Thermal Design Basics | Practical Example

Thermal design is one of those things engineers don’t really learn in school and hobbyists often don’t even think about. This article is going to show some basic math with a practical example.

One of my portable police scanners has an external 6V jack. To use it in my car I used my standard linear voltage regulator board and a high quality ST L7806 voltage regulator to get the ~13.8V of the car down to 6V. Maximum observed current of the scanner was 0.25A. So the thermal design question of the day is: How hot will the linear regulator get and do I need a heatsink?

Universal Linear Regulator Board

Universal Linear Regulator Board

So lets start with the obvious first question: How hot is too hot? The answer is of course to be found in the datasheet. The datasheet states an absolute maximum of 150 °C. Note that this is the maximum rating though. While you can safely run the device at 150 °C, you probably don’t want to. Remember that 100 °C is the boiling point of water. So 150 °C is pretty darn hot. But it’s within the parameters given to us.

ST L7800 Datasheet

ST L7800 Datasheet

So how do we calculate how hot the device gets? The key to that question is the dissipated power and a figure called the thermal resistance junction-ambient, symbolized as theta-ja (θja). It is also shown in the previous datasheet snapshot. This figure basically says how many degrees the device’s junction temperature rises ABOVE ambient temperature for a given amount of dissipated power. Ambient temperature, or “room temperature” is often assumed to be at 25 °C. And that’s what we’re gonna work with but when you do the math, please be practical. If you can reasonably expect the temperature to rise above 25 °C, then do the math accordingly.

So our formula for junction temperature is this:

Tjunction = Tambient + (θja * power)

Alright, let’s piece together what we have. Let’s start with the dissipated power. We put in 13.8 V at 0.25 A and get out 6V. That makes 1.95 Watts ([13.8V – 6V] * 0.25A) of power to turn into heat. To calculate the expected junction temperature we simply plug all the values into the formula and solve.

25 + (50 * 1.95) = 122.5 °C

That means we can expect the junction temperature of the device to reach 122.5 °C. This is within the given maximum ratings and thus the answer to the heatsink question is no, we do not need a heatsink.

But not the reality check, think along with me. Again remember that 100 °C is the boiling point of water. Do we really want a device 22.5 °C above that sitting around somewhere? And also we assumed ambient to be at 25 °C. Car ambient temperatures frequently rise well above that, especially when exposed to sunlight. On top of that, car voltages aren’t even close to stable and can exceed 14 volts easily. So the practical answer would be that we would elect to use a heatsink. And that’s exactly what I did.

How to size heatsinks is a more complicated story and will be part of a different article.

Links and Sources:

[1] L7800 Series Datasheet, ST: https://baltic-lab.com/wp-content/uploads/2016/01/L7800.pdf

 

Hacking a Strobe Light Controller

Not too long ago I bought some white strobe lights with a strobe controller of Amazon. This exact controller is spread all over Amazon and eBay but only provides strobe patterns that I didn’t particularly like. So it’s time for a hack.

The strobe lights I purchased were white in color but they have the same kit in other colors like red, blue, amber, green and purple. Or a combination of those colors. The controller, however, remains the same regardless of color.

To hack this controller turned out to be way easier than ever expected. The on board IC and the ATtiny45 (or the tuny85) appear to have a similar pin layout. Vcc and GND are where they are supposed to be and the input and outputs make it straight onto I/O Pins. The only unfortunate thing is that the third button is connected to the pin corresponding to the Reset pin on the Atmel MCU. The reset functionality can be disabled, however, if you need that third input. I chose to use it in its function as a Reset to disable the strobing pattern. But first things first, this is what the controller looks like opened:

Original controller with IC still installed

Original controller with IC still installed

The first step is to remove the original IC. I cut all the pins of the IC and then carefully desoldered each pin individually using solder wick and vacuum suction.

IC desoldered

IC desoldered

To make programming and experimentation easier, I decided to solder a 8 pin IC socket in place of the old IC. You don’t have to use one if you don’t intent to change anything later on.

