Goldilocks Analogue – Wrap Up

This is the final item on the Goldilocks Analogue as a design and production exercise.

Thank you for pledging on the Kickstarter Project page. Closed on November 19th 2015, with 124% funding. Now that the Kickstarter Pledges have been shipped, the Goldilocks Analogue is available on Tindie.

I sell on Tindie

I’ve been updating this post with the pre-production and production experience over the past few months.

The pre-production design materials, correcting the errata noted on Prototype Version 4, have been finalised and sent to Seeed Studio.
GoldilocksAnalogue_Seeed_20151120

The interim backer report is out, and now manufacturing quantities for procuring parts ready for the February production run have been finalised.

An updated version of the Goldilocks Analogue User Manual is available, and the Production Testing Document has reached Version 2 following inclusion of Windows 10 test procedures.

Revised Arduino IDE Variant files for Goldilocks Analogue using the Arduino core are available on Github.

Also additional optional libraries to provide support for each of the advanced features of the Goldilocks Analogue are available in the Arduino IDE Library Manager.

Arduino IDE compatibility testing revealed only a few remaining issues related to support of the ATmega1284p used in the Goldilocks Analogue. Two issues have been raised and resolved as 2 pull requests on the main Arduino IDE development path.

Both these issues have been committed into the Arduino main git tree, and they have landed in Arduino IDE Release 1.6.8.

The only remaining known issue is the limitation in the configuration of the Tones() code to use only Timer 2. We would like to use Timer 2 for the RTC. There is no other option but to use this Timer for the RTC support, so it would be good if Tones() could be configured to use a different timer.

Testing

Rather than going back over old ground, I’ll just be testing the pre-production version against the Version Prototype 4, to ensure that the things that should have improved, are improved, and that nothing has become broken.

Power Supplies

In the image below, Channel 1 (yellow) is 4.47mV of noise present at the output capacitor for the power supply, and Channel 2 (blue) is the 3.47mV supply noise present on a test Vcc pin closest to the MCU.

The significant improvement in noise level for the pre-production version at the MCU is similar to that achieved for the Prototype 4 (even slightly better), and this is probably due to reduced capacitive coupling into the ground plane by removing the ground copper from directly under the main supply inductor.

GA PP Power Supply Noise

GA PP: 5V Power Supply Noise

Remembering, for context, that 4mV is still the same order of the least significant bit for a 5V 10 bit ADC sampler, as found in the ATmega1284p, and a one bit change in the LSB of the MCP4822 input generates a 1mV change in output.

Checking the other power supplies on the board, Channel 1 (yellow) is the 3.3V positive supply, provided by a linear regulator. This supply is not used for analogue components, so the 4.0mV noise level is not critical, but never the less it is slightly less than on the Version P4.

Channel 2 (blue) below shows the -3V supply for the Operational Amplifier. This shows that the supply voltage noise of 5.9mV after filtering by a first order LC filter further smooth this supply. Compared to the Version P4 with no filtering (shown below) the noise is reduced substantially. The Version P4 shows a 10mV ramp, because it is a capacitive charge switching device. The addition of this LC filter was the one substantial change from the Prototype 4, so it is good to see the positive effect on the negative supply input to the Op Amp.

GA PP 3.3V and -3V Power Supply Noise

GA PP: 3.3V and -3V Power Supply Noise

Goldilocks Analogue Prototype 4 - 3.3V & -3V Supply Noise

GA P4: 3.3V & -3V Power Supply Noise

Analogue Output

The standard test that I’ve been using throughout the development is to feed in a 43.1Hz Sine wave generated from a 1024 value 16 bit LUT. The sampling rate is 44.1kHz, which is generated by Timer 1 to get the closest match.

The spectra and oscilloscope charts below can be directly compared to the testing done with prototype Version P4 and earlier versions of the Goldilocks Analogue.

The below chart shows the sine wave generated at the output of the Op Amp. This is exactly as we would like to see, with no compression of either the 4.096V peak, or the 0V trough.

Goldilocks Analogue – 43Hz Sine Wave – Two Channels – One Channel Inverted

GA PP: 43Hz Sine Wave – Two Channels – One Channel Inverted

Looking at the spectra generated up to 953Hz it is possible to see harmonics from the Sine Wave, and other low frequency noise.

The spectrum produced by the Goldilocks Analogue shows most distortion is below -70dB, and that the noise floor lies below -100dB. The pre-production sample shows slightly higher noise carriers than the Version P4, but the difference is not substantial.

GA PP 953Hz

GA PP: 43.1Hz Sine Wave – 953Hz Spectrum

In the spectrum out to 7.6kHz we are looking at the clearly audible range, which is the main use case for the device.

The Goldilocks Analogue has noise carriers out to around 4.5kHz, but they are all below -80dB. After 4.5kHz the only noise remains below -100dB.

GA PP 7k6Hz

GA PP: 43.1Hz Sine Wave – 7k6Hz Spectrum

The spectra out to 61kHz should show a noise carrier generated by the reconstruction frequency of 44.1kHz.

The Goldilocks Analogue shows the spectrum maintains is low noise level below -90dB right out to the end of the audible range, and further out to the reconstruction carrier at 44.1kHz.

GA PP 61kHz

GA PP: 43.1Hz Sine Wave –  61kHz Spectrum

The final spectrum shows the signal out to 976kHz. We’d normally expect to simply see the noise floor, beyond the 44.1kHz reconstruction carrier noise.

The Goldilocks Analogue has a noise carrier at around 210kHz, probably generated by the -3V supply. The noise carrier at 340kHz is generated through the 5V SMPS supply, and is absent when powered by USB socket. Aside from the two carriers mentioned, there is no further noise out to 976kHz.

GA PP 976kHz

GA PP: 43.1Hz Sine Wave – 976kHz Spectrum

The Pre-production analogue output works as specified, and is essentially identical to the analogue output on the Prototype 4. It can maintain the 72dB SNR required, of which it should theoretically be capable.

XBee Walkie Talkie

I’m building an advanced Arduino clone based on the AVR ATmega1284p MCU with some special features including a 12 bit DAC MCP4822, headphone amplifier, 2x SPI Memory (SRAM, EEPROM), and a SD Card. There are many real world applications for analogue outputs, but because the Arduino platform doesn’t have integrated DAC capability there are very few published applications for analogue signals. A Walkie Talkie is one example of using digital and analogue together to make a simple but very useful project.

Two Goldilocks Analogue prototypes with XBee radios, and Microphone amplifiers.

Two Goldilocks Analogue prototypes with XBee radios, and Microphone amplifiers.

The actual Walkie Talkie functionality is really only a few lines of code, but it is built on a foundation of analogue input (sampling), analogue output on the SPI bus to the MCP4822 DAC, sample timing routines, and the XBee digital radio platform. Let’s start from the top and then dig down through the layers.

XBee Radio

I am using XBee Pro S2B radios, configured to communicate point to point. For the XBee Pro there needs to be one radio configured as the Coordinator, and the other as a Router. There are configuration guides on the Internet.

I have configured the radios to wait the maximum inter-character time before sending a packet, which implies that the packets will be set only when full (84 bytes). This maximises the radio throughput. Raw throughput is 250 kbit/s, but the actual user data rate is limited to about 32 kbit/s. This has an impact on the sampling rate and therefore quality of speech that can be transmitted.

Using 10 bit samples companded using A-Law to 8 bit code words, I have found that about 3 kHz sampling generates about as much data as can be transmitted without compression. I’m leaving G.726 compression for another project.

