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Friday, January 24, 2020

How to make a 1.1 ported speaker box with 20 Watt amplifier


In this post, I have shown how to build a ported or vented 1.1 speaker box which
has one 4 ohm tweeter, one 4 inches 4-ohm woofer with DIY 20-watt amplifier with
bass/woofer & volume control.

Video

You can check the video for the construction

Theory

The main component of the speaker box is its amplifier. The amplifier is built using
the IC TDA2005 which gives an output around 20 watts. The power to the amplifier
is supplied using the transformer & regulated using the IC LM338. The
amplifier is designed in such a way that it can also accept input from an external
amplifier. The amplifier also has the option of controlling the bass or volume using
the two potentiometers.
Now coming to the speaker box, the speaker box is built using the MDF sheets.

Features of the amplifier

  • Vented or Ported Speaker
  • Volume & Bass Control
  • Can accept input from an external amplifier

Things & Components you need

  • 1 * TDA2005
  • 1 * LM338
  • 6 * 1N4007
  • 1 * 4 Ohm Speaker
  • 1 * 4 Inch 4 Ohm Woofer
  • 1 * Electrolytic Capacitor 2200uF/25V, 10uF/25V, 4.7uF/25V, 0.22uF/25v, 1000uF/25V, 2.2uF/25V
  • 3 * Electrolytic Capacitor - 100uF/50v
  • 5 * Ceramic Capacitor - 0.1uF
  • 2 * Ceramic Capacitor - 0.22uF
  • 1 * Metal Film Capacitor - 0.47nF
  • 1 * 5k Trimmer
  • 1 * 10k & 47k Normal Pot or Logarithmic Pot
  • 2 * 1k Ohm, 10 Ohm, 1.5 Ohm
  • 1 * 120 Ohm, 680 Ohm
  • 1 * Switch
  • 1 * 220v to 15-0 1 Amp transformer or 220v to 12-0 1 Amp transformer
  • Connectors like RCA, MDF Sheets & tools

Affiliate Links

Banggood
Amazon India
Amazon USA & UK
AliExpress

Making

You can create the circuit on a perf board or order a professional PCB board by
downloading the Gerber file shared at the bottom of the page. I recommend using
a professional board so you can avoid unwanted noise in the output. The Gerber file
shared was created using KiCad software which is one of the recommended CAD
software by the fabricator that I am using. The fabricator that I am using is
JLCPCB.com you can check them by Clicking Here, they provide very good quality
PCB board for a very cheap price. After you receive the board assemble the board
as shown in the video.
Once the board is assembled connect all the connectors which are necessary like
RCA Jacks, switch.
Once all the assembly is done, the first thing you need to adjust is the input
voltage. The input voltage should be around 12.5 to 14.5v. To adjust the voltage
connect two wires to the Vtp (voltage test point) on the amplifier board &
then connect the wires to the multimeter & adjust the voltage using the
trimmer RV1.

Circuit Diagram




Circuit Diagram used for fabrication




How to connect this speaker to an external amplifier

While connecting to an external amplifier make sure your speaker is not connected
to the power. The power required by the speaker is provided by the amplifier so we
do not need the speaker to be connected to the power. Now coming to the
connection, connect the output of the amplifier to the RCA Jack which says Amp
In/T Out (Amplifier In/Tweeter Out) & Amp In/SW Out (Amplifier
In/SubWoofer Out). Make sure the output of the amplifier is not too much the
speaker & woofer your using. Always check the output watts of your amplifier
before connecting it to the speaker.

How to connect this speaker to an external speaker

Connect the external speaker to the RCA Jack which says Amp In/T Out (Amplifier
In/Tweeter Out) & Amp In/SW Out (Amplifier In/SubWoofer Out)

Speaker & Amplifier Board Connection

This section of the article is only if you're using the PCB board design I shared
Potentiometer Connection
The 47K pot is for Woofer/Bass control & 10K is for volume control.




Speaker Connection
Many woofers are polarized so make sure while connecting you connect it to the
right polarity




RCA Connection
This is to connect to an external amplifier or to connect an external speaker.




