Calibrate a magnetic sensor

I recently worked on a project that required a magnetic sensor (MPU-9250) be calibrated to get best accuracy. I had some basic understanding on how to calibrate a magnetic sensor, although I’ve not done calibration before. The calibration turned out to be a bit complicated and took a while to understand. I got some help, including method to get best calibration, from the author of the MPU9250 Arduino library, Kris Winer. I thought that if I shared my experience here, others that are planning to calibrate their magnetic sensors may find it useful.

First of all, what is calibration? In a general sense, calibrating a sensor makes the sensor provide the most accurate readings allowed by the sensor’s own precision. As an example, let’s assume for a moment that the earth’s magnetic field and any other stray magnetic fields are shielded and you have a uniform magnetic field generated artificially for the sole purpose of calibration. Let’s say that the field strength is 400 mG (milliGauss), equivalent to 40,000 nT (nanoTesla). Now if you align one axis of your magnetic sensor parallel to the direction of the field, it should read 400mG. If you then carefully rotate your sensor so that the axis is anti-parallel with your field, it will read -400mG. If you didn’t do a good job in either alignments, you will read less values, say 390mG, if you’re off by about 13 degrees, because only a portion of the field, which is a vector, is projected along your magnetic sensor’s axis.

In the diagram above, the thick blue arrows represent the constant magnetic field of 400mG pointing to the right. The thin arrows represent various orientations your sensor could take. If your sensor + axis is also pointing to the right, you get the full 400mG. If your sensor + axis points to the left, you get -400mG. If your sensor + axis makes an angle, it reads a projection of the field, which is less. You can figure out the angle:

The above was assuming that there IS a constant magnetic field and the sensor’s reading IS symmetric along its positive and negative axis, meaning with zero magnetic field, the sensor reads zero. When not calibrated, the sensor reading will NOT be zero under zero field. It could read say 10mG. As a result, you might get say 510mG and -490mG with the field on. You know what that means. There is an offset (bias) of 10mG that should be subtracted from your reading to get the correct reading of +-400mG.

The above was the basis for calibration to remove the offset (bias) on each axis. In order to get the maximal and minimal value, you need to write your code to store max/min out of a stream of live data while you rotate your sensor in space, trying to maximize or minimize the readout. Then repeat two more times for a 3-D magnetic sensor. Since you don’t have a magnetic shield, you are relying on the earth’s magnetic field as the constant field. The earth’s magnetic field is not horizontal, or pointing from north to south. In most areas, the field either has a vertical up component, or a down component. And in most cases the field points from south to north as the rotational north pole (AKA the north pole) is near the magnetic south pole, where field lines go in, not coming out. In my area for example, the earth magnetic field points primarily downwards, only slightly towards north, making an angle over 70 degrees with the horizontal. The magnetic field has very little component in the east direction. The relative strength between East, North, and Downward is about 1:64:195. The angle the magnetic field vector makes with the horizontal is called magnetic inclination, with downward being positive. This is approximately atan(195/64)=72 degrees. The angle the magnetic field vector’s horizontal component makes with the true north is called magnetic declination, with east being positive. This is approximately atan(1/64)=0.9 degrees. The properties of magnetic field varies greatly from place to place and also changes from time to time. To find out the magnetic field in your area, visit noaa.gov:

https://www.ngdc.noaa.gov/geomag-web/#igrfwmm

The following is from my area:

The next calibration is for sensitivity. The sensor either returns an analog voltage or a digital value. How do we convert this return into actual magnetic field in mG? This means finding the relation between the sensor readout and actual physical values. Say the sensor is digital and returns values between 0 and 32767, which represents magnetic field between 0 and 49150mG. Then you can use the conversion vactor 49150/32767=1.5mG/LSB to convert your readout. Here LSB means one digit (least significant bit). For an analog sensor, you will need an x.xx mG/V.

All sensors provide this factor in their spec sheets so you can just use this factor to get the actual magnetic field. But since not all sensors were made identical, some sensors should use larger or smaller values than the spec’s factor. Some manufacturers test their sensors at factory and store a correction factor for each axis in the sensor for better accuracy. For example, the MPU-9250 sensor (the magnetic sensor is AK8963) has digital magnetic field sensor output. One of the sensors I got has the following factory trims:

X-Axis sensitivity 1.18

Y-Axis sensitivity 1.19

Z-Axis sensitivity 1.14

So instead of a straight 1.5mG/LSB, the x-axis has 1.5*1.18=1.77mG/LSB. We’ll multiply this factor to the x-axis readout to get x magnetic field in mG. Same for y and z axes.