The XBee radios are configured in AT mode, which acts as a transparent serial pipe between the two endpoints. This is the simplest way to connect two devices via digital radio. And it allowed me to do simple testing, using wire, before worrying about whether the radio platform was working or not.

XBee Packet Reception in Purple

XBee Packet Reception in Purple

Looking at the tracing of a logic analyser, we can see the XBee data packets arriving on the (purple) Rx line of the serial port. The received packet data is stored into a ring buffer, and played out at a constant rate. I have allowed up to 255 bytes in the receive ring buffer, and this will be sufficient because the XBee packet size is 84 bytes.

The samples to be transmitted to the other device are transmitted on the (blue) Tx line, more or less in each sample period even though they are buffered before transmission. The XBee radio buffers these bytes for up to 0xFF inter-symbol periods (configuration), and only transmits a packet to the other endpoint when it has a full packet.

Sampling Rate

Looking at the bit budget for the transmission link, we need to calculate how much data can be transmitted without overloading the XBee radio platform, and causing sample loss. As we are not overtly compressing the voice samples, we have 8 bit samples times 3,000 Hz sampling or 24 kbit/s to transmit. This seems to work pretty well. I have tried 4 kHz sampling, but this is too close to the theoretical maximum, and doesn’t work too effectively.

Sample rate of 3,000 Hz seems to be the optimum.

Sample rate of 3,000 Hz seems to be the optimum.

Looking at the logic analyser, we can see the arrival of a packet of bytes commencing with 0x7E and 0x7C on the Rx line. Both the Microphone amplifier and the DAC output are biased around 0x7F(FF), so we can read that the signal levels captured and transmitted here are very low. The sample rate shown is 3,000 Hz.

Sample Processing

I have put a “ping” on one output to capture when the sampling interrupt is being processed (yellow). We can see that the amount of time spent in the interrupt processing is very small for this application, relative to the total time available. Possibly some kind of data compression could be implemented.

DAC and sample processing

DAC and sample processing

During the sampling interrupt, there are two major activities, generating an audio output, by placing a sample onto the DAC, and then reading the ADC to capture an audio sample and transmit it to the USART buffer.

This is done by the audioCodec_dsp function, which is called from the code in a timer interrupt.

void audioCodec_dsp( uint16_t * ch_A,  uint16_t * ch_B)
{
	int16_t xn;
	uint8_t cn;
	/*----- Audio Rx -----*/

	/* Get the next character from the ring buffer. */

	if( ringBuffer_IsEmpty( (ringBuffer_t*) &(xSerialPort.xRxedChars) ) )
	{
		cn = 0x80 ^ 0x55; // put A-Law nulled signal on the output.
	}
	else if (ringBuffer_GetCount( &(xSerialPort.xRxedChars) ) > (portSERIAL_BUFFER_RX>>1) ) // if the buffer is more than half full.
	{
		cn = ringBuffer_Pop( (ringBuffer_t*) &(xSerialPort.xRxedChars) ); // pop two samples to catch up, discard first one.
		cn = ringBuffer_Pop( (ringBuffer_t*) &(xSerialPort.xRxedChars) );
	}
	else
	{
		cn = ringBuffer_Pop( (ringBuffer_t*) &(xSerialPort.xRxedChars) ); // pop a sample
	}

	alaw_expand1(&cn, &xn);	// expand the A-Law compression

	*ch_A = *ch_B = (uint16_t)(xn + 0x7fff); // move the signal to positive values, put signal out on A & B channel.

	/*----- Audio Tx -----*/

	AudioCodec_ADC( &mod7_value.u16 );	// sample is 10bits left justified.

	xn = mod7_value.u16 - 0x7fe0;	// center the sample to 0 by subtracting 1/2 10bit range.

	IIRFilter( &tx_filter, &xn);	// filter transmitted sample train

	alaw_compress1(&xn, &cn);	// compress using A-Law

	xSerialPutChar( &xSerialPort, cn);	// transmit the sample
}

I am using the AVR 8 bit Timer0 to generate the regular sample intervals, by triggering an interrupt. By using a MCU FCPU frequency which is a binary multiple of the standard audio frequencies, we can generate accurate reproduction sampling rates by using only the 8 bit timer with a clock prescaler of 64. To generate odd audio frequencies, like 44,100 Hz, the 16 bit Timer1 can be used to get sufficient accuracy without requiring a clock prescaler.

The ATmega1284p ADC is set to free-run mode, and is scaled down to 192 kHz. While this is close to the maximum acquisition speed documented for the ATmega ADC, it is still within the specification for 8 bit samples.

ISR(TIMER0_COMPA_vect) __attribute__ ((hot, flatten));
ISR(TIMER0_COMPA_vect)
{
#if defined(DEBUG_PING)
  // start mark - check for start of interrupt - for debugging only (yellow trace)
  PORTD |= _BV(PORTD7); // Ping IO line.
#endif

  // MCP4822 data transfer routine
  // move data to the MCP4822 - done first for regularity (reduced jitter).
  DAC_out (ch_A_ptr, ch_B_ptr);

  // audio processing routine - do whatever processing on input is required - prepare output for next sample.
  // Fire the global audio handler which is a call-back function, if set.
  if (audioHandler!=NULL)
    audioHandler(ch_A_ptr, ch_B_ptr);

#if defined(DEBUG_PING)
  // end mark - check for end of interrupt - for debugging only (yellow trace)
  PORTD &= ~_BV(PORTD7);
#endif
}

This interrupt takes 14 us to complete, and is very short relative to the 333 us we have for each sample period. This gives us plenty of time to do other processing, such as running a user interface or further audio processing.

SPI Transaction

At the final level of detail, we can see the actual SPI transaction to output the incoming sample to the MCP4822 DAC.

SPI DAC Transaction

SPI MCP4822 DAC Transaction

As I have built this application on the Goldilocks Analogue Prototype 2 which uses the standard SPI bus, the transaction is normal. My later prototypes are using the Master SPI Mode on USART 1 of the ATmega1284p, which slightly accelerates the SPI transaction through double buffering, and frees the normal SPI bus for simultaneous reading or writing to the SD Card or SPI Memory, for audio streaming. In the Walkie Talkie application there is no need to capture the audio, so there’s no down side to using the older prototypes and the normal SPI bus.


void DAC_out(const uint16_t * ch_A, const uint16_t * ch_B)
{
  DAC_command_t write;

  if (ch_A != NULL)
  {
    write.value.u16 = (*ch_A) >> 4;
    write.value.u8[1] |= CH_A_OUT;
  }
  else // ch_A is NULL so we turn off the DAC
  {
    write.value.u8[1] = CH_A_OFF;
  }

  SPI_PORT_SS_DAC &= ~SPI_BIT_SS_DAC; // Pull SS low to select the Goldilocks Analogue DAC.
  SPDR = write.value.u8[1]; // Begin transmission ch_A.
  while ( !(SPSR & _BV(SPIF)) );
  SPDR = write.value.u8[0]; // Continue transmission ch_A.

  if (ch_B != NULL) // start processing ch_B while we're doing the ch_A transmission
  {
    write.value.u16 = (*ch_B) >> 4;
    write.value.u8[1] |= CH_B_OUT;
  }
  else // ch_B is NULL so we turn off the DAC
  {
    write.value.u8[1] = CH_B_OFF;
  }

  while ( !(SPSR & _BV(SPIF)) ); // check we've finished ch_A.
  SPI_PORT_SS_DAC |= SPI_BIT_SS_DAC; // Pull SS high to deselect the Goldilocks Analogue DAC, and latch value into DAC.

