{"id":505,"date":"2016-01-20T21:54:52","date_gmt":"2016-01-21T05:54:52","guid":{"rendered":"http:\/\/pididu.com\/wordpress\/solarbike\/?p=505"},"modified":"2016-01-20T21:54:52","modified_gmt":"2016-01-21T05:54:52","slug":"board-assembly-and-bringup-1","status":"publish","type":"post","link":"http:\/\/pididu.com\/wordpress\/solarbike\/board-assembly-and-bringup-1\/","title":{"rendered":"Board Assembly and Bringup 1"},"content":{"rendered":"<p>I&#8217;m in the process of bringing up the Power Transfer Controller (PTC). When I was 16, I might have loaded everything onto the board at once, then just fired it up. Today, I take a more incremental approach, loading the minimum number of components for the next test. The board is loaded with test points, so testing has been relatively easy so far.<\/p>\n<figure id=\"attachment_508\" aria-describedby=\"caption-attachment-508\" style=\"width: 1000px\" class=\"wp-caption aligncenter\"><a href=\"http:\/\/pididu.com\/wordpress\/solarbike\/files\/2016\/01\/PtcPartialBuild1.jpg\"><img decoding=\"async\" loading=\"lazy\" class=\"size-full wp-image-508\" alt=\"some smt installed\" src=\"http:\/\/pididu.com\/wordpress\/solarbike\/files\/2016\/01\/PtcPartialBuild1.jpg\" width=\"1000\" height=\"750\" srcset=\"http:\/\/pididu.com\/wordpress\/solarbike\/files\/2016\/01\/PtcPartialBuild1.jpg 1000w, http:\/\/pididu.com\/wordpress\/solarbike\/files\/2016\/01\/PtcPartialBuild1-300x225.jpg 300w\" sizes=\"(max-width: 1000px) 100vw, 1000px\" \/><\/a><figcaption id=\"caption-attachment-508\" class=\"wp-caption-text\">Putting together the board is a very manual process for a hobbyist like me. As I solder parts on, I check them off on the Bill of Materials (BOM).  Note the on-the-fly changes to the BOM, either because of parts availability, or design changes to address problems discovered.<\/figcaption><\/figure>\n<p>I&#8217;m soldering by hand with a pair of irons, as I don&#8217;t have an SMT hot air tool. If you want to see how&#8230;<br \/>\n<iframe loading=\"lazy\" src=\"https:\/\/www.youtube.com\/embed\/V3HQigfzzNM\" height=\"315\" width=\"560\" allowfullscreen=\"\" frameborder=\"0\"><\/iframe><br \/>\nCome to think of it, my wife has an embossing hot air wand. I might try to use that to anneal the solder joints later. Maybe.<\/p>\n<figure id=\"attachment_509\" aria-describedby=\"caption-attachment-509\" style=\"width: 1024px\" class=\"wp-caption aligncenter\"><a href=\"http:\/\/pididu.com\/wordpress\/solarbike\/files\/2016\/01\/PtcPartialBuild2.jpg\"><img decoding=\"async\" loading=\"lazy\" class=\"size-full wp-image-509\" alt=\"enough parts to actually convert energy\" src=\"http:\/\/pididu.com\/wordpress\/solarbike\/files\/2016\/01\/PtcPartialBuild2.jpg\" width=\"1024\" height=\"567\" srcset=\"http:\/\/pididu.com\/wordpress\/solarbike\/files\/2016\/01\/PtcPartialBuild2.jpg 1024w, http:\/\/pididu.com\/wordpress\/solarbike\/files\/2016\/01\/PtcPartialBuild2-300x166.jpg 300w\" sizes=\"(max-width: 1024px) 100vw, 1024px\" \/><\/a><figcaption id=\"caption-attachment-509\" class=\"wp-caption-text\">Here is the board with more parts in place. The inductor is just a temporary one. The actual toroid is the yellow thing in the background to the right. Supercapacitors have not been installed yet, nor most of the synchronous rectifiers. \u00a0The board as shown is already capable of converting energy.<\/figcaption><\/figure>\n<p>To bring the board up on the bench, I&#8217;ve substituted a laptop power brick for the solar panel, and use incandescent lamps as dummy loads. Although not all parts are loaded, \u00a0the correct final devices are mounted &#8211; the sole exception being the main inductor. \u00a0The final part has 25 leads, and would be hard to remove if redesign was required.