And yet sometimes these adjustments are still not able to make all 3 axes read the “400mG” value. They are very close to be identical already so we can apply a small correction. We average the maximal readings from all three axes, then divide by the maximal reading of each individual axis to get three factors. If say the x-axis reads slightly higher maximum than y and z axes. Then the avg_max/x_max will be slightly less than 1. We apply this factor to the the final result:

x_field=(1.5mG/LSB)*(x_sensitivity)*(avg_max/x_max)*x_readout

For one of my sensors, this yields 1.5*1.180*0.975*x_readout=1.726*x_readout(mG)

If the sensor you’re using doesn’t have the factory trim, then you’re out of luck unless you have both a magnetic shield and a nice uniform magnetic field inside the shield so you can find out the trim.

The following are steps for the AK8963 magnetic sensor calibration I did, using Kris Winer’s MPU9250 Arduino library:

  1. Extract factory sensitivity factor by calling initAK8963().
  2. Call readMagData() to extract raw data repeatedly enough to get accurate max/min for all axes.
  3. Calculate bias in raw counts by (max+min)/2, such as (510+ (-490))/2=10
  4. Combine factory sensitivity factor and Kris’s scale factor described above.
  5. Keep these biases and factors in program.

As a testimony to the method that works, here are two graphs.

This graph has three separate plots from raw data that represent mx vs. my, mx vs. mz, and my vs. mz. I rotated my sensor as much as I could for a few minutes before I got bored and couldn’t think of any other ways of rotation. The fact that all three plots are near circular means that the sensor’s three axes have very similar sensitivities. I was simply rotating the sensor around, giving all three axes opportunities to read the whole magnetic field. This means when the x axis reads the whole field, y and z axes read nothing. Some trigonometry can show that the result is a series or circles making a disc. But the discs were not centered as I expected, because the z axis had a very large bias (this means the blue is mx vs. my). After my bias calibration, here is what I got:

Now all three plots are centered at zero pretty well visually, although I didn’t multiple the factory sensitivity or the final factor from Kris’s calculation. This shows that bias calibration is the most crucial. If your sensor doesn’t have stored factory sensitivity factors, getting it calibrated for bias alone will go a long way.

FYI, this is my sensor board inside an enclosure. I found it much easier to hold and rotate when it’s in a box. The cable became much less of an issue when I was rotating the box. The black square board is my SDI-12 USB adapter. The purple board is the sensor board. I customized the SDI-12 USB adapter by gluing the sensor board to it and connecting it to the I2C bus on the adapter.

Second update on the new SDI-12 USB adapter

I found sometime to assemble a batch of the new boards. I populated the 12-pole terminal block on top and a row of headers on this one board for firmware development. Since not everyone will need these new features, the 12-pole block and the header for extension board or UART serial port will be optional and you can specify with your order that you need them. Adding these components adds more cost due to parts cost, assembly, and testing time. You could solder these headers yourself if you have some basic soldering skills. The UART serial port header is soldered on the underside of the board with a right-angle header to avoid the extension board and keep wires tidy.

If you need to use these boards over UART serial port such as connecting them to an Arduino or MicroPython board, please let me know with your order. I will place a solder blob between two pins on the USB serial IC so that it is placed in RESET mode to not interfere with UART serial communication with your microcontroller off board.

Here is the high-precision analog input extension board:

I assembled two extension boards, stacked them on top of the adapter, and set them to address 0 and address 1. These extension boards with come with a stacking header soldered on and four M3 standoffs, washers, and nuts. This ensures the proper spacing between boards to prevent short circuiting. I also need to trimming 20 pins on the underside of the board so that the underside of one extension board won’t touch the top side of another extension board below it. If you want, you can buy a set of 4 3-pole terminal blocks and populate them on the extension board to connect to more SDI-12 sensors, although I don’t recommend more than about 8 SDI-12 sensors from any vendor on the same adapter and extension board. A basic test running the SDI-12 + Analog USB adapter firmware on this adapter and extension board was successful, which was how I tested the extension board’s assembling quality.