  SPI_PORT_SS_DAC &= ~SPI_BIT_SS_DAC; // Pull SS low to select the Goldilocks Analogue DAC.
  SPDR = write.value.u8[1]; // Begin transmission ch_B.
  while ( !(SPSR & _BV(SPIF)) );
  SPDR = write.value.u8[0]; // Continue transmission ch_B.
  while ( !(SPSR & _BV(SPIF)) ); // check we've finished ch_B.
  SPI_PORT_SS_DAC |= SPI_BIT_SS_DAC; // Pull SS high to deselect the Goldilocks Analogue DAC, and latch value into DAC.
}

Wrap Up

Using a few pre-existing tools and a few lines of code, it is possible to quickly build a digitally encrypted walkie talkie, capable of communicating (understandable, but certainly not high quality) voice. And, there ain’t no CB truckers going to be listening in on the family conversations going forward.

This was a test of adding microphone input based on the MAX9814 to the Goldilocks Analogue. I will be revising the Prototype 3 and will add in a microphone amplification circuit to support applications needing audio input, like this walkie talkie example, or voice changers, or vocal control music synthesizers.

I’m also running the ATmega1284p devices at the increased frequency of 24.576 MHz, over the standard rate of 20 MHz. This specific frequency allows very precise reproduction of audio samples from 48 kHz down right down to 4 kHz (or even down to 1,500 Hz). The extra MCU clock cycles per sample period are very welcome when it comes to generating synthesised music, or encoding audio samples.

Code as usual on Sourceforge AVR freeRTOS Also, a call out to Shuyang at SeeedStudio who’s OPL is awesome, and is the source of many components and PCBs.

Goldilocks Analogue – Prototyping 3

The Prototype 4 has now been designed, read here for the next iteration. I’ve received the Prototype 4 back and now I’m testing them.

Following my initial design article, and the follow up design article, I’ve put quite a lot of thought into how I can make this Goldilocks Analogue device best achieve my stated goals. Pictured is the new 3rd Goldilocks Analogue Prototype

Goldilocks Analogue Prototype 3

The finished prototype boards are now in my hands, and testing of the PCB configuration the new SPI EEPROM and SRAM capabilities, together with MSPIM interface for the DAC begins. These two features contribute to making the Goldilocks Analogue great analogue synthesiser platform.

P1010913

Combined with a Gameduino2 LCD and touch screen, it creates flexible sound touch controller, with quality analogue output.

Goldilocks Analogue - Prototype 3

Goldilocks Analogue – Prototype 3

This is the working design document. It will grow as I get more stuff done, and notes added here. I’ve pretty much finished the paper design now, and will let it settle for a few weeks over the 2014 holiday season. It is sometimes good to do things again, with a few weeks perspective from the original decisions.

Goldilocks Analogue - Prototype 2

Goldilocks Analogue – Prototype 2

Major Revision in Strategy

Over the past months I’ve been spending time writing code to go along with the latest revision of the Goldilocks Analogue. I have successfully implemented a version of the NASA EEFS simple flash file system, to use to buffer data either for acquisition or for analogue playback, and I’ve been working on streaming functions to get data off the SD card and off the EEFS flash file system. The outcome is that it is not possible to do everything with just one SPI bus, and keep generality when needed. The SD card is just too slow, and can’t be easily interrupted. The FRAM/SRAM/EEPROM doesn’t have enough storage to effectively stream GigaBytes of data, as a uSD card can achieve.

So, what to do? Adafruit uses a software bit-banged SPI outcome to drive their MCP4921 and doesn’t get close to the maximum speed I want to achieve. Fortunately, with the ATmega1284p there is a simple answer at hand. I have decided to move the MCP4822 off the standard SPI pins, and connect it to the USART1 TX and XCK pins, using the USART in its Master SPI mode.

This is a major revision in strategy. Previously I have been very adverse to putting anything on the standards Arduino pins, preferring to keep all of the Goldilocks extra features off the Arduino footprint. However, the outcome is well worth using the USART1 to drive the MCP4822, and nothing is compromised.

USART MSPI mode is available on any ATmega device. On the UNO platform, using the ATmega328p, there is only one USART and so of course it is reserved for serial communications. The Goldilocks ATmega1284p has two USART interfaces, and usually the second one (USART 1) goes unused. Therefore connecting its XCK and TX pins to the MCP4822 is the simplest and best outcome to achieve high throughput and regularity SPI output on a non-shared SPI interface. And, as the MCP4822 DAC has high impedence (~10kOhm) inputs, having the DAC sharing the pins won’t affect normal pin usage to any extent.

And, there’s more win. The USART MSPI has double buffering for the transmit function. This means that we can actually achieve a higher throughput using the USART MSPI than we can using the standard SPI bus! These logic traces demonstrate that the my best implementation of the SPI interface requires 4.58us to transmit a “frame” of information, consisting of two 12 bit samples. Using the USART MSPI interface we can achieve 4.25us per frame.

DAC control using SPI bus.

DAC control using SPI bus.

DAC control using SPI bus.

DAC control using USART MSPI bus.

Either way, achieving 44.1kHz stereo output is not an issue. This trace shows the time spent in the DAC-out interrupt for a simple function, with the samples being played out at 44.1kHz.

44.1kHz samples using USART MSPI output.

44.1kHz samples using USART MSPI output.

Guessing that this would be a great outcome, I ordered new PCBs from Seeed which implement the new pin assignments for the MCP4822. They will be here shortly.

My Revision Plans

Revert the uSD card 3V SPI bus drivers back to the quad and single buffers. The TXB/TXS story remains unresolved, and I can’t be bothered to work out why, when a simple answer is at hand. – DONE

Connect the uSD _CARD_DETECT to PC2 which has no other function except JTAG. – DONE

Remove the FTDI 6 pin for USART0. Or, better to move it to connect to USART1, so that USART1 can be addressed by an external FTDI device. Move it to the end of the board, so it doesn’t block Shield usage. Note the RTS/CTS Reset is not connected because this is replaced by a DAC A/B channel. – DONE

Remove the Analogue outputs from centre of board. Move them to the end of the board and integrate them into the FTDI USART1 socket on the RTS and CTS pin positions (obviously not on Tx or Rx pins, or on Vcc or GND either). – DONE

Connect the MCP4822 _LDAC pin to enable sychronisation of the A and B channels. Connect to PC3 which has no other function except JTAG. Remember the _LDAC is pulled to GND by default. – DONE

Have another look at the output filtering on the DAC, perhaps it could be a little stronger than the prototype with the corner at 23kHz. Single pole R1=68Ω C1=100nF. – DONE

This 2nd order filter is still linear, but filters significantly more (6dB rather than 3dB per decade) than the single pole version on the prototype.

2nd Order RC Low Pass Filter

Using standard Resistor and Capacitor values R1=47Ω C1=100nF R2=47Ω C2=100nF in a 2nd order CR Low-pass Filter Design Tool.

Extend the prototyping area by three columns. – DONE

Add a pin-out to allow the DS3231 RasPi module (battery or super capacitor) from Seeed Studio to be easily attached. Unfortunately, the devices I have don’t implement an _INT/SQW output, so alarms and wake on alarm won’t be possible. – DONE

Push the JTAG pads to the back of the board, without forgetting to flip the pin layout around. – DONE

Add SRAM or FRAM SPI storage. FRAM is non volatile storage, that has no delay. With a reasonable amount of storage we can use it to provide short audio samples, and get them back relatively easily, without file system and uSD card overheads. But FRAM is pretty expensive, and SRAM chips with same pin-out are available for much cheaper, that might fulfil the job of buffering or capturing samples.

