Design of the FM transmitter: Some hobby FM transmitters are designed with 3 transistors and 3 inductors and some are designed with only one transistor and one inductor. All the FM transmitters with 3 transistors have an audio amplifier circuit whereas the single transistor FM transmitters have only the oscillator circuit, there is no extra amplification for frequency modulated signal. That’s why the transmitters with 3 transistors perform better than the other one. The resistors and the capacitors placed in the circuit have a huge role in determining how far the signal can go. Usually, the designers of the transmitter have a tentative range in their minds. Based on their objective, they choose the components or design the PCB in such a way that their transmitter would transmit the signal up to a certain range with a certain quality. For example, we usually see S9018(AM/FM Amplifier, Local Oscillator of FM/VHF Tuner) and S9014(for pre-amplifier) transistors in most of the FM transmitters. If you see their datasheets, you will know why they are used.

2. Antenna length: I have noticed that increasing the length of the antenna also extends the range of transmission. I tested the long-range 3 transistor FM transmitters with a 20cm long antenna first and it could transmit up to 100 meters, but when I increased the length to 60cm, the signal was transmitted up to 500 meters easily. If you a longer antenna in any FM transmitters, you get better reception and they travel farther.

3. Type of FM receiver- digital or analog: Digital FM receivers are far better than analog receivers to test the transmitters. The first advantage, we know the exact frequency the transmitter is transmitting to the receiver.  We can search for a free frequency on a digital FM receiver than on an analog one. If we can find a free frequency, we can use that for transmitting our signal without interrupting the commercial FM broadcast signals. It is illegal to interrupt the commercial FM stations in several countries.

In analog FM receivers, the tuning is not precise. The transmission from two commercial FM broadcasts also overlaps with each other.  When the transmission signal is strong, it overlaps the commercial broadcast signals and the audio is heard clearly on the receiver. Once we go far away from the transmitter(beyond the transmission range), the signal fades away and the commercial broadcast is heard again. In order to eliminate the overlapping of signals and distortion, it is recommended that we use a digital FM receiver.

4. Antenna of the FM receiver: Most of the commercial FM receivers come with a telescopic antenna. Their reception is excellent. It is recommended that you use a receiver with a telescopic antenna. When we use the FM feature of a mobile phone, the reception is not as good as the commercial FM broadcasts. However, you can use your phone to test the transmitter. But, there is no guarantee that the phone’s FM receiver can receive the signal to the maximum transmission range.

5. Power: If a transmitter has a power supply rating from 3V to 9V, the transmission is stronger at 9V than at 3V. At 3V, you will not get the same signal strength as you would get with a 9V battery.

6. Transmission method- voice or audio: If you transmit the FM signal connecting it to an audio source, for example, a mobile phone or an mp3 player, the transmitted audio signal is stronger than the voice-activated signal. A voice is converted to an electrical signal by the electret microphone, that electrical signal is oscillated and transmitted as an electromagnetic wave, it would never be as strong as the direct audio signal. The audio signal is an electrically activated signal which can be controlled by a volume controller also and amplified according to our needs. Therefore, audio signals directly fed from an audio source are transmitted farther than the normal voice signal.

7. Volume controller- audio booster: Two of our FM transmitters have a volume controller. I have noticed that the volume controller contributes to the strength of the transmitted signal which eventually determines how far the signal would travel. The following transmitters have a volume controller:

a. FM transmitter with 3 transistors- Basic (with no tuning)

b. FM transmitter with 3 transistors- Advanced (with tuning)

8. Transmitter location: Where are you transmitting from? Your FM transmitter will give better results in an open space rather than in an urban area with a lot of buildings or obstacles. Make sure that you transmit the signal from a height (if possible) so that the signal can travel farther. I tested all of my transmitter from a height (7-10m), usually the second or third floor of a building, and also tested them from the ground floor, I found the transmission quality and range vary drastically. Testing the transmitter from a height gives the best result, that’s why commercial FM stations’ antennas are kept in hills or on top of buildings.