My next steps are:

Extension board:

  • Expend the firmware to talk to as many as 4 such extension boards for a total of 16 high-precision analog inputs
  • Test address-setting jumpers (don’t expect any issues)
  • Populate SDI-12 headers on one extension board and test it (don’t expect any issues)

With one extension board and its address set to 0, getting high-precision analog readings is the same as using the SDI-12 + Analog USB adapter, by sending zM! and zM1! (differential reading), then using zD0! to retrieve data. With more extension boards, reading the 4 channels on board with address 1 will be zM2! and zM3! (differential reading) then the same zD0! to retrieve data. Board address 2 will have zM4! and zM5!, while board address 3 will have zM6! and zM7!. Then zM8! is reserved for the on-board basic analog channel read, while zM9! retrieves number of pulses from these channels.

Main adapter:

  • Develop firmware to read analog channels on the adapter itself (for basic analog signals at around 5mV precision).
  • Develop firmware to read pulses from the analog channels on the adapter itself (for rain gauges, flow meters etc. that output pulses).

Then I’ll test everything with a test rig. Stay tuned!

Upgrades to the SDI-12 USB adapter

I have been working on some updates to the SDI-12 USB adapter so that it would add more features to a data logging system. So far, I’ve updated the PCB (left board) to include additional connectors. The top of the board will have 4 analog channels. This is not as accurate as the red SDI-12 + Analog USB adapter boards. The SDI-12 + Analog USB adapter has practical accuracy of 20 microvolts and has differential input channels. The 4 channels on the basic SDI-12 USB adapter have accuracy of about 5 millivolts. Also there is not a voltage reference so the measurement will be affected by the USB voltage, which is only nominally 5V. Nevertheless, if there are some sensors that output voltages in 0-5V range you want to log with moderate accuracy, such as a potentiometer, or a thermistor for approximate temperature calculation, you can use these channels. The breakout looks the same as the SDI-12 + Analog USB adapter. There are no serial resistors so you have to add yours if you want to convert resistance to voltage.

I will release a new firmware version on these newer boards. At the same time, I am considering adding digital counting features to these analog channels so if someone wants to count pulses such as flow meters or rain gauges, they can use these channels for such purpose. I plan to develop this part in the summer.

Another connector (bottom one on left board) I have added will connect the adapter to an analog extension board (right board), which sports the same 20 microvolt accuracy as the SDI-12 + Analog USB adapter, in case you want to add these channels say for pyronometers or other low voltage and high precision measurements after initially getting the basic adapter. You can stack up to 4 such analog extension boards. Each board has an address jumper (right board, white rectangle) for one of the four addresses the analog-to-digital converter supports. That gives you a total of 16 high-precision analog input channels. Each extension board also comes with a few additional connectors for SDI-12 sensors as an option. You can more easily wire up more SDI-12 sensors to the adapter. I don’t recommend wiring up more than 6-8 SDI-12 sensors to the same adapter. Some sensors come with strong pull-down resistors. When too many of them are wired to the same adapter, they may prevent some other sensors from correctly communicating on the bus.

The last connector (left board middle) I have added will help developers using MicroPython platforms easily connect to it via serial ports, since most MicroPython boards don’t have USB hosts. I will start shipping these newer SDI-12 USB adapter boards soon although new firmware that makes use of these features will have to wait until later.

Will this affect your existing projects? Very unlikely. The new adapter has all the features of the old adapter. The SDI-12 + Analog adapter will still be around since it is a nice compact form factor. The new SDI-12 adapter plus the analog extension board will be approximately the same price as as the SDI-12 + Analog adapter.

More SDI-12 sensors tested with the adapters

As more researchers and developers are using my SDI-12 USB adapters, more sensors have been tested to run with the adapter. Here are some of the new additions recently:

Gill Instruments:

  • WindSonic Ultrasonic Wind Sensor (Thanks MG!)

HSTI:

  • HydraSCOUT multi-sensor soil moisture and temperature probe (Thanks Bertrand!)

Sutron:

  • Accubar SDI-12 Barometric Pressure Sensor, Model 5600-0120-3 (Thanks Meidad!)

Unidata:

  • Starflow QSD Ultrasonic Doppler Velocity And Depth sensor (Thanks Yiren!)