MB85RS64V FRAM is the only reasonable device available for 5V supply. And it is a reasonable price of $1.80 per unit. But it is much too small to use as an analogue sample store. Need to use the 128kB MB85RS1MT FRAM version, but this required being driven from Vcc 3V3. At 8kHz sampling, 128kB gives us 16 seconds of sound, which is quite a lot. It costs around $6 which seems to be the sweet spot in pricing now. Will have to add another 3V3 to 5V MISO buffer. Use PC4 as the MB85RS1MT SPI _SS line.

Alternatively, just make the pinout for SPI 5V and implement SRAM using the Microchip 23LC1024 device, which is $2.50 each. We can choose FRAM or SRAM at assembly. Or even both, as there is a spare _SS available. So let’s do two devices at Vcc 5V supply.

Put 10kOhm pull-up resistors on all of these _SS lines, _CARD_DETECT and _HOLD. – DONE

Add 10kOhm pull-down resistors on _LDAC allowing active _LDAC control but not requiring it. – DONE

Convert the 3.3V regulator to AP1117 type in SOT89-3 package. No space for SOT223. Upgrades the 3.3V supply from 150mA to 1000mA. Heat spread on Layer 2 GND and on Layer 15. – DONE

Initial Board Layout

I’ve finished the schematic and the board layout, and now I just have the detailed work of checking all the things, again, and again. I’ve come back to this after letting it stew for a few days with the thought of changing just one component. But, as usual have made a host of minor adjustments that should make it better. These include further clearance of the ground plane under the analogue components, and untangling and straightening signals and vias where possible.

The Goldilocks Analogue Schematic  in PDF format.

Front of board (All Layers)

The board is now pretty tightly packed. But, there is still a large number of options for prototyping on the board, or to exit the board with 8-pin headers. Each of Port A, Port B and Port D can be taken off board with one header each. Alternatively, a 2×8 connector can be attached, with the pins assigned and connected as desired.

The DAC A (L) and DAC B (R) channels are integrated into the far right edge of the board, along with TX1 and RX1 pins in the form of a FTDI 6 pin interface (including 5V and GND).

The first 5 pins of Raspberry Pi IO are replicated, to allow DS3231 RTC modules (designed for RaspPi) to be connected. For permanent mounting, the module can be flipped on its back to show the battery, and be mounted over the DAC which keeps the prototyping area clear.

I have been able to fit 2x SPI SRAM (or FRAM or NVRAM or EEPROM) on the board, using the spare JTAG IO pins. It is very tight, but having the option to fit up to an extra 2Mbit of SRAM will be quite useful for buffering and storing large amounts of data (audio, or samples).

15th April

The finished boards are now in my hands, and testing of the new SPI EEPROM and SRAM capabilities, together with MSPIM interface for the DAC begins.

Goldilocks Analogue - Prototype 3

Goldilocks Analogue – Prototype 3

Of course, new features are coming to mind. I’ll be putting them into the fourth prototype, which should come soon.

9th March

The blue PCB are back. Everything looks in order. The board is almost identical to the previous one. Just the change to the SPI attachment of the MCP4822 DAC to use the second ATmega1284p USART in MSPI mode.

The boards are now being built, and should be finished by the end of March. Looking forward to testing. I’ve requested that the boards be build with 2Mbit EEPROM and 1Mbit EEPROM combined with 1Mbit SRAM options. I don’t think having FRAM will be useful as the storage capability will be too small and too expensive. The EEPROM option will allow up to 16 seconds of high quality audio samples to be stored (without using an SD card). The SRAM option will allow samples of audio to be stored, and then used to play back, but given quality will only be 8 or 10 bits because of the inbuilt ADC capability, up to about 16 seconds can again be recorded.

Goldilocks Analogue - 2x SPI Memory Devices

Goldilocks Analogue – 2x SPI Memory Devices

16th February

Major revision. Moved the DAC control to use the USART1 MSPI function. It will be connected to Arduino Pin 4 XCK1 and Pin 3 TX1. This will ensure that we can stream data from the uSD card or the FRAM/SRAM/EEPROM on the main SPI bus to the DAC on the USARTt1 MSPI bus with no contention issues.

PCB with the revised connections is on its way.

21st January

The boards are back. Everything looks in order. The concept of using the keep-out layer to write in silkscreen works as hoped, so the labels on the edge are legible.

Time to get to ordering the new components, and building.

Goldilocks Analogue - Prototype 3

Goldilocks Analogue – Prototype 3

31st December

Cleaned up the board to allow more labels to be applied, trying to make it self-documenting. Packed the analogue section a bit tighter, and improved the power routing.

Screenshot from 2014-12-31 15:47:28

21st December

Cleaned up many traces and cleared the Layer 2 GND plane even more. Discovered the DS3231 modules don’t implement the _INT/SQW function, but leaving the connection to PB2 (INT2) on the pin-out for the future.

Screenshot from 2014-12-21 17:36:10

16th December

Screenshot from 2014-12-16 22:12:43

Top Layer

Labels for the DAC A and DAC B and FTDI interface have been put into the keep-out layer in the silk screen on the edge. They will appear when the silk is printed.

Added Test Points for the 3.3V SPI signals, which are the only signals that can’t be tested off a pin-out somewhere.

31st December

Added labels for the I2C (Raspberry Pi IO1 through IO5) pin out, by moving the analogue section left.

Screenshot from 2014-12-31 15:45:41 Screenshot from 2014-12-31 15:45:55

21st December

Screenshot from 2014-12-21 17:22:27 Screenshot from 2014-12-21 17:22:52

16th December

Screenshot from 2014-12-16 22:10:31 Screenshot from 2014-12-16 22:12:18

Layer 2 – GND

The GND plane remains whole under the DAC and Amplifiers.

31st December

Moving the analogue section to the left and compressing it moves components more over the solid ground plane.

Screenshot from 2014-12-31 15:46:07 Screenshot from 2014-12-31 15:46:17

21st December

Improved the ground plane by moving traces out from under components, and re-routing AVCC line.

Screenshot from 2014-12-21 17:28:45 Screenshot from 2014-12-21 17:29:03

16th December

Screenshot from 2014-12-16 22:10:58 Screenshot from 2014-12-16 22:10:43

Layer 15 – 5V (and 3.3V)

The 5V layer, with the 3.3V and AVCC 5V supplies too.

31st December

Resolved the S-bend power to the I2C 5V pin out, and removed some dead traces.

Screenshot from 2014-12-31 15:46:30 Screenshot from 2014-12-31 15:46:44

21st December

Kept the 5V AVCC line on this layer which makes it longer, but avoids using vias. Tidied up some other power routing.

Screenshot from 2014-12-21 17:30:16 Screenshot from 2014-12-21 17:30:30

16th December

Screenshot from 2014-12-16 22:11:29 Screenshot from 2014-12-16 22:11:10

Bottom Layer

All the pin-outs are defined on the bottom. Unfortunately, there is no space on the top layer.

The JTAG is now pushed to the back of the board. This will make using the JTAG more difficult, but at least it will not interfere with shields, should the solution require testing when in a system.

9th March 2015

The back side is clean, and all of the labels are unchanged.

Goldilocks Analogue

Goldilocks Analogue – Prototype 3

21st January 2015

The back side is clean, and all of the labelling will ensure that the board is self documenting. I was unsure whether putting text in the keep-out layer would work, but it seems to work very well. That’s a win.