Transformer Connection




Audio In Connection




Speaker Box Dimensions

Please note I am only sharing the external dimensions, so please make the joint,
connectors & speakers adjustment according to your requirement.
Front, Back, Top & Bottom
Width - 14cm, Length - 22cm & Thickness - 0.8cm
Sides
Width - 22cm, Length - 22cm & Thickness - 0.8cm

How to make an Electronic Dice


In this post, I have shown how to build an Electronic Dice. The electronic dice I
have shown is a double dice & it can also be used as single dice.

Video

You can check the video for the construction

Theory

The electronic dice has two main components. The two main components are
CD4017 which is decade counter & 555 Timer.
Now coming to the working the 555 timer provides the necessary clock required by
the CD4017. The CD4017 once provided with the clock signal will start the counter.
The counter sequence generated by the CD4017 will be in order but the dice
requires random numbers so the following will be done
  • First, the count is limited to certain numbers. If you see the circuit diagram the Pin 1 (Q5) is given to the Pin 15 (Reset) which will reset the count to the starting point
  • Even after the first step, the counter will be in order, For randomizing the count we use resistors & transistors. This can be arranged in any order.

Features of the amplifier

  • Single or Dual Dice
  • Can operate with a wide range of voltage (5 to 12V)

Things & Components you need

  • 2 * IC 4017
  • 1 * IC 555
  • 1 * 1uF/25V
  • 14 * LEDs
  • 5 * 1K Ohm
  • 6 * 470 Ohm
  • 16 * 10K ohm
  • 2 * BC557
  • 6 * BC547

Affiliate Links

Banggood
Amazon India
Amazon USA & UK
AliExpress

Making

The Gerber file shared was created using KiCad software which is one of the
recommended CAD software by the fabricator that I am using. The fabricator that
am using is JLCPCB.com you can check them by Clicking Here, they provide very
good quality PCB board for a very cheap price & they ship the products within 
two days. After you receive the board assemble the board as shown in the video.
Once the board is assembled connect all the connectors which are necessary like
DC Jacks, switch.
Once all the assembly is done, power the circuit & enjoy your board games
like Snake & Ladder or Ludo.

Circuit Diagram

This can be downloaded from the link given under download section along with the
Gerber & the drill file. Also, note there are two parts to the circuit diagram



The first part which is shown above can be used as a single dice without any
modification



The above circuit diagram can be combined with the first circuit diagram to
achieve the dual dice.

Building high performance 70 Watt audio power amplifier with mute function


In this post, I will share the details on how to make a high performance 70 Watt 
audio power amplifier with mute function using IC LM3886TF.

Video

You can check the video for assembly of the amplifier & also for the testing of the 
amplifier

Theory

The main component of the amplifier is LM3886TF which is a high-performance
audio power amplifier with mute function. The IC package which I used in my video
is 11 pin T220 plastic package. The IC can deliver 68-watt continuous average 
power to a 4-ohm load & 34-watt average power to an 8-ohm load.
The other main components are the voltage regulators LM317 & LM337. Where 
LM317 provides positive voltage & LM337 provides negative voltage ranging from 
1.2 to 37 & -1.2 & -37 respectively.

Features of the amplifier

  • LM3886TF has a wide input supply range (20v to 94v)
  • The amplifier comes with a Mute Function
  • Signal to Noise ratio greater than 92dB
  • LM3886TF has Output short circuit protection built into it
  • Input supply under-voltage protection
  • The design I shared needs a supply voltage between 20v to 40v input supply for the amplifier to work
  • The amplifiers power circuit is also protected from both input & output short circuit

Things & Components you need

  • 1 * LM3886TF
  • 1 * LM317
  • 1 * LM337
  • 8 * 1N4007
  • 1 * Electrolytic Capacitor 22uF/50v
  • 2 * Electrolytic Capacitor - 1000uF/50v, 10uF/50v
  • 3 * Electrolytic Capacitor - 100uF/50v
  • 1 * Ceramic Capacitor - 0.1uF
  • 2 * Ceramic Capacitor - 0.22uF
  • 2 * 5k Trimmer
  • 1 * 10k Normal Pot or Logarithmic Pot
  • 1 * 22k Ohm
  • 2 * 120 Ohm, 1k Ohm
  • 1 * Slide Switch
  • 1 * 220v to 24-0-24 1 Amp transformer
  • Speakers, Connectors & other switches

Affiliate Links

Banggood
Amazon India
Amazon USA & UK
AliExpress

Making

You can create the circuit on a perf board or order a professional PCB board by 
downloading the Gerber file shared at the bottom of the page. I recommend using 
a professional board so you can avoid unwanted noise in the output. The Gerber 
file shared was created using KiCad software which is one of the recommended 
CAD software by the fabricator that I am using. The fabricator that I am using is 
JLCPCB.con you can check them by Clicking Here, they provide very good quality 
PCB board for a very cheap price. After you receive the board assemble the board 
as shown in the video.