Since Decagon has merged with a German company UMS into METER Group, some of their product lines are renamed and other products are added to these new lines. Here is a list of tested sensors from them:

METER group (formally Decagon and UMS):

  • Atmos 22 (DS-2) (Sonic Anemometer)
  • Atmos 14 (VP-4) (temperature, vapor pressure, relative humidity sensor)
  • Atmos 41 weather station (solar radiation, precipitation, vapor pressure, relative humidity, air temperature, barometric pressor, horizontal wind speed, wind gust, wind direction, compass heading, tilt, lightning strike count, lightning average distance) (Thanks CD!)
  • PRI (spectral reflectance sensor)
  • NDVI SRS (spectral reflectance sensor)
  • GS3 (Ruggedized Soil Moisture, Temperature, and Electrical Conductivity Sensor)
  • TEROS 21 (MPS-6) (Calibrated Water Potential Sensor)
  • ECH2O 5TE (5TE) (Volumetric Water Content, Electrical Conductivity, and Temperature)
  • ECH2O 5TM (5TM) (Soil Moisture and Temperature Sensor)

If you are using the SDI-12 USB adapters, I’d love to include your SDI-12 sensors on my list of tested sensors. Leave me a message.

Careful with Python indentation

If you are like me, using the default Python integrated development environment, IDLE, you probably feel like me, desiring more features, such as line numbers, horizontal scrolling, code folding, etc. I am aware of a Python module called IDLEX, which has lots of these features. On the other hand, if you are already familiar with text editors such as Notepad ++ (Npp in short), which is excellent, you may want to just switch over to Npp for your Python script editing. You can either use their default color theme or edit it to look like IDLE. There is an essential feature you need to set in order to produce correct indentation though.

Because unlike other major programming languages such as C/C++, Java, etc. Python uses indentation to indicate structure. If you write an if-statement, you do this:


if (statement==True):
    print('It is true!')
else:
    print('It is not true!')

I’ve learned a lesson of mixing tab characters and white spaces as indentation. It’s a bad mix. Although I love the tab character more than spaces, I consider spaces better in Python since it is the Python standard. Here is some tab vs. space discussion. They each have advantages. So how do we set up Npp to produce the Python standard 4-spaces whenever we press the TAB key on the keyboard? Here it is:

This “Preferences” dialog is under “Settings” menu. Just make sure you select “Language” on the left and then “Python” on the right (not the middle), deselect “use default value”, and select “Replace by space”. This produces Python 4-space indentations. Once you’re done, you may want to inspect your exist script to see if there are any tabs by selecting option “Show all characters” under “View” menu’s “Show Symbol” option. This way tab characters look like red arrows while white spaces look as red dots.

Now you are using Npp for editing, you can create a “Run” command inside Npp to run your Python code:

Under “Run” menu “Run…” option, you can type up the command python -i “$(FULL_CURRENT_PATH)”

Save a short cut such as Shift + F5. Then you can run the code with the shortcut.

Interesting indoor temperature data

As a demonstration for my SDI-12 USB adapter, I have a raspberry pi zero-w log temperature from a Decagon (METER group) 5TM soil temperature probe using the adapter. The probe is not buried in soil so it is just sensing the indoor temperature. The sensor is located away from direct sun light, just in case you wonder. Here are two snapshots of the data stream:

https://thingspeak.com/channels/462583

One-day

Multi-day

Except for the daily dip-and-rise combinations (why?), the temperature of my home is rather constant near 21.5 Degree Celsius. That is good to know that there is no issue with my thermostat in stabilizing temperature. So why the daily dip-and-rise combinations? The top graph was from Sunday. Notice two dip-and-rise combinations on the plot instead of one? The lowest points occurred around 2:30pm and 8:30pm but that’s not important. What’s important are when the dips started, around 1pm and 7pm. Those were the times we were cooking! The extra heat from the kitchen must have triggered the thermostat to turn off the heater, which made the room temperature drop before it kicked back in and heated the room back up. Without the heater on, the room drops steadily by 0.3 degC per hour. When heat is turned back on, the heater raises temperature at 0.5 degC per hour. You can also see that we were cooking dinner every night. Who would have thought that by posting room temperature online they are giving up a lot of privacy? 🙂

Data logging with Wipy and SDI-12 dongle

If you have heard of the Python programming language and its easy-to-learn and easy-to-use fyou’ll be pleasantly surprised that someone has successfully implemented Python on microcontrollers a few years ago, appropriately named MicroPython! He has developed his own MicroPython board and ported the code to a number of similar microcontrollers. Imagine a low-power microcontroller with “lots” of memory (compared with Arduino) happily running Python code that talks to the internet etc. I’ll start writing about MicroPython and how you may use it for DIY electronics and data logging in a number of posts but this post is an announcement related to MicroPython and the SDI-12 serial dongle:

This dongle has a similar set of features as the SDI-12 USB adapters but lacks the USB connectivity, just having serial connection to arduino. Since all MicroPython compatible boards have serial ports and library to run the port, you can connect a MicroPython compatible board to one of these dongles and run almost the same Python data logging code I provide to SDI-12 USB adapters. Here is the first successful attempt that made it happen. Jason is a developer on the Wipy platform, which is a microcontroller supporting MicroPython. He is developing a data logger. In order to talk to SDI-12 sensors, he got one of my SDI-12 dongles. The Wipy board has serial ports but at 3.3V logic. The dongle has 5V logic. I built a simple voltage divider on the dongle for him and he was able to communicate with it using the Wipy board. Here is the code that he wishes to share:

Wipy_logger.py

This script runs on Wipy (or similar MicroPython platforms) and logs data from SDI-12 sensors to the on-board SD card. Here is what a Wipy board V 3.0 looks:

SDI-12 USB adapter and manual updates

If you have been looking at the SDI-12 USB adapters lately, you may have noticed that the manual got updated a bunch of times between February and March (latest version being 3/19/2018). I’ve been updating the manual to:

1. Introduce the newer SDI-12 USB adapter (black) that replaced the original adapter (green).

Original SDI-12 USB adapter since 2015:

slide2

Updated SDI-12 USB adapter:

SDI-12 USB + adapter

Notice that now the updated adapter is the same size as the other flavors of the adapters, such as the SDI-12 + Analog adapter and the SDI-12 + GPS adapter. These are the features the updated adapter has:

  • Four SDI-12 sensor connectors
  • External power connection and sensor power selector (5V USB or external)

2. I updated several sections of the manual to make the manual easier to understand.

  • Bookmarks in the .PDF file
  • More detailed description of the updated adapter
  • Details of how to configure an SDI-12 adapter
  • Other places have been tidied up as well

By the way, did I mention that I reduced all my adapters by $5 to $10?

  • SDI-12 USB adapter (updated) $45 ($5 cheaper)
  • SDI-12 + GPS USB adapter $60 ($10 cheaper)
  • SDI-12 + Analog USB adapter $80 ($10 cheaper)
  • There will be discounts for bulk purchases, such as 10, 20, 50 etc. Please contact me if you intend to buy more adapters so I can send you an accurate quote of prices with discounts and shipping cost.
  • If you still need the green adapter for its simplicity or form factor, you can contact me to do bulk orders, 10 adapters or more.
  • If you need something else to be on your adapter to connect to a particular sensor, contact me to see how I can help you achieve that. The sensor would definitely not be SDI-12 but I’ll make it so that reading from it is just like reading from any other SDI-12 sensor so your program needs little to no change.

Since I am assembling and testing these adapters myself and use trustworthy US parts vendors, I will have to get more efficient in my work to make up the difference. I made some improvements on a reflow oven that I will be using for new batches of adapters. I hope the effort pays off. I would be able to assemble a batch, load into the reflow oven, and assemble the next batch or do cleanup or soldering thru-hole components such as the screw terminal blocks while the oven reflows automatically. I’ve been using a manual control (Variac transformer) for reflow for the past several years, which requires constant attention.

One negative impact from the US postal service, since the end of January 2018, USPS will no longer ship merchandise via international first-class letter. The only alternative is first-class package, which is a much more expensive service. A package containing one adapter that used to cost less than $4 will now cost $9 to ship to Canada (come on!) or $14 to most of the rest of the world. I felt that I’m being squeezed out of the international market by the postal service. The only upside is that now the package seems to come with complete tracking in both countries. I made a small change to the first-item shipping cost and additional item shipping cost.

I am also considering designing a complete low-cost data-logging system so it would be more integrated than the adapters. The adapters have proved to be very successful indeed. It shows up as number-1 search for keywords “SDI-12 adapter” or “SDI-12 USB adapter”. I didn’t pay google anything for the free advertisement. Everyone that searched and read my blog helped spread the word! Thank you!

I plan to keep improving the adapters so that anyone that is integrating SDI-12 sensors will find it easy to just get an adapter and add SDI-12 sensors. For anyone else that is interested in low-cost data logging solutions but are more interested in a turn-key solution instead of investing time and effort in learning python programming or raspberry pi, this logger will make things easy for you!