Goldilocks Analogue - Prototype 3

Goldilocks Analogue – Prototype 3

31st December

Added labels for the “FTDI like” pin out, combined with the DAC outputs, to improve self documentation.

Screenshot from 2014-12-31 15:47:01 Screenshot from 2014-12-31 15:47:15

21st December

Added more accurate descriptions, and tidied some routing.

Screenshot from 2014-12-21 17:33:28 Screenshot from 2014-12-21 17:34:33

16th December

Screenshot from 2014-12-16 22:11:57 Screenshot from 2014-12-16 22:11:43

Pin Mapping

This the map of the ATmega1284p pins to the Arduino physical platform, and their usage on the Goldilocks Analogue

Arduino
UNO R3
328p Feature 328p Pin 1284p Pin 1284p Feature Comment
Analog 0 PC0 PA0
Analog 1 PC1 PA1
Analog 2 PC2 PA2
Analog 3 PC3 PA3
Analog 4 SDA PC4 PA4 PC1 I2C -> Bridge Pads
Analog 5 SCL PC5 PA5 PC0 I2C -> Bridge Pads
Reset Reset PC6 RESET Separate Pin
Digital 0 RX PD0 PDO RX0
Digital 1 TX PD1 PD1 TX0
Digital 2 INT0 PD2 PD2 INT0 / RX1 USART1
Digital 3 INT1 / PWM2 PD3 PD3 INT1 / TX1 USART1
-> MCP4822 MOSI
Digital 4 PD4 PD4 PWM1 / XCK1 16bit PWM
-> MCP4822 SCK
Digital 5 PWM0 PD5 PD5 PWM1 16bit PWM
Digital 6 PWM0 PD6 PD6 PWM2
Digital 7 PD7 PD7 PWM2
Digital 8 PB0 PB2 INT2 <- _INT/SQW
Digital 9 PWM1 PB1 PB3 PWM0
Digital 10 _SS / PWM1 PB2 PB4 _SS / PWM0 SPI
Digital 11 MOSI / PWM2 PB3 PB5 MOSI SPI
Digital 12 MISO PB4 PB6 MISO SPI
Digital 13 SCK PB5 PB7 SCK SPI
 (Digital 14) PB0  T0 -> SDCard SPI _SS 3V3
 (Digital 15) PB1  T1 -> MCP4822 SPI _SS
SCL PC0 SCL I2C – Separate
SDA PC1 SDA I2C – Separate
PC2 TCK JTAG <- _CARD_DETECT
for uSD Card
PC3 TMS JTAG -> MCP4822 _LDAC
PC4 TDO JTAG -> RAM SPI _SS_RAM0
PC5 TDI JTAG -> RAM SPI _SS_RAM1
PC6 TOSC1 <- 32768Hz Crystal
PC7 TOSC2 -> 32768Hz Crystal
XTAL1 PB6
XTAL2 PB7
 (Analog 6) PA6 -> Pad / Hole
 (Analog 7) PA7 -> Pad / Hole

Discussion on RTC

At the end of the day, the DS3232 / DS3231 device is around $8 best case to me. But modules are available complete with super capacitors from Seeed for around $6. There’s no win here. Stick to the crystal and existing solution, but make it easier to use the Seeed RasPi solution.

Digikey has the DS3231 at $8 per piece. This is pretty expensive, for what it delivers. And there are solutions available with super capacitor backing for under $6 from Seeed.

Design in the DS3232 on the TOSC1 input for the TCXO 32kHz clock and PC5 input for the INT/SQW line. Supply from 3V3 Vcc. Read that the I2C lines can run to 5V5 without issue. INT/SQW outputs are open drain and the INT/SQW can be disabled (high impedance). Let the ATmega1284p switch on its pull-ups for INT/SQW to function. Make sure 20kOhm pull ups on the SCL/SDA lines too.

The DS3232 has 236 Bytes of SRAM, and a push-pull output on TCXO 32kHz line so this is better as an asynchronous clock input.There is an accurate (0.25°C) thermometer function included. It comes in an 20SOIC package which is quite large. Having some SRAM will be very useful for storing configurations that change often (where EEPROM would wear out).

The DS3232M has 236 Bytes of SRAM, and a push-pull output on 32kHz line so this is better as an asynchronous clock input. Having some SRAM will be very useful for storing configurations that change often (where EEPROM would wear out). But, it doesn’t have 5.5V capability on its I2C lines. – Deselect

The DS3231 version comes in an 16SOIC package, which might be better, but it doesn’t have any SRAM, and the TXCO is open drain. – If we need smaller then this is where we go.

The DS3231M MEMS version comes in an 8SOIC package, which might be better, but it is only +-5ppm (rather than +-2ppm). – Don’t need the small package, so go for XTAL version DS3231 in the SOIC16 package.

Digikey has the DS3232 at $8.60 per piece. This is pretty expensive, for what it delivers.

Delete the 32kHz crystal, and capacitors.

Add on a 3V Lithium battery holder. Or a Super Capacitor and a charging diode

Leave the TOSC2 pin floating, as it is not useable when the Timer 2 Asynchronous Clock Input is enabled on TOSC1.

Remove pull-up resistors from RST, as the DS3231 has pull-ups as does the ATmega1284p. The DS3231 has a debounce and 250ms delay function to manage the MCU start up.

Design Input from Angus

IC6 is missing silkscreen marking for pin 1. – DONE

Designator layer needs a cleanup. I had to spend a lot of time in
EAGLE checking which components were which, and what orientations
they had. On such a full board with close-spaced components this is
very important – ideally place each designator between the pads it
refers to, with a consistent orientation relative to the pads. – DONE

Some 0603/0402 components seemed to have wrong pad sizes compared to
BOM output, ie R17 & C13. I placed according to what parts were
supplied. I know this has been revised further but it might be worth
checking BOM output for any remaining anomalies. – CHECKED

If possible move components away from IC bodies, for example C36 is
very close. Even for a pick & place machine I suspect this would be
hard. – DONE

Labels on silkscreens would be very helpful. For instance the power
selection & DTR jumpers, other pin breakouts. For Freetronics boards
we aim to have all of these connections self-documenting, ie each
option labelled somehow. This can be difficult but part of the
appeal of a development board is being able to easily make
customisations without requiring an external reference. – DONE

It’d be great if you could find a way to better convey the offset
pin numbering for pins 8-13. – NO BETTER ANSWER

The MCU 1284p solder stencil paste layer has too large of an
aperture for the thermal pad. If you look at the paste layer of IC1
and compare to IC2 then you’ll see what I mean. The aperture needs
to be cut down in this way or the central pad gets too much paste
and “floats” up, leading to the outer connections not forming
correctly. – OK Can’t change Library

Suggest adding test points for likely problem connections. ie
analogue section power rails, 3.3V SPI connections, raw DAC
outputs. These can just be bare SMD pads on top or bottom of
board. Label with a designator (at least) or a descriptive label if
possible. For an example of what I mean, the OpenVizsla boards have
a really nice set of 4 power test points near the bottom of the
board. – DONE Power is easy off pins. Added 3.3V SPI test points. Other pins all have pin-outs.