IC socket soldered in place of the original IC

IC socket soldered in place of the original IC

Lastly, the programmed ATtiny45 is inserted into the socket and the light show can begin. The software part is discussed further down int his article.

ATtiny45 socketed in,  in place of the original IC

ATtiny45 socketed in, in place of the original IC

So what do the new strobing patterns look like you ask? Like this:


Let’s talk about the software. I wrote the few lines of code in BASCOM AVR. A demo version of BASCOM AVR is available for download on the internet. But of course you can write your own code using the Arduino or any other environment that supports ATtiny45s. If you don’t want to spend the time compiling this project, you can download the .hex and .bin files right here.

Here is the BASCOM code I used:

‘ Atmel ATtiny45
$regfile = "attiny45.dat"

‘ Fuse-bits 8 MHz int. div. by 8
$prog &HFF , &H42 , &HDF , &HFF

‘ 1 MHz internal clock
$crystal = 1000000

‘ PortB is Output

Config Portb.= Output
Config Portb.= Output

Config Portb.= Input
Config Portb.= Input
Config Portb.= Input


Pinb.= 1
Pinb.= 1

Dim Buff1 As Bit
Dim Buff2 As Bit
Buff1 = 0
Buff2 = 0


‘ Start flashing
Do

   If Pinb.= 0 Then Buff1 = Not Buff1
   If Pinb.= 0 Then Buff2 = Not Buff2

   ‘ Debounce

   Waitms 25

   If Buff1 = 1 Then Gosub Pattern1

   If Buff2 = 1 Then Gosub Pattern2


Loop


Pattern1:

   Portb.= 1
   Portb.= 1
   Waitms 125
   Portb.= 0
   Portb.= 0
   Waitms 75
   Portb.= 1
   Portb.= 1
   Waitms 125
   Portb.= 0
   Portb.= 0
   Waitms 75

   Portb.= 1
   Waitms 75
   Portb.= 0
   Waitms 50
   Portb.= 1
   Waitms 50
   Portb.= 0
   Waitms 50

   Portb.= 1
   Waitms 75
   Portb.= 0
   Waitms 50
   Portb.= 1
   Waitms 50
   Portb.= 0
   Waitms 50

Return

Pattern2:

   Portb.= 1
   Waitms 75
   Portb.= 0
   Waitms 50
   Portb.= 1
   Waitms 75
   Portb.= 0
   Waitms 75

   Portb.= 1
   Waitms 75
   Portb.= 0
   Waitms 50
   Portb.= 1
   Waitms 75
   Portb.= 0
   Waitms 75
Return

 

Secondary Surveillance Radar | An Introduction

Quick introduction to Secondary Surveillance Radar and how it works. After explaining the absolute basics, I am showing how one can simulate transponder responses using off-the-shelf test equipment. RTL1090 is used to verify the generated signals as valid.

If you want the arb waveform file for the 7777 Mode A response, here it is:

https://baltic-lab.com/wp-content/uploads/2015/12/SQUAWK_7777_IDENT.zip

 

Instrument Landing System Testing

This video shows how easy it is to test an Instrument Landing System, ILS for short, receiver for localizer and glideslope accuracy.

This video was shot in DNxHD using the Blackmagic HyperDeck shuttle I showed in another video (https://www.youtube.com/watch?v=cc83-Cc-vtw). After editing in Adobe Premiere and finishing it off in SpeedGrade, I exported it to h.264 at a variable bitrate averaging 35 Mbps. Please let me know if you see an increase in image quality.

 

ILS Localizer / Glide Slope Test Signal Generation

In a previous video I have shown how to generate test signals for a VOR radio navigation system for aircraft.. This article will take a look at another radionavigation system, the Instrument Landing system or “ILS” for short. The ILS is used by aircraft around the world every single day. It is designed to guide aircraft safely to a runway even with bad or no visibility.