<\/p>\n<p>In addition to my multimeter and scope, I use little test programs to stimulate and test sections of the board. Some of the data is gathered by the PTC&#8217;s own sensors, and printed to a log file.<\/p>\n<p>So far, here are the things that are working. They correspond roughly to the assembly and bringup order:<\/p>\n<ul>\n<li>voltage regulators<\/li>\n<li>visibility flasher<\/li>\n<li>processor<\/li>\n<li>push-button input and indicator LEDs<\/li>\n<li>sensors (characterization data below for my later use)<\/li>\n<li>analog voltage limit comparator<\/li>\n<li>basic power transfer<\/li>\n<\/ul>\n<table width=\"700\" border=\"3\">\n<thead>\n<tr>\n<th>\u00a0Sensor<\/th>\n<th>\u00a0Zero Reading Base<\/th>\n<th>\u00a0Sensitivity<\/th>\n<th>\u00a0Native Reading<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>\u00a0Input Voltage<\/td>\n<td>\u00a00 counts<\/td>\n<td>\u00a0102 mV\/count<\/td>\n<td>\u00a050 mV\/V<\/td>\n<\/tr>\n<tr>\n<td>\u00a0Input Current<\/td>\n<td>\u00a0106 counts<\/td>\n<td>\u00a025 mA\/count<\/td>\n<td>\u00a0200 mV\/A<\/td>\n<\/tr>\n<tr>\n<td>\u00a0Mid Current<\/td>\n<td>\u00a0103 counts<\/td>\n<td>\u00a051 mA\/count<\/td>\n<td>\u00a0100 mV\/A<\/td>\n<\/tr>\n<tr>\n<td>\u00a0Output Voltage<\/td>\n<td>\u00a00 counts<\/td>\n<td>\u00a081 mV\/count<\/td>\n<td>\u00a063 mV\/V<\/td>\n<\/tr>\n<tr>\n<td>\u00a0Output Current<\/td>\n<td>\u00a0103 counts<\/td>\n<td>\u00a051 mA\/count<\/td>\n<td>\u00a0100 mV\/A<\/td>\n<\/tr>\n<tr>\n<td>\u00a0Temperature<\/td>\n<td>\u00a00 counts<\/td>\n<td>\u00a00.51 \u00baC\/count<\/td>\n<td>\u00a010 mV\/\u00baC<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n","protected":false},"excerpt":{"rendered":"<p>I&#8217;m in the process of bringing up the Power Transfer Controller (PTC). When I was 16, I might have loaded everything onto the board at once, then just fired it up. Today, I take a more incremental approach, loading the minimum number of components for the next test. The board is loaded with test points, &hellip; <a href=\"http:\/\/pididu.com\/wordpress\/solarbike\/board-assembly-and-bringup-1\/\" class=\"more-link\">Continue reading <span class=\"screen-reader-text\">Board Assembly and Bringup 1<\/span> <span class=\"meta-nav\">&rarr;<\/span><\/a><\/p>\n","protected":false},"author":1,"featured_media":0,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[2],"tags":[],"_links":{"self":[{"href":"http:\/\/pididu.com\/wordpress\/solarbike\/wp-json\/wp\/v2\/posts\/505"}],"collection":[{"href":"http:\/\/pididu.com\/wordpress\/solarbike\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"http:\/\/pididu.com\/wordpress\/solarbike\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"http:\/\/pididu.com\/wordpress\/solarbike\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"http:\/\/pididu.com\/wordpress\/solarbike\/wp-json\/wp\/v2\/comments?post=505"}],"version-history":[{"count":0,"href":"http:\/\/pididu.com\/wordpress\/solarbike\/wp-json\/wp\/v2\/posts\/505\/revisions"}],"wp:attachment":[{"href":"http:\/\/pididu.com\/wordpress\/solarbike\/wp-json\/wp\/v2\/media?parent=505"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"http:\/\/pididu.com\/wordpress\/solarbike\/wp-json\/wp\/v2\/categories?post=505"},{"taxonomy":"post_tag","embeddable":true,"href":"http:\/\/pididu.com\/wordpress\/solarbike\/wp-json\/wp\/v2\/tags?post=505"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}