9. The transmitting or receiving frequency: The frequency we are transmitting to should be free in order to avoid the overlapping of signals. Usually, when we use an FM transmitter without a variable capacitor or variable inductor(for example, FM transmitter with 3 transistors- Basic), the transmitter transmits its signal at a random frequency, which we cannot change. For example, the FM microphone and FM transmitter with enclosure do not have a variable capacitor or inductor.  That completely restricts the transmitters from changing their frequency which ends up overlapping the commercial FM signal. It is very important the transmitter transmits to a free frequency that is not used by commercial stations. If we transmit to an occupied or a closer frequency, there is a high chance of hearing distortion. As we go far away from the transmitter, the commercial FM overtakes its original frequency and our FM signals fade away.

These transmitters do not  have a variable capacitor or inductor

10. Weather: Weather has impacts on the capacitance and inductance of the circuit. Even negligible change in its electric parameters can drift the frequency of the transmitter. The wind, atmospheric pressure, temperature and humidity also have effects on the transmission. Please read these three interesting articles:

We are selling these FM transmitters

Sold out
BC-56145

Type 1- Long range DIY FM transmitter with 3 transistors and 3 inductors

US $11.95
  • Long-range FM transmitter: 100m-500m. Tested several times
BC-4614345

Type 2- Long range DIY FM transmitter with 3 transistors and 3 inductors

US $8.38
  • Long-range FM transmitter: 100m-300m. Tested several times

DARK SENSITIVE SWITCH

Dark Sensitive switch project based on single BC547 transistor, Relay operates when light that falls on the LDR, goes below a set point. It’s very simple and low cost dark sensitive switch required few components.

FEATURES

  • Input : 12 VDC @ 55 mA
  •  Relay output : NC – C – NO
  •  Onboard preset to set the level
  •  Power-On LED indicator
  •  Relay On LED indicator
  •  Screw terminal connector for easy relay output connection
  •  Four mounting holes of 3.2 mm each
  •  PCB dimensions 44 mm x 40 mm

SCHEMATIC

schPARTS

bom

PCB

DC MOTOR DRIVER USING L293D

This project is a DC motor driver, suitable for motors of low or medium power. Allows controlling up to 6 motors or 3 motors if you want to control the rotation of the motors.

DESCRIPTION

The controller is build around the IC L293D that can provide 600mA per channel, and a H-Bridge designed with transistors NPN and PNP transistors, than can provide 1.15A per channel.

The controller has the following connections:

  • INPUTS (A, B, C, D ,E, F). These are receiving the analog or digital signals that can be sent for example, from a microcontroller.
  • ENABLE (E1-2, E3-4). These activate the inputs from the L293D. The supply voltage can’t be higher than 7V.
  • OUTPUTS (+M1, -M1, +M2, -M2, +M3, -M3). Here is where the motors should be connected.
  • +9-12V. Here’s where is connected a supply voltage that will give power to the motors. This input, gives voltage in the L293D and the H-Bridge, the supplied voltage have to be 36V max, but for the H-Bridge it’s recommendable to use 24V max. (In case you want to use only the L293D, you can remove the jumper).
  • +5V. This input receive the logic supply voltage for the L293D. You can connect a supply voltage higher than 5V because this input it’s connected to a voltage regulator (LM7805), but you not must to exceed 30V.

DC_motor_driver_photo_6

SCHEMATIC

Schematic

CONNECTIONS

Example_Connection

PCB

3D_pcb

3D PCB

DC_motor_driver_photo_1

DC_motor_driver_photo_2

DC_motor_driver_photo_33D PCB Render

photo_1

photo_2

photo_3

photo_4

 

TRIAC BASED LAMP DIMMER

Triac based Indecent lamp dimmer is a simple circuit and it doesn’’t requires additional power supply, works directly with 110V AC or 230V AC.

