Archive for the ‘Projects and Tech’ Category

From the laboratory notes of Abraham van Helsing

Generation of high differential tension and effect on tissue (living and dead)

Who is not familiar with the galvanic reaction?  While Galvani made many fine contributions to science, history will best remember him for his demonstration of the invigoration and  reanimation of a severed frog’s leg by means of electrical application.  This most fascinating application, taken to an extreme by the hubris of doctor Victor Frankenstein, suggests a use for this phenomenon somewhere between a twitching severed limb and a monstrous creature last spotted above the Arctic circle.

I have had the occasion and privilege of speaking at length with a brilliant Austrian, Nikola Tesla, at the Exposition Universelle in Paris.  The brunt of our conversation fixed primarily on Herr Tesla’s furtherance in generating large differential potentials from meaner levels.  His demonstrations of lightning summoned and tamed by his hand were like watching a Zeus of old.  While his displays harmed him not, he noted that without his preparations, the wrath of the tamed bolts would be terrible to behold.

On the train back from the Exposition, my mind had occasion to wander from Herr Tesla’s display to Volta’s demonstration of Galvani’s work.  While the apparatus Tesla employs for his work was great in power, so too was it in bulk.  If, perhaps, less power were employed, the size may be reduced to something a man may easily carry?  For  any tissue, whether it belong to those living or once living, will jump and tense to the influence of a bolt of electricity.  Among the creatures I have read of or even had the occasion to face, all shared the commonality of flesh.  To this end, their bodies betraying their will by the introduction of a high potential, I bend my next focus.

The resultant device created quite satisfying displays, and its damped bite was enough to deny me the use of my hand for a notable duration.  I must note that the full effect must be terrible indeed to be effective against the things outside man’s usual sphere: to this caution must be taken not to introduce the effects of this on a man, as the result will be most severe.  The device proved, the next challenge comes in reducing the size of coils and galvanic pile to something that can be carried – currently the excitation device occupies much of a laboratory table.”

As part of a costume for the character of Abraham van Helsing (less the bold scholar of medicine in Bram Stoker’s Dracula, more the swashbuckling character in a recent movie), I created several props of varying degrees of function.  One of them is this baton capped with man’s lightning.  For this, I gutted an inexpensive stun gun, and formed the rod around the secondary, high-step transformer.  The priming circuitry, responsible for stepping 9V up to a few hundred, was housed in an arm guard that was frankly ugly.

The central ball was one of the output electrodes, and the guard ring around it the second half.  When it was energized, arcs would strike at random around the ring.  The energized section was isolated from the control by an acrylic rod (illuminated with an LED for effect)

Notable problems I had with this device:

  • Variable display: the arcing display would not be consistent, varying with environmental conditions and ring oxides, from violet tracers (like a plasma ball) to full arcs, to no arcs.
  • Insulator breakdown: I do not know if the potential reached the neighborhood of the advertized 100kV, but the insulation between the outer bronze conductors and the hidden wire to the secondary transformer developed a flaw.  It began arcing across the base.  Once the initial strikes burned through the insulation, I could not create a good replacement.  I tried stripping the area and filling it with hot glue, resin epoxy, clay, even silly putty (which burns interestingly, by the way).

It was a learning experience, and one I think I will revisit at some point to finalize.  I have some corona dope, so I am hopeful.

Toy LED Lantern

Posted: January 12, 2014 in Projects and Tech
The culprit, functional now

The subject of this discussion

Lights are an impulse buy I constantly struggle against. Soooo many lovely varied options.  My young son gives me new excuses to give in to that impulse.  On the Fourth of July, I was shopping at Michael’s when I found an LED lantern in the discount bin.  It seemed sturdy enough, with good fittings and a solid-feeling switch.  So I gave in to the impulse. After all, my son will be out after dark tonight, right?  He will need the lantern.

I loaded it up with 4xAA (NiMH, but the lower voltage shouldn’t cause any performance issues) and we took it to the evening fireworks show.  The lamp was bright through the evening, and my son turned it on and off at his whim. On the way back from fireworks, however, the new little plastic lantern started flickering.  I cracked it open, expecting a loose wire, or cold solder joint – both common problems in cheap consumer goods, especially with ROHS directives and lead-free solder.  The litany of problems went far deeper than that. The three white LEDs were wired in parallel, a fair design choice.  It could have used one fewer batteries at that point, but we will let that pass.  They were current-limited by a 22Ω, 1/8W, 5% resistor, which I noticed was hot to the touch.  Very hot.

Running the calculations*, each branch of the LEDs were running at ~37mA, which is 120% of their MAXIMUM rating.  Further, the resistor was dissipating ~260mW, about 200% of its maximum rating.  As a side note, the resistor had externally visible voids and a poor paint job, indicating possibly a rejected part (aka cheaper); it did measure within tolerance, though. As it turns out, one of the LEDs was partially burned out – occasionally working, occasionally shorting, causing the whole unit to flicker.  This particular LED configuration is not fault-friendly – if one shorts, the entire set goes out; if one opens, the other two LEDs each experience half of the burned-out LED’s current in addition to their own.

Oh, also the wiring was flimsy with cold soldering and no strain relief and part of the diffuser latch was cracked.

Many parts of this product were shodding (opposite of shining) examples of the shoddy engineering and poor foresight that plagues many consumer goods, many of which could be rectified inexpensively and easily.   Using a 33Ω instead of a 22Ω resistor (1/4W) would dramatically decrease the failure rate of these products, cutting down on returned product.  The human eye is not very sensitive to differences in high light levels, and LED life sharply decreases with higher currents / overcurrent.  I would venture that the consumer of a toy lantern is not looking for a room-lighting device so much as a rugged, long-lasting device.

This has turned into something of a rant.  In the end, I repaired the lantern with some white LEDs I had on-hand and a correct 33ohm resistor. Take-away lessons:

  1. A 1/4 cent oversight/savings can be rectified with $1.51 in parts and $100 in equipment – on a $5 plastic lantern
  2. Don’t be afraid to open up a product, and do question everything. Just because it is on the market does not mean that it is correct, and price tag does not dictate quality. There are some quite elegant solutions found in cheap toys, as well as appalling oversights.
  3. When buying cheap toys, don’t loose your receipt. You can’t take it back, and then you have to fix it.  :)

* Simple LED current-voltage calculations for single and paralleled configurations, derived from Ohm’s Law and Kirchhoff Current Laws A single LED driven by a voltage source and with a current limiting resistor is defined by the following equations:

I=\frac{V_{s}-V_{f}}{R}       OR       R=\frac{V_{s}-V_{f}}{I}

  • Vf is the forward voltage drop of the LED (a characteristic of the LED based on its color) [volts]
  • Vs is the voltage source [volts]
  • R is the value with a current limiting resistor [ohms]
  • I is the current through the branch (from the voltage source, through the resistor and the LED) [amps]

Given the forward voltage (available on the datasheet or package for the LED, or here) and the maximum continuous current (again, datasheet or package), you can determine the resistor needed, rounded to the next largest standard resistor value. With this information, LEDs wired in parallel (all anodes tied together and all cathodes tied together) being limited by a single resistor would be described by:

I_{LED}=\frac{V_{s}-V_{f}}{R \cdot N}       OR       R=\frac{V_{s}-V_{f}}{I_{LED} \cdot N}

with N being the number of (identical) LEDs wired in parallel.  ILED now only describes the current through a single LED. The calculations above were used with the assumptions of Vf=3.6V, ILED=Imax=30mA for LED characteristics, which are typical for a white “superbright” type LED.