Design Input from Freetronics Forum

Keep the JTAG header, but also distribute the pins to the 2nd Non-Arduino shield pins. – Going to push the JTAG to the back of the board. It will be inconvenient to use, but won’t block the use of Shields when it is actually being used so this is better. This also frees more space for a RTC and battery option. – DONE

Add a RTC option. – Using the 32kHz crystal on Timer 2 the RTC is working fine. Battery and power options can be off board, and as comprehensive and accurate as needed. – DONE

Other RTC options include using the DS3231, which would be more accurate than a 32kHz crystal, and includes an integrated RST debounce timer. Can use the 32kHz output to feed the ATmega1284p Timer 2 and therefore have both devices locked to the same clock. Chronodot as an example for using this RTC. – DONE

Goldilocks Analogue – Testing 3

Summary

I’m still working (slowly) on a new development for my ATmega1284p platform, called Goldilocks.

My initial design for the Goldilocks Analogue was flawed in several ways, so I revised the design and produced a new prototype.

Following up on the initial testing matched against the Stanford Analog Shield, I’m now testing against the Open Music Labs Audio Codec Shield.

Goldilocks Analogue & OML Audio Codec Shield

Goldilocks Analogue & OML Audio Codec Shield

Both devices output excellent looking 43.1Hz sine waves, at 44.1kHz reconstruction rate, from the previous 16 bit 1024 sample Sine Wave.

The Goldilocks Analogue produces 0V to 4.096V 1:1 buffered signals from its DC outputs, and an AC amplified headphone output in parallel. The Audio Codec Shield produces 0V to +3V line level signals into 10kOhm, together with an amplified headphone signal.

 

OML Audio Codec Shield 43.1Hz Sine wave, one channel inverted.

OML Audio Codec Shield 43.1Hz Sine wave, one channel inverted.

Open Media Labs – Audio Codec Shield

The Audio Codec Shield uses a very capable Wolfson Audio WM8731 device to generate its output. The WM8731 has stereo 24-bit multi-bit sigma delta ADCs and DACs complete with oversampling digital interpolation and decimation filters. Digital audio input word lengths from 16-32 bits and sampling rates from 8kHz to 96kHz are supported. The WM8731  has stereo audio outputs which are buffered for driving headphones from a programmable volume control and line level outputs are also provided complete with anti-thump mute and power up/down circuitry.

Nominally, it is unfair to compare the MCP4822 12 bit DAC against the 24 bit 96kHz WM8731 DAC, but let us see how this looks, when both are driven with 44.1kHz 16 bit inputs. But, based on pricing information from Digikey, they are available at around the same price range, so this has to be a reasonable test.

Head to Head

Testing was done using a 16 bit 1024 sample Sine Wave file. Outputs were generated by a timer triggered to interrupt every 22.7us (44.1kHz), and produce a new output level. Testing should show only a main signal at 43.1Hz, and the reproduction frequency of 44.1kHz. The Goldilocks Analogue discards the lower 4 bits of the samples and only outputs the 12 most significant bits. The WM8731 could produce 24 bit audio from its DAC, but in this test it will be run at 16 bits only.

OML Audio Codec Shield & Goldilocks Analogue with Red Pitaya

OML Audio Codec Shield & Goldilocks Analogue with Red Pitaya

All outputs generated by a 1024 sample 16 bit Sine wave, generated with a 44.1kHz reconstruction sample rate, triggered by an interrupt timer.

The OML Audio Codec Shield produces very nice Sine waves.

OML Audio Codec Shield 43.1Hz Sine wave, one channel inverted.

OML Audio Codec Shield 43.1Hz Sine wave, one channel inverted.

The top of the wave form

OML_43.1Hz_3V

and the bottom of the waveform. Show some high frequency noise. This could be removed by the on-board digital filters on the WM8731, but in this testing situation the have not been turned on.

OML_43.1Hz_0V

 

Looking at the spectra generated by both implementations up to 953Hz it is possible to see harmonics from the Sine Wave, and other low frequency noise.

OML_43.1Hz_Sine_953Hz

OML Audio Codec Shield – 43.1Hz Sine Wave – 953Hz Spectrum

GA_43.Hz_953Hz

Goldilocks Analogue – 43.1Hz Sine Wave – 953Hz Spectrum

 

The Audio Codec Shield has a significant noise present at 50Hz, which may be caused by noise leakage through the PC USB power supply not being completely filtered before the supply is provided to the WM8731. Other noise rises up to 80dB, and is present right across the spectrum.

OML Audio Codec Shield – 43.1Hz Sine Wave – 7.6kHz Spectrum

OML Audio Codec Shield – 43.1Hz Sine Wave – 7.6kHz Spectrum

GA_43.1Hz_7.6kHz

Goldilocks Analogue – 43.1Hz Sine Wave – 7.6kHz Spectrum

 

 

And here.

OML Audio Codec Shield  – 43.1Hz Sine Wave – 61kHz Spectrum

OML Audio Codec Shield – 43.1Hz Sine Wave – 61kHz Spectrum – Harmonics around 44.1kHz reconstruction frequency

Goldilocks Analogue – 43.1Hz Sine Wave – 61kHz Spectrum

Goldilocks Analogue – 43.1Hz Sine Wave – 61kHz Spectrum

 

And here.

OML_43.1Hz_Sine_976kHz

OML Audio Codec Shield – 43.1Hz Sine Wave – 976kHz Spectrum

GA_43.1Hz_976kHz

Goldilocks Analogue – 43.1Hz Sine Wave – 976kHz Spectrum

Algorithmic Symphonies

I’ve added some algorithmic symphony code to both solutions.

Here’s a short clip of one 8 bit algorithmic symphony played by the Goldilocks Analogue.

Goldilocks Analogue – Testing 2

Recap

I’ve been working (slowly) on a new development for my ATmega1284p platform, called Goldilocks.

My initial design for the Goldilocks Analogue was flawed in several ways, so I revised the design and produced a new prototype.

Here it is:

P1010277

Goldilocks Analogue – Prototype 2

Now that the new prototype for the Goldilocks Analogue is completed, it is time to test it to see how successful the design was. And interestingly, in the time that I’ve been designing the Goldilocks Analogue, Stanford University in collaboration with Texas Instruments have produced their own Analog Shield.

So this test will compare the Goldilocks Analogue with its dual channel 12bit MCP4822 DAC with the Stanford Analog Shield quad channel 16bit DAC8564 DAC. In a later test sequence, using the same test tone, I compare the Goldilocks Analogue with the Open Music Labs Audio Codec Shield using a Wolfson Micro WM8731 24 bit Codec with ADC, DAC, and signal processing capabilities.

Summary (TL;DR)

The test platform is essentially the same ATmega1284p device, clocked at 22.1184MHz. For the Goldilocks Analogue it is integrated on to the main board. For the Analog Shield I used a Goldilocks device as provided in the Pozible project.

You don’t need a lot of space to have great tools. I’m using a Red Pitaya device, configured as an oscilloscope and as a spectrum analyser, together with a Saleae Logic to capture SPI transactions.

P1010271

Micro Test bench – Red Pitaya and Saleae Logic

Both Goldilocks Analogue and Analog Shield are comfortably capable of producing reasonable quality stereo signals at 44.1kHz sampling rate. Both devices output beautiful looking 43.1Hz sine waves, at 44.1kHz reconstruction rate, from a 16 bit 1024 sample Sine Wave.

The Goldilocks Analogue produces 0V to 4.096V 1:1 buffered signals from its DC outputs, and an AC amplified headphone output in parallel. The Analog Shield produces -5V to +5V balanced amplified signals from the 0 to 2.5V DAC.