Once the board is assembled connect all the connectors which are necessary like 
RCA Jacks, Slide switch for mute function.

Once all the assembly is done, the first thing you need to adjust is the input
voltage. The input voltage should be above 20v. To adjust the positive voltage
connect two wires to the V+ & Gnd on the board at TP(Test Point) & then connect
the wires to the multimeter & adjust the voltage using the trimmer RV1. Now 
similarly adjust the negative voltage, but this time change the wire of V+ to V- & 
adjust the voltage using the trimmer RV2. This is a one time process.

Things to know about

In the circuit, RV3 is used for controlling the volume. J2 is the Audio input from
your laptop or mobile phone. SW1 is used for mute function. You can also change
the value of capacitor C8 to change how the amplifier sounds. My recommend
value is 22 or 47uF. Also, note LM3886TF has to be attached to a big heat sink
since it heats up when used for a long time. Also, add a small heat sink to the
voltage regulators.

Circuit Diagram





Thank you for reading !!!

5 in 1 transformer-based Adjustable Bench Power Supply

In this post, I will show you how to make transformer-based power supply which
has built-in functions like Connectivity Tester, IR or Remote tester &
LED Tester

Theory

The main part which is the bench power supply is built with the IC LM317 adjustable
voltage regulator. LM317 provides an output voltage of 1.2v to 37v depending on the
input supplied. For example, if you supply 24v as the input you will only be able to get an
output around 21v. In the circuit Diode D5 & D6 protects from short circuit.
Diode D1, D2, D3 & D4 are arranged in a bridge rectifier configuration.
Capacitor C1 & C2 is used as a smoothing capacitor.
For connectivity & LED testing circuit BC548 transistor is used. And for the
IR or Remote testing LM358 is used.

Video

     You can also watch the video for all the details on how to make this project


Things & Components you need

  • 1 * LM317 with Heat Sink
  • 1 * LM358
  • 6 * 1N4007
  • 1 * IR Rx
  • 1 * Pot Knob
  • 1 * Buzzer
  • 1 * 8 Pin Socket
  • 5 * 2 Pin Terminal Block
  • 1 * 3 Pin Terminal Block
  • 1 * Voltmeter with Ammeter
  • 2 Pair * Banana Connector male & female
  • 1 * LED
  • 1 * BC548
  • 1 * AC Cable
  • 1 * 10K Trimmer
  • Ceramic - 0.1uF
  • 1 * 2 Way Switch
  • 1 * 4.7K Pot with Knob
  • Resistor - 2 * 120, 330, 470, 10K
  • Electrolytic Cap - 10uF/50v , 470uF/50v
  • 1 * 220v to 0-24v 1Amp Transformer

Affiliate Links

Banggood
Amazon India
Amazon USA
AliExpress

Making & Assembly

Using the circuit diagram which is shared create the PCB Layout & generate
the Gerber files for Fabrication.





Once the Gerber file is generated upload the same on the fabricator website.
My fabricator being JLCPCB. The board provided by the JLCPCB was very good.
I recommend JLCPCB for fabrication. Note: You can download the Gerber files for
ordering your own PCB board at the download section. Also, note the Gerber file is
created using KiCAD.





After receiving the board mount all the components according to the circuit
diagram & part number.





After completing the board, make holes in a container for mounting all the external
components & connectors and also the PCB board & transformer.





After making holes mount all the components, PCB board & the connectors
and then make all the required connection between the PCB board & the
external components & connectors. For the connections, you can refer to the
block diagram.





Once everything is mounted name the connectors accordingly.





Now for using the bench power supply, power the circuit with 220v AC & use
the knob to adjust the voltage as per your requirement.





For connectivity test, First set the voltage to around 5 to 9V, then connect two wires
 in the Connectivity section & use the switch to select the connectivity &
then check for the connectivity in any circuit.