DESCRIPTION

It is a low cost dimmer circuit for adjusting the light brightness of incandescent, Halogen Lamp, Light Bulb load up to 250 W.

FEATURES:

– Input supply: 230 VAC or 110 VAC
– Output: 250 W
– Triac controlled
– On board Potentiometer for adjusting level
– Power Battery Terminal (PBT) for easy input / output connection
– Four mounting holes of 3.2 mm each
– PCB dimensions 40 mm x 34 mm

SCHEMATIC

SCH

CIRCUIT DESCRIPTION

This kit consists of BT 136 Triac, resistors and capacitor.  CN1 connector is for Load connections and CN2 connector for power supply connections.

BT136: It is a sensitive gate Triac, used in general purpose bidirectional switching and phase control applications where high sensitivity is required.

DB3: It is a DIAC that functions as a trigger diode with a fixed voltage reference.  It can be used in conjunction with Triac for simplified gate control circuits or as a starting element in fluorescent lamp ballasts.

WORKING PRINCIPLE

This kit is used as a Light dimmer kit.  It is used to adjust the brightness of the Halogen Lamp, Light Bulb up to 250 W.  A power supply of 230 or 110 VAC is supplied to the kit at CN 2 connector and a light bulb is connected at the CN 1 connector.  Using the POT we can adjust the brightness of the bulb.

APPLICATIONS

It is used to adjust the brightness of incandescent, halogen lamp, light bulb up to 250 W.

PARTS LIST

BOM

 

PCB

MICROCONTROLLER BASED RUNNING LIGHT CONTROLLER

This project is a lights effects board using common bulbs.

DESCRIPTION

This project provides some lighting effect by the blinking pattern of the bulbs connected at its output. Up to 8 Bulbs can be connected in between connector CN2 to CN9 and AC power to control them should be connected at Connector CN10. DC Power should be applied at Connector CN11 in accordance with the polarity marked on this connector. Care should be taken while using this it as it contains Main Power on the board.

We can change the Blink pattern by the press of the SET switch and change the blinking speed by the press of the UP and DOWN keys on the PCB. Fuse F1 will protect the Kit from any possible short circuit and excess current flowing through it.

FEATURES:

  • Microcontroller based design for greater flexibility and ease of control
  • Triac based switching of loads connected to the circuit
  • Industry standard isolation with the help of Opto enabled Triac Control
  • Fuse protection for AC output
  • SUPPLY 9-12V DC & 230V AC
  • LOAD-100W max on each output
  • Simple and easy to use 3 tactile switch enabled control of the project
  • PBT type connector for connecting supply (AC/DC) and TRIAC output on the PCB
  • Onboard regulator for regulated supply to the project
  • Diode protection for reverse polarity connection of DC supply to the PCB
  • Four mounting holes of 3.2 mm each
  • PCB dimensions 86 mm x 173 mm

SCHEMATIC

schematic

PARTS LIST

BOM

PCB

RGB LED DISCO LIGHTS

This project is a microcontroller based RGB LED lights effects.

DESCRIPTION

RGB LED disco light is a simple project designed around PIC16F72 microcontroller.

This firmware is a RGB driver, as name suggests it is used to derive or light red, green and blue LEDs in particular fashion. Its main feature is the pattern shown on LEDs. It is quite difficult to describe pattern in words but we want to specify that first it will derive red then green then blue three times and then a particular pattern is shown on LEDs and again the three LEDs light.

In this project we have used PIC 16F72 microcontroller. The various pin configurations are shown below:

  • OUTPUT: PORTC
  • Red Led: PORTC.F0
  • Green Led: PORTC.F1
  • Blue Led: PORTC.F2
  • External Oscillator (crystal: 4MHz)
  • Microcontroller: PIC 16F72
  • SUPPLY : 12-18V DC

SCHEMATIC

RGB_LED_Based_Disco_Lights_main_board_schematic

RGB_LED_Based_Disco_Lights_LED_Board_Schematic_th

PARTS LIST

RGB_LED_Based_Disco_Lights_main_board_BOM

RGB_LED_Based_Disco_Lights_led_board_BOM

PCB

LED VU METER WITH LM3916

This project is a LED VU meter based on LM3916.