GA&AS_Scope

Full Swing 43.1Hz Sine Wave Goldilocks Analogue – Blue 0V to +4.096V Analog Shield – Red -5v to +5V

The Analog Shield shows a lot of harmonics at high frequencies as shown. Comparing the two solutions, the Analog Shield doesn’t do justice to the extra 4 bits (theoretically 98dB SNR 16 bit DAC), over the Goldilocks Analogue (theoretically 74dB SNR 12 bit DAC). The BOM price difference between MCP4822 ($4.60) and DAC8564 ($20) is hard to justify given the performance demonstrated.

I think that using the platform of the AVR ATmega (Arduino) there is little point using a 16 bit DAC. There is too much noise (many mV) in the power supply and around Goldilocks or Arduino Uno or Mega boards to make more than 10 to 12 bits of DAC resolution (or ADC resolution) in any way relevant.

GA&AS_43Hz_976kHz

Overlaid 976kHz Spectrum – Analog Shield Red – Shows significant harmonics

Stanford – TI Analog Shield

As part of its microcontroller course, Stanford University required a platform to sample and generate analogue signals. The Standford – TI Analog Shield arose from this need.

The Analog Shield contains a Texas Instrument quad channel ADC and a quad channel DAC, together with a variable voltage supply. I have not tested the ADC.

The DAC capability is based on a Texas Instrument DAC8564 device. This device has many interesting features, including the ability to synchronise loading of updated digital outputs, and to maintain multiple power-down states. The DAC8564 has many great features, and it comes with a price tag to match its capabilities.

P1010273

Analog Shield – Quad 16bit DAC & Quad 16bit ADC – Stanford University & Texas Instruments

Signals generated by the DAC8564 (from 0v to 2.5V) are biased around 0V and amplified to produce a 10V full swing output. The output exhibits some “cramping” around 0x0000 (-5V) outputs.

AS_Schematic_RevD

Analog Shield – Quad DAC Schematic – -5V to +5V full swing

Head to Head

Testing was done using a 16 bit 1024 sample Sine Wave file. Outputs were generated by a timer triggered to interrupt every 22.7us (44.1kHz), and produce a new output level. Testing should show only a main signal at 43.1Hz, and the reproduction frequency of 44.1kHz. The Goldilocks Analogue discards the lower 4 bits of the samples and only outputs the 12 most significant bits.

Theoretically, the Goldilocks Analogue MCP4822 DAC should be able to achieve 74dB SNR, with its 12 bits of resolution, based on the rule of thumb SINAD = (6.02 x BITS) + 1.76. For the Analog Shield DAC8564 the number is 98db SNR.

P1010270

Head to Head Testing – Using Red Pitaya and Saleae Logic

All outputs generated by a 1024 sample 16bit Sine wave, generated with a 44.1kHz reconstruction sample rate, triggered by an interrupt timer.

GA_43.1Hz

Goldilocks Analogue – 43Hz Sine Wave – Two Channels – One Channel Inverted

AS_43.1Hz

Analog Shield – 43Hz Sine Wave – Two Channels – One Channel Inverted

In previous testing on the Goldilocks Analogue prototype I had found that my OpAmp devices were unable to achieve 0V properly. In this new prototype I have produced a stable -1.186V Vss supply for the OpAmp. The signals at 0x000 show that I’ve achieved the required result, with the output being smooth down to the 0x000 level, and up to 0xFFF as well.

GA_43.1Hz_4V

Goldilocks Analogue – 0xFFF Output

GA_43.1Hz_0V

Goldilocks Analogue – 0x000 Output

The Analog Shield also produces smooth signals, but it does display some compression around 0x0000 levels. Possibly because of some issues with generating the Vss rail for the OpAmps.

AS_43.1Hz_+5V

Analog Shield – 0xFFFF Output

AS_43.1Hz_-5V

Analog Shield – 0x0000 Output – Slight Clipping

Looking at the spectra generated by both implementations up to 953Hz it is possible to see harmonics from the Sine Wave, and other low frequency noise.

The spectra are not directly comparable, because the Goldilocks Analogue is producing a 4V full swing, or -4dBm, whilst the Analog Shield is producing a 10V full swing, or 3.7dBm. Distortions in the Analog Shield need to be reduced by 7.7dB to be equivalent to distortion in the Goldilocks Analogue.

The spectrum produced by the Goldilocks Analogue shows most distortion is below -70dB, and that the noise floor lies below -100dB.

GA_43.1Hz_953Hz

Goldilocks Analogue – 43.1Hz Sine Wave – 953Hz Spectrum

The Analog Shield has a significant noise present at 50Hz, which may be caused by noise leakage through the PC USB power supply not being completely filtered before the supply is provided to the DAC8564. Other noise rises above -80dB, and is present right across the spectrum.

AS_43.1Hz_953Kz

Analog Shield – 43.1Hz Sine Wave – 953Hz Spectrum

In the spectra out to 7.6kHz we are looking at the clearly audible range, which is the main use case for the devices.

The Goldilocks Analogue has noise carriers out to around 4.5kHz, but they are all below -80dB. After 4.5kHz the only noise remains below -100dB.

GA_43.1Hz_7.6kHz

Goldilocks Analogue – 43.1Hz Sine Wave – 7.6kHz Spectrum

The Analog Shield shows noise carriers out to only 2.5kHz, but on one channel these are above -80dB. Otherwise the test shows mainly background noise below -100dB beyond 2.5kHz.

AS_43.1Hz_7.6kHz

Analog Shield – 43.1Hz Sine Wave – 7.6kHz Spectrum

The spectra out to 61kHz should show a noise carrier generated by the reconstruction frequency of 44.1kHz.

The Goldilocks Analogue shows the spectrum maintains is low noise level below -90dB right out to the end of the audible range, and further out to the reconstruction carrier at 44.1kHz.

GA_43.1Hz_61kHz

Goldilocks Analogue – 43.1Hz Sine Wave – 61kHz Spectrum

Similarly, the Analog Shield is quiet out beyond the audible range. It exhibits a strong noise carrier at the reconstruction frequency. Also, it shows some beat frequencies generated by a small noise carrier at 10kHz, and the reconstruction carrier. These noise carriers might be caused by the TPS61093 boost power supply used to generate the +ve and -ve supplies for the output buffer OpAmps, although it has a characteristic frequency at 1.2MHz, or it might be leakage from some other device.

AS_43.1Hz_61kHz

Analog Shield – 43.1Hz Sine Wave – 61kHz Spectrum – Harmonics around 44.1kHz reconstruction frequency

The final two spectra show the signal out to 976kHz. We’d normally expect to simply see the noise floor, beyond the 44.1kHz reconstruction carrier noise.

The Goldilocks Analogue has a noise carrier at around 210kHz. This could be generated by one or both of the TPS60403 devices used to generate the negative AVss supply. These devices have a typical switching frequency of 250kHz, specified between 150kHz and 300kHz, so this is possible. Aside from the single carrier mentioned, there is no further noise out to 976kHz.

GA_43.1Hz_976kHz

Goldilocks Analogue – 43.1Hz Sine Wave – 976kHz Spectrum

The Analog Shield shows the reconstruction carrier noise at -50dB, and then harmonics of this carrier all the way out to 976kHz. Not sure why these artifacts are appearing. There is a chance that noise derived from these signals is impacting the overall outcome for the DAC8564.

AS_43.1Hz_976kHz

Analog Shield – 43.1Hz Sine Wave – 976kHz Spectrum

Using the Saleae Logic we can capture the SPI transactions generating the analogue result. To maintain the 44.1kHz reconstruction rate a set of samples needs to be transferred every 22.7us.