For testing the IR or remote, First set the voltage to around 5 to 9V, then face the
remote towards IR Rx and press any button, as the button is pressed the LED will
start blinking. At first, if you have a problem getting LED to blink try adjusting the
10K trimmer while pressing the button in the remote until you get a blink.





For LED Testing use the same setting as the connectivity testing.





Circuit Diagram






Block Diagram




Thank you for reading !!!

Decorative flower RGB LED Light | Photo Frame

In this post, I will show you how to make a decorative flower RGB light using an old
cooker washed & cardboard sheets.

Video

You can also watch the video for all the details on how to make this project

Things & Components you need

  • 47 * RGB LEDs (2 Pin)
  • 16 * 120 or 220 Ohm
  • Heat Sink Tube
  • Straw
  • DC Plug
  • Fish Wire for crafts
  • Old Cooker Washer
  • Wires
  • Cardboard Sheets

Affiliate Links

Banggood
Amazon India
Amazon USA

Making

First, take a piece of cardboard piece and mark the outer diameter of the cooker
washer and then remove the excess cardboard sheet.






Now connect the RGB LED leads to the wires & secure them with solder.





Next insert the RGB LEDs into two straws.





Now secure the straws & the RGB Led with the heat sink tube or insulation
tape.




Now place the fish wire on the washer as shown in the below image.

Now place the LED in a such a way that LED is in the back, washer is the middle
& the fish wire is in the front. Now make a knot as shown in the image to
secure all the three together
  



Now make the knots similarly to cover the entire washer & at the end secure
the fish wire with a Zip tie.
 


After making the knots, connect every three LEDs in series to make one pair



Now use the cardboard sheet to cover the back side & also expose the two
external leads of the LEDs. And also cover the front side with the cardboard sheet.
For securing the sheet you can use the zip tie.
 


Next make a box which can fit exactly at the back & cover all the circuits

Now use the circuit diagram as a reference & make a circuit board with all the
resistors in it. For each pair(3 led in series) needs a resistor.

 
Now connect all the Anode of each pair to a resistor & all the cathode together
 


Now glue the box to the back & connect a DC plug.

To the front glue a photo you want.
Finally power the circuit with 9 to 12v & enjoy the decorative lighting.

Thank you for reading !!!

Thursday, January 23, 2020

12V to 220V inverter using IR2153 with casing | Emergency Light

In this post, I will show you how to make your own 12V to 220V inverter using
IR2153 with casing.

Theory

For this project, I will be using the IC IR2153 which is a self-oscillating half-bridge
driver with a front end oscillator similar to that of 555 timer. You can also control
the oscillation using a trimmer or pot connected to PIN 2 of the IC. One of the
advantages of using this IC is that it protects your battery from over-discharging.
This is achieved when the Pin 3 of the IC gets supplied with a low voltage it
disables the gate outputs protecting the battery. The minimum voltage which can
be supplied is between 9 to 10 volts, anything below you won't get any outputs.
The MOSFETs are used to drive the output powers. The transformer is used in a
reverse configuration to get 220 to 240v output.
The output of the inverter depends on three factors
  • Transformer: Higher the rating higher power but this largely depends on the next factor
  • Power Supply: The output largely depends on the power supplied. Please do not expect to get high outputs from the low supply. Also please note the ampere rating of your supply should be equal to or less then your transformer rating or else you will end up with a fried transformer.
  • MOSFET: Adding more MOSFETs gives you powerful inverter

Video

You can also watch the video on how to make the inverter



Things & Components you need

Making

Create the PCB layout for fabrication using the KiCAD & generate the Gerber
files & the zip the Gerber folder with all the files in it.





Now upload the Zipped folder to your fabricator website for PCB production.
My fabricator being JLCPCB, you can check them out by Clicking Here




After receiving the PCB mount all the components according to the annotation.
For annotation please refer the circuit diagram




For casing i am using a Plastic Container Box. In the container box make necessary
holes to mount the plugs & switches







Now mount all the switches & plugs on to the container box & secure
them with screws




Now connect all the things together with help of the block diagram shared




Once everything is done check the connection one final time & supply the
power to use your inverter




Circuit Diagram





Block Diagram





Thank you for reading !!!