DESCRIPTION

LM3916 is a dedicated IC for VU LED meter. Unlike LM3915 which have 3dB step between voltage levels, the LM3916 have nonlinear steps: -20, -10, -7, -5, -3, -1, 0, +1, +2, +3db, just like old school analog VU meters. I saw in YouTube an interesting commercial LED VU meter, which imitates the needle movement in analog VU meters and I thought I can make a similar one. All I needed I found in the datasheet of LM3916.

 The LM3916 can be feed with AC signal without any rectification, but I wanted to implement a precision full wave rectification. I chose the schematic on page 13, fig.21 of the datasheet: “Precision Full-Wave Peak Detector”.

The LEDs are connected via sockets J3 to J12 (only one row LEDs is shown on the schematic) and I found that it’s cheaper to use a 28 pin IC sockets cut in half than regular 40 pin sockets. Of course LEDs can be soldered directly on the PCB.

The schematic needs bipolar power supply to work correctly, but the negative rail can be as low as -5V or even -3.3V. The positive rail must be bellow +25V and combined voltage of negative and positive rails must not exceed 36V. The minimum positive rail voltage depends on the voltage of the LEDs. For example if the LED have 1.9V forward voltage and we have 7 LEDs on one pin, then the minimum positive voltage will be 7*1.9V + 1.5V (drop voltage at LM3916) = 14.8V. The green LEDs usually have little higher forward voltage – 2.2V – 2.4V, so +18V will be sufficient in most cases.

The LEDs current is determined by R1_REF, and with 2.2k resistance it will be 5 – 6 mA.
The formula is Iled = 10 * (1.2V / R1_REF).

IC2 is connected as precision full wave rectifier and can be any general purpose dual opamp – TL072, TL082, LF353.

The output mode can be set with 3-pin jumper JP1. Shorting pins 1-2 will set the bar mode and shorting pins 2-3 will set the dot mode.

The max input voltage of the LM3916 is set to 1.2V, and with R8-R7 we can adjust the input level.

The color of the LEDs is your choice. I used green LEDs for negative levels, yellow for 0dB and red for positive levels. For this project I bought transparent rectangular LEDs, but they have two drawbacks. First – when one column lights up the adjacent columns also significantly lights up. My solution was to paint the sides of the LEDs with black marker. There also can be used a black tape around the entire collumn.

Second drawback is that because of the transparency, the LEDs emit light from one point, which is not very pleasant. The solution here was to rasp the top side of the LEDs with rough file, so the light to diffuse more even.

SCHEMATIC

LED_VU_Meter_(schematic)

 

PCB

2 CHANNEL RELAY BOARD

This project is a 2 Channel Relay Board.

DESCRIPTION

2 channel Relay driver project can be controlled by feeding 2-12V trigger voltage, Very useful project for application like Micro-Controller based projects, Remote controller, Lamp on Off, and any circuits which required isolated high current and high voltage switching by applying any TTL or CMOS level voltage. Two LED works as operation indicator while in , 3 pins screw terminals to connect load and provides  both normally open and normally closed switching.

  • Input: 12 VDC @ 84 mA
  • Output: Two SPDT relay
  • Relay specification: 5 A @ 230 VAC
  • Trigger level : 2 to 12 VDC
  • Header connector for connecting power and trigger voltage
  • LED on each channel indicates relay status
  • Power Battery Terminal (PBT) for easy relay output connection
  • Four mounting holes of 3.2 mm each
  • PCB dimensions 49 mm x 68 mm

SCHEMATIC

2_Channel_Relay_Board_SCHEMATIC

CONNECTION

2_Channel_Relay_Board_CONNECTIONS

PARTS LIST

2_Channel_Relay_Board_BOM

PCB

USB SINGLE CELL LIPOLY CHARGER

Lithium Polymer Batteries are a very common source of power today. Many electronics gadgets have one inside, and they have some reasonable features. I’ve bought great batteries, with different sizes and capacities for my electronics projects. So long I’m using this batteries, coming the problem: charge them.