Any comments, suggestions, your use case, including what sensors and telemetry solutions you want that you would like to share? Leave a comment! The design of the data logger is still very fluid so that your opinions WILL influence its development!

The development of a turn-key solution WILL positively affect the adapter development as well. I expect to have a 3-prone approach ultimately: USB adapters to add SDI-12 sensors to existing logger projects that use computers/raspberry pi, serial dongles/shields to do the same for Arduino-based existing logger projects, and a complete logger for those seeking turn-key solutions.

Have a nice spring/fall day!

JLCPCB – A new PCB fabrication house

I was recently approached by a new PCB fabrication house JLCPCB (technically they’ve been in business for some time but just started advertising to USA customers) to write some reviews on their service. Given my experience designing PCB and using PCB fabrication services (batchpcb, seeedstudio, iteadstudio, oshpark etc.) over the past decade, writing a review shouldn’t be too hard. If they are any good, I could use their service myself and recommend them to others in the hobby electronics community. So I sent them two of my designs and got them back relatively fast, with DHL. Since I still have some older versions of one of the boards, I could make a comparison with the two fabrication services. JLCPCB has offered their service free of charge for the exchange of a fair review. So I decide to not mention which competition I pitched JLCPCB against. What I primarily looked at was how accurately each layer of board is printed and how well they are aligned with one another from each fab service. JLCPCB‘s results are very good. Its competition, a long-standing name among DIYers, doesn’t look quite as good.

In case you’re still learning how to design PCBs, especially surface-mount components, here are some terms I’m going to use:

Top layer: this logic layer contains all copper traces, pads, and vias on the top side of the two-sided circuit board. A process is used to protect all aforementioned features specified in this layer when the entire board is etched in acid. If the process isn’t accurate, then your features aren’t exactly where they are supposed to be.

Top solder paste: this logic layer contains only pads for surface-mount components. It is a subset of top layer and is used to generate stencils for reflow soldering. Again if the fabrication isn’t very good, these features tend to not align with other features.

Top solder resist: this logic layer contains similar information to the pads and vias contained in top layer but the sizes of the features in this layer are slightly enlarged to a peel-back amount so they don’t accidentally apply solder resist on top of your pads where solder should go. Solder resist is a lacquer that prevents solder from adhering to the copper traces. They also protect the bare copper from rusting away. You will want them to be applied to all your traces and only leave the pads exposed so later process will cover them with a very thin layer of solder (the shiny looking stuff) and you then reflow solder your components to these pads. If the registration of this layer of lacquer is not well registered with the top layer, you will see visually under a magnifier. This is why fabrication houses usually do quite a bit of peel-back so they leave room for themselves to be less-aligned but still the lacquer won’t cover up the pads.

The following images are from an FTDI chip (FT232RL). The pitch was the finest on my board so I selected these pads for comparison of how well the different layers register with one another on these two service providers.

Top: JLCPCB Bottom: competition


They look similar. I’ve unfortunately scratched the pads on the competition’s board. I applied solder paste to that board and later cleaned the paste off so I could photograph its pads. My bad.
On a closer look there is a difference:

SMD pads (SSOP 0.65mm pitch):

Top: JLCPCB Bottom: competition
You can see that JLCPCB‘s boards (top) have SMD pads (shiny metal pads) that are very symmetrically situated inside the solder-resist masks (slightly larger dark rectangle). The solder resist also goes closer to the board than its competition. These are manufactured from the same designs! The engineers at the competition must have increased the peel-off (sizes of feature not covered by solder resists) to offset their less-perfect layer registrations and/or accuracy on each layer. As you can see, not all pads and their solder resist have the same offset. Some look better than others. This is clear with the second to the last pad and the last pad. The pads are not centered at all. This is very consistent across the board made by competition. JLCPCB has better overall registration than competition. Better registration translates into better chance to prevent solder bridges and less chances to reworking on your boards after you reflow them, that means time and money saved.

Thru-hole pads (o.1″ spacing):

Top: JLCPCB Bottom: competition

The top one has less size solder resist layer, the edges of the red lacquer surrounding the shiny pads (almost same size as the thru-hole pads) and very symmetrical. The competition has again increased the solder resist layer and couldn’t keep the layer registered well with the pad.

