Fitting all of the necessary components of the LSDX-4 on to the required 1" by 2" board (or smaller) PCB board has been an interesting endeavor. Each subsystem has its own challenges. The power regulators, for example, for the light output have to be well isolated from the rest of the circuit, which can cause audible noise in the audio lines and faulty reception from the sensitive accelerometer. This is kind of hard to do considering the small overall size. Trying to confine increasingly more features into the design has led us to adopt some of the most advanced (or at least miniaturized) parts in existence.
Many of today's consumer electronics use SMD (surface mount devices) versus through hole components to both eliminate the difficulties associated with routing the internal circuit traces and to allow for easier machine assembly. The SMDs intended for use with the LSD-X4 are especially small. The Ultrasound board used plenty of barely visible 0402 resistors and capacitors, which many users never even knew were there. Now, we're dropping the size of these down to a quarter of their original area (0201). Additionally, to further reduce size requirements, we've built the circuit around all low profile chips, many of which are lead-less components which must be carefully soldered and x-ray examined to ensure correct solderability.
Unfortunately, this is still not enough! The circuit board itself must be upgraded. We're going with a 6-layer design, which I was warned by an Advanced Circuits representative, "...will make the cost go up exponentially." In that case, I hope we don't have to use a 10 layer design.
Since the board is populated on both front and back with components, many chips from one side will need to communicated and react with components on the other leading to a large number of connections (PCB traces) which must pass through to the other side. Doing so, without an external jumper cable, requires small holes drilled through and plated, called vias. Dealing with "micro-vias" leads to alignment difficulties as each layer of the circuit board is pressed and sealed together. Then, electrical tests are required to guaranty that the circuit is consistent.... more money for that too...
Not to worry though. It's coming together! I'm very enthusiastic about this project!
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As am I enthusiastic, but I do wonder that when all the costs are added that we aren't going to be shelling out $200+ for just a soundboard.
ReplyDeletePlease keep the progress reports coming!
(And do we have an updated ETA?)
Hey Skott,
ReplyDeleteThe sale price estimation, as before, is still $160.00. Basically the high costs we're facing up front (the prototype) will be divided out by the quantity we produce. The more people interested, the lower the price, that's the main objective.
Thanks, everyone, for the continued interest in this project.
Please tell me here... what's on your mind!?
Oh and about the ETA... I don't want to disappoint anyone and I honestly am not sure. But it's going to happen. This project will be followed through to the end.
ReplyDeleteThat's all we have been hoping to hear Nova.. a serious desire to see it through and provide the community with an excellent sound system option at a reasonable price. Keep it up and keep us updated as often as possible (even if it's just little idea updates or pics of current builds). we'll do our part and keep the good word spreading.
ReplyDeleteThanks for the update
ReplyDeleteHey Nova
did the power off time get reviewed? The US boards take too long to power off the board IMO
can it be user defined?
Cheers
Mersenne, The Ultrasound boards shut down as soon as the retraction sound effect is finished playing. If that sound effect were shorter, then the shut down time would be decreased. Also though, the amount of time the button must be held to begin the shutdown sequence was, in my opinion, too long. This parameter (button hold time) will be completely adjustable in the LSD-X4. Any button sequence will be definable. A user might, for example, require a "double-click" to shut down the saber, which can be implemented in the LSD-X4.
ReplyDeleteThanks Nova
ReplyDeleteit was the 'button hold time' that I meant, so it's great to hear it will be user defined. Sorry for any confusion. Felt like it was 'wait I'm powering down the saber guys ....... yeah it's almost done ....... Ok now we're good to go'
brilliant improvement
Jesse,
ReplyDeleteI know what you mean regarding the design issues. I work in the CAM department at a PCB manufacturer. Glad to hear things are progressing, good luck with the technical issues!
I know it is kinda late in the game to mention this... but what about the possibility of a scrolling effect for led string blades?
ReplyDeleteI would like to see the actual mounts for the leads to the saber components to be through hole devices to make it easier to solder the wires to the board.
ReplyDeleteAny new updates? We're coming up on your deadline nova.
ReplyDelete