CHARGER VERSION 1

So, we start to find the correct circuit for my DIY charger. After some Google research I found the Maxim MAX1811 IC. It’s a single-cell Lithium battery charger that can be powered directly from a USB or from an external supply up to 6.5V. It’s use a SO-8 Package, easy to solder and can be sampled at Maxim. Other chip features are:

You can select between 4.1V and 4.2V battery regulation point;

• You can select between 100mA and 500mA current drain from USB;

• There’s a open drain pin (pin_8) for signaling end of charge condition (2.5V < VBATT < BATT Regulation Voltage);

• A internal thermal loop limits the MAX1811 die temperature to +135°C by reducing the charging current as necessary.

According to datasheet, MAX1811 is specifically made for USB devices. The minimum voltage to a common USB-powered device may be as low as 4.35V when cable and connector drops are considered. The MAX1811 is optimized for operation at these low input voltage levels. But USB hubs may also provide as much as 5.5V!. At high input voltages (5.5V) and low cell voltages (2.7V), the MAX1811’s thermal loop may limit the charge current until the cell voltage rises.

My design uses 500mA was charging current (pin 2 – SELI – pulled up), but MAX1811 only taken this current if the device is a USB powered source. The other parts are two very common tantalum capacitors and a LED for charging indication. LED is ON on charging state, and OFF when it’s end.

Above you see the schematics and PCB of my version 1:

Schematic_1

PCB_1

USB_LiPoly_Charger_5

CHARGER VERSION 2

Once I’ve finished the version 1 and tested working fine, I look at the board and think “Why the hell I can’t put a USB Type A male connector on board?”. Well, that’s why there’s some project versions.

After redesign the circuit, the result was very good, with a new compact board, that now is able to handle batteries with the common JST connector. See the pictures:

Schematic_2

PCB_2

SAMSUNG DIGIMAX A503

CONCLUSION

Was a first incursion on LiPo chargers, this project end was success to me. The tests show that MAX1811 is a reliable choice and good alternative over other common choices, like MAX1555 IC.

The thermal loop gives some security to device, so you can connect it to your PC or notebook without fear.

The Eagle files can be downloaded from my blog at http://rusticengineering.wordpress.com. Any question, email me.

SAMSUNG DIGIMAX A503

SAMSUNG DIGIMAX A503

 

PCB

LASER DIODE DRIVER

Laser Diode Driver project will help you safely drive (constant current) a 3 mW visible Laser Diode for your application.

  • Input supply – 2.5 to 6 VDC
  • Onboard preset to adjust the current flow to the Laser Diode
  • Power-On LED indicator
  • Header connector for easy input supply and LASER DIODE module connection
  • Laser diode is not included
  • Circuit is designed around Sanyo DL3148-025 LASER DIODE
  • PCB dimensions 37 mm x 42 mm

SCHEMATIC

LASER DIODE DRIVER SCHEMETIC

PARTS LIST

LASER DIODE DRIVER BOM

 

PCB

SINGLE CHANNEL SMD RELAY DRIVER

SPECIFICATIONS

  •     Input supply 12VDC @ 42 mA
  •     On Board 5V Regulator provides 5V output
  •     Output SPDT Relay
  •     Relay specification 5 A @ 230 VAC
  •     Trigger level 2 ~ 9 VDC
  •     Header connector for connecting power and trigger voltage
  •     Relay operations status LED
  •     Power LED
  •     Tiny Design
  •     Screw terminal connector for easy relay output connections

I040B

SCHEMATIC

SINGLE CHANNEL RELAY SCH

PARTS LIST

BOM

PHOTOS

I040D

PCB

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