The via to the right of the bottom right through hole pin hole will be compared next. On JLCPCB‘s board, its solder resist has 2.8mm diameter when displayed on my computer monitor. On the competition board, it is 3.1mm. The images were taken under a high-magnification lens and I checked the images to be exactly the same zoom, measuring the same across the same features on screen. What this means is that if you have a lot of vias in one area, very close to one another, you may get some solder bridges between the vias if there is not enough solder resist to separate them. Not a problem on this board but a problem if you happen to have vias very close and also close to thru-hole components. You solder the thru-hole and inevitably fill the adjacent vias with some solder. This could short vias.

Overlay (white texts):

The quality of the white overlay texts are about the same between the two fabricators, although at some places you see one board having better quality than the other board while at different places the quality is reversed. This is not a crucial feature to look at though.

JLCPCB: top, Competition: bottom

With the explanation above, you can easily distinguish these two photos. The bottom one has so much space between the edges of the shiny pads and the red lacquer (less qualty). The top one has so much less and so symmetric.

So the results are clear. JLCPCB is a pretty decent PCB fab house and I will order my next batch from them. The shipping cost is also slightly less than competition if you use DHL. I always use DHL. They do a good job delivering to small cities like the one I live in!

Here is a link to JLCPCB’s website:

www.jlcpcb.com

I am not getting any commissions for your purchases. The link has no “trackers” 🙂

P.S.: I had a research student hand solder this board (yes, every single chip resistor and the FTDI chip) as a good test of his skills and it turned out fine. This is a proof that having the right size solder resist helps, really. This is what the board looks like after assembly:

Augmented reality sandbox control box updated

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I constructed a couple of these control boxes for my ARsandbox project using Arduino Micro and Adafruit Feather 32u4. The main goal is to make the interaction between a user and the software more intuitive. The two flashing buttons add and remove water from the simulation, which is pretty nice. I wanted to add another feature, to move the elevation up and down. Say you have a lot of sand in the box but you want to display some “water”. You have to remove a lot of sand (time consuming) from the box or edit a config file (near impossible for an average user). On the other hand, if I can change the base plane location in the calculation, I can achieve the above goal without removing sand or editing files. With help of the original developer Dr. Oliver Kreylos, I started messing with the source code. It took me a day to understand what I could do to change the base plane and how to do it. I ended up creating a tool to manipulate the plane. Now that the plane can be moved, I added a rotary encoder to the control box to emulate the keyboard keys assigned to move the plane. Voila!

The photo gallery above shows 5 shots of different elevation values. You can clearly see the “sea” on bottom right is shrinking after each turn of the knob.

Here is a short video. I was slowly raising the elevation so more and more land became above water. Then I quickly returned the land back into water:

Here is a photo of the inside of the box:

I added a breakout board for rotary encoder and buttons. It’s very tightly sandwiched between the two buttons. There is no space between the board and the buttons, not even a fraction of millimeter. I don’t know how these pieces just managed to fit. Here is the breakout board:

I made this a while ago as an interface for my phi-panels LCD backpacks. This breakout board is pretty simple. There are two encoder channels and one shaft button, plus six push buttons, which I am not using. I just connected to the encoder channels, shaft button, and the common. I had to cut off a strip on the right side of the board to fit into the box. I was using my phi_interfaces library to read the encoder and emulate a button push if the encoder is rotated one way, another button if the encoder is rotated the other way. I didn’t assign any function for the shaft button. I am thinking that I should use it to switch between elevation adjustment and water speed adjustment.

I haven’t updated the Adafruit Feature 32u4 version but will probably design a new printed circuit board so assembling will be easier, and not involving cutting off part of a board. Some code in case anyone wants to replicate it.


/*
 * Credit: Dr. John Liu
 * Purpose: This sketch emulates keyboard keys "1" and "2" with two push buttons with LEDs. It also flashes the LEDs
 * If a rotary encoder is present, it will emulate '5' and '6' if you rotate the encoder's shaft. This combined with my modification on ARsandbox source code will shift color mapping up and down.
 * This version uses p-channel mosfets and open drain with 10Kohm pull-up to 5V to control LEDs with the 3.3V Adafruit Feather32u4.
 * Notes: On Adafruit Feather 32u4, pin 9 is connected to battery sensing voltage divider.
 * 2018-01-28
 * Visit https://liudr.wordpress.com for more information
 */
#include "Keyboard.h"
#include <phi_interfaces.h>
#define USING_MICRO
#ifdef USING_MICRO
const int button_1=2; // 11 for Adafruit feather 32u4, 2 for Arduino Micro;
const int button_2=3; // 10 for Adafruit feather 32u4, 3 for Arduino Micro
const int EncoderChnA=7;
const int ChnCommon=8;
const int EncoderChnB=9;
const int ShaftBtn=10;
const int EncoderDetent=18;
#endif