In the code I’ve used to generate the signal an interrupt timer triggers every 22.7us indicated by the rising edge of “Channel 6”. Once the interrupt has finished processing it lowers the Channel 6 line, indicating that control has returned to the main program. If required the main program has to use the remaining time to generate the required signal. Clearly the faster the SPI transaction to set up the transaction can be completed the more time available for other purposes.

The MCP4822 found in the Goldilocks Analogue has 4 control bits and 12 data bits, which are transferred in 2 8 bit transactions. To set two channels only 4 SPI transactions are required, taking 7.25us.

GA_43.1Hz_44.1kHz_sample_SPI_transaction

Goldilocks Analog SPI transaction – Interrupt duration 7.25us

The DAC8564 used in the Analog Shield has 8 control bits and 16 data bits, which are transferred in 3 8 bit transactions, or 24 SPI clock cycles. For two channels this takes 6 SPI transactions and 9.08us.

Both devices leave sufficient time for calculation of simple VCO, or other multiply based, effects in real time with 44.1kHz dual channel. Halving the sample rate to 22.05kHz would be necessary to provide more opportunity to retrieve data from uSD cards or other more complex data sources.

AS_43.1Hz_44.1kHz_sample_SPI_transaction

Analog Shield SPI Transaction – Interrupt duration 9.083us

The final reality check in this Head-to-Head comparison is provided by Digikey. I must say that some of the features of the DAC8564 had convinced me to look at migrating the production Goldilocks Analogue to use this new TI DAC. However, seeing that the BOM cost for the TI DAC is approximately 4 times greater than the MCP4822 device soon cooled those thoughts.

Given the cost sensitive nature of the Arduino environment it is not practical to use a device costing nearly US$20 on the Goldilocks Analogue platform, irrespective of its performance.

And, given that the Analog Shield provides no justification in terms of signal quality over the existing Goldilocks Analogue solution there seems to be no technical merit in changing the DAC specification, either.

The Microchip MCP4822 is available from US$4.60 at Digikey.

GA_MCP4822_digikey

Digikey MCP4822 Pricing

The Texas Instrument DAC8564 is available from US$18.60 at Digikey.

AS_DAC8564_digikey

Digikey DAC8464 Pricing

Design Review

The remaining features and functions of the Goldilocks Analogue have been tested, and resulting from these tests I’m going to make the following redesigns and changes.

  • Revert to tri-state buffers for uSD I/O logic conversion CMOS 5v to CMOS 3v3 – Bi-directional translators pure fail! I tried both TI TXB and TXS devices and they simply didn’t work as specified.
  • Remove USART pin-out – unnecessary feature and just takes board space.
  • Move DAC pin-out to right hand edge of the prototyping space – easier to use if not covered by UNO format shield. As the Goldilocks Analogue is slightly longer than standard Arduino UNO shields, putting the DAC DC output pins outside the shield outline on the right hand end of the board will allow easier access for connections.
  • Increase prototyping space – fill in space freed by pin-out removals.
  • Use smaller packages where possible – heading for production.
  • Increase bypass capacitors on uSD 3V supply – uSD cards consume significant current, potential for instability because of long 3V3 supply
  • Use a JTAG pin for MCP4822 LDAC – to enable synchronization of the DAC channels.

Goldilocks Analogue – Prototyping 2

Introduction

Following my initial design article, and the testing article, I’ve put quite a lot of thought into how I can make this Goldilocks Analogue device best achieve my stated goals. Pictured is the only Goldilocks Analogue Prototype in existence.

Goldilocks Analogue - Top Left

Goldilocks Analogue Prototype – Analogue section front of image.

From the testing it was clear that the MCP4822 DAC fully achieved the goals that I had set out to achieve, but that my design for the analogue buffer stage behind it was really quite bad. Fixing it was going to take some thought.

I have decided to separate the analogue output stage into two sections. An AC section which drives the headphone socket, with a designed for purpose headphone amplifier device, and a DC section using a high current rail to rail OpAmp and a negative 1.18V supply rail to allow the OpAmp to fully reach GND or the equivalent 0x000 digital input.

I also found a better solution for the uSD level translation. There is a device designed for purpose, which I’ve now designed into the Goldilocks Analogue.

DAC – MCP4822

The selected dual DAC uses the SPI bus to write 12 bit values to each of its channels. The increments are either 1mV or 0.5mV giving full scale at DC 4.096V or 2.048V depending which scale factor is being used. The testing showed that the DAC is capable of achieving close to the 72dB of SNR that is its theoretical capability.

DAC 43Hz Sine - 7k6Hz

So from my point of view the DAC, and the AVcc filtering system employed to provide a clean analogue power rail, have achieved their design goal. Let’s not change anything.

Headphone (AC) Output – TPA6132A2

Driving a headphone socket with a nominal impedance of 32 ohm is a hard job for an OpAmp, and they are not designed specifically for this job. Therefore, I thought it would be best to separate the two outputs into two separate full-time output devices, specialised for their purposes (AC headphones, and DC PID or general pin-out).  Both Goldilocks Analogue output options are driven simultaneously, and they will not interfere with each other.

GoldilocksAnalogueDACAmplifiers

For the AC and headphone output, using a specific single ended “DirectPath” headphone amplifier device enabled me to remove the large output coupling capacitors but still achieve a good low frequency output response.

The TPA6132A2 is capable of driving 25 mW into 16 ohm headphones. Its amplifier architecture operates from a single supply voltage and uses an internal charge pump to generate a negative supply rail for the headphone amplifier. The output voltages are centred around 0 V and are capable of positive and negative voltage swings. This means that the TPA6132A2 doesn’t need output blocking capacitors, and therefore can achieve a very good low-frequency fidelity. Using the 1 uF input capacitors stops any turn-on pop or noise, and achieves a low frequency corner below 10 Hz.

As the DAC outputs a signal with up to 4 V peak to peak, I have set the gain on the TPA6132A2 to -6dB. This should result in the full range of the headphone signal being 1 V peak to peak, with approximately 25 mW being delivered into 32 ohm headphones.

The TPA6132 also has a very high power supply an RF noise rejection ratio. Although I’ve gone to a lot of effort to filter the AVcc power supply, the power supply noise generated was still significant. Having over 90 dB PSRR will help to keep the output quiet.

Analogue (DC) Output – TS922A

I originally selected a highly regarded audiophile OpAmp for use in the Goldilocks Analogue. That device was incapable of operating close to its GND rail, and caused significant distortion in the output signal. Based on that experience, I decided to use a rail-to-rail output OpAmp to provide the DC buffered signal.

Even though rail-to-rail OpAmp devices are sold as full Vcc to Vss outputs, under high current loading they all have significant output droop. The only way to avoid this is to avoid driving the (any) OpAmp close to its supply rails.

The positive rail is ok. The supply voltage is a well regulated 5 V DC, and the maximum voltage required from the OpAmp is 4.096 V which is 0xFFF input to the DAC. It is the Ground Rail, which causes the issue, as the OpAmp will be unable to deliver the analogue equivalent 0x000 under high current situations.

The only way to get an OpAmp to deliver a solid GND potential output, is to supply it with a negative supply voltage Vss.  Getting a Vss rail is described below.

The TS922A device is designed for high current rail-to-rail outputs, and is specified to work into 32 ohm headphones, 75 ohm video, and 600 ohm inputs. This DC coupled output can be used to drive PID, Triac or any other application requiring a precise analogue signal up to around 50 kHz.

OpAmp Vss (negative) rail

The TS922A can support over 50 mA per channel output, but at this current its output resistance has dropped its ability to reach both rails to greater than