In order to provide both lateral and vertical guidance, the ILS consist out of two individual subsystems. The part used for lateral guidance is called the localizer. For the vertical guidance component the term is glide slope. Both localizer and glide slope use a surprisingly simple way of telling on aircraft where to go. The localizer and glide slope each consist out of two independent transmitters with the same frequency and a special antenna array. The antenna arrays each create a radiation pattern with two sidelobes. One sidelobe per transmitter. One sidelobe is fed by a transmitter modulated with a 90 Hz signal and the other sidelobe is fed by carrier modulated with a 150 Hz signal. The antenna pattern is so that the two sidelobes overlap with equal intensity when the aircraft is exactly on the intended path. An AM receiver tuned to the frequency of either the localizer or glide slope will “hear” both the 90 Hz and 150 Hz tones with equal intensity when on the right path. Sounds complicated? Let’s try a picture:

So how does the airplane (and the pilot) know where to go? The ILS receivers simply compare the intensity for the 90 Hz and 150 Hz signals and display the difference. This is done independently for the localizer and the glide slope. If the 90 Hz and 150 Hz tone intensity is exactly the same, the plane is on the right path. But if one signal becomes stronger than the other, the plane is off the desired path. In the case of the localizer for instance, the 90 HZ tone will be stronger if the aircraft is off to the left of the desired course. And accordingly, the airplane is off to the right of the desired course if the 150 Hz tone is stronger. For the glide slope a stronger 90 Hz tone means that the plane is above the intended glide path. For a dominant 150 Hz tone on the glide slope, the plane is below the intended glide path. Simple, isn’t it?

It’s so simple that even some handheld airband radios can decode ILS signals and offer a backup for on board instruments in case of an instrument or electrical failure. An example for such radios are the Yaesu FTA-550 (localizer only) and the FTA-750 (localizer, glide slope and GPS). I recently bought a FTA-550 and when it arrived, I wanted to test it. Unfortunately, I live out of reach of a ILS localizer. But no problem, I’m an engineer.

Tektronix AFG3102 with resistive combiner used as baseband generator

Tektronix AFG3102 with resistive combiner used as baseband generator

To generate the 90 Hz and 150 Hz signals, I used by Tektronix AFG3102 signal generator. The two signals were fed into a resistive combiner and from there directly into the external modulation input of my HP8657D. The HP8657D signal generator was set to amplitude modulation and a frequency in the airband, 110 MHz in this case. When you do experiments like this, make sure that you use very low power, a frequency that is not used in your area and abide all communications laws. The last thing you want to do is to interfere with a real aircraft. It is advisable to use a shielded connection to the radio regardless of power.

HP8657D used as VHF AM modulated Signal Generator

HP8657D used as VHF AM modulated Signal Generator

With equal amplitude of the 90 and 150 Hz signal, the localizer needle of your ILS receiver should be exactly in the center. As you can see on the picture, my FTA-550 passed this test with flying colors. You can test the glide slope portion of your receiver in the same fashion. The glide slope transmitters transmit on UHF. So that the pilot isn’t bothered with entering two frequencies, the VHF localizer and UHF glide slope frequencies are paired so that only the VHF frequency needs to be known. IF you want to test the glide slope portion of the receiver, you need to look up the UHF glide slope frequency corresponding to your VHF localizer. You can look-up ILS frequency pairs on the internet [2].

Equal signal amplitude = exactly on centerline

Equal signal amplitude = exactly on centerline

If we lower the 90 Hz signal’s amplitude, we expect the receiver to show us to the right of the correct course. As you can see on the following picture, the FTA-550 masters this test as well.

A dominant 150 Hz signal means we are to the right of the runway centerline

A dominant 150 Hz signal means we are to the right of the runway centerline

This article is a great example how complex avionics systems can be tested with inexpensive and readily available test equipment. Avionics shops spend tons of money on specialized test equipment. Some are required to be compliant with the law, some aren’t. But on the avionics test market there appears to be a large gap between “super old and cheap” and “brand new but very expensive” when it comes to specialized test sets. Using standard off-the-shelf test equipment may be an alternative to get state of the art test sets for little money.

Links and Sources:

[1] “Instrument Landing System”, Wikipedia: http://en.wikipedia.org/wiki/Instrument_landing_system
[2] “Instrument Landing System (ILS) Frequencies”, Radioreference.com: http://wiki.radioreference.com/