#ifdef USING_FEATHER
const int button_1=11; // 11 for Adafruit feather 32u4, 2 for Arduino Micro;
const int button_2=10; // 10 for Adafruit feather 32u4, 3 for Arduino Micro
#endif

const int led_1=6;
const int led_2=5;
const unsigned long led_on_ms=300;
const unsigned long led_off_ms=1700;
const unsigned int button_1_key='1'; //KEY_LEFT_ARROW;
const unsigned int button_2_key='2'; //KEY_RIGHT_ARROW;
const unsigned int UpKeyOut='5';
const unsigned int DownKeyOut='6';

int prev_1=HIGH;
int prev_2=HIGH;
int led_stat=LOW;

unsigned long prev_1_ms=0;
unsigned long prev_2_ms=0;
unsigned long blink_timer_0_ms=0;
unsigned long blink_timer_1_ms=0;

int debounce_ms=25;

char mapping[]={'U','D'}; // This is a rotary encoder so it returns U for up and D for down on the dial.
phi_rotary_encoders MyEncoder(mapping, EncoderChnA, EncoderChnB, EncoderDetent);
//multiple_button_input* dial1=&my_encoder1;

void setup()
{
  // make pin 2 an input and turn on the
  // pullup resistor so it goes high unless
  // connected to ground:
  pinMode(button_1, INPUT_PULLUP);
  pinMode(button_2, INPUT_PULLUP);
  pinMode(led_1,OUTPUT);
  pinMode(led_2,OUTPUT);
  pinMode(ChnCommon,OUTPUT);
  digitalWrite(led_1,LOW);
  digitalWrite(led_2,LOW);
  digitalWrite(ChnCommon,LOW); // Using this pin as ground since some prototypes don't have enough gnd pins.
  Keyboard.begin();
  blink_timer_0_ms=millis();
}

void loop()
{
  unsigned char ch=MyEncoder.getKey(); // Rotary encoder emulates two buttons.
  if (ch==mapping[0])
  {
    Keyboard.write(UpKeyOut);
  }
  else if (ch==mapping[1])
  {
    Keyboard.write(DownKeyOut);
  }

  switch (led_stat)
  {
    case LOW:
    if (millis()-blink_timer_0_ms>led_on_ms)
    {
      blink_timer_0_ms=millis();
      led_stat=HIGH;
      pinMode(led_1,INPUT); // Open drain to let pull-up resistor pull drain to 5V.
      pinMode(led_2,INPUT); // Open drain to let pull-up resistor pull drain to 5V.
    }
    break;

    case HIGH:
    if (millis()-blink_timer_0_ms>led_off_ms)
    {
      blink_timer_0_ms=millis();
      led_stat=LOW;
      pinMode(led_1,OUTPUT); // Pull drain to GND.
      pinMode(led_2,OUTPUT); // Pull drain to GND
    }
    break;
  }

  if ((digitalRead(button_1) == HIGH)&&(prev_1==LOW))
  {
    if (millis()-prev_1_ms>debounce_ms)
    {
      prev_1_ms=millis();
      Keyboard.release(button_1_key);
      //Serial.println("1 released");
    }
    prev_1=HIGH;
  }

  if ((digitalRead(button_1) == LOW)&&(prev_1==HIGH))
  {
    if (millis()-prev_1_ms>debounce_ms)
    {
      prev_1_ms=millis();
      Keyboard.press(button_1_key);
      //Serial.println("1 pressed");
    }
    prev_1=LOW;
  }

  if ((digitalRead(button_2) == HIGH)&&(prev_2==LOW))
  {
    if (millis()-prev_2_ms>debounce_ms)
    {
      prev_2_ms=millis();
      Keyboard.release(button_2_key);
      //Serial.println("2 released");
    }
    prev_2=HIGH;
  }

  if ((digitalRead(button_2) == LOW)&&(prev_2==HIGH))
  {
    if (millis()-prev_2_ms>debounce_ms)
    {
      prev_2_ms=millis();
      Keyboard.press(button_2_key);
      //Serial.println("2 pressed");
    }
    prev_2=LOW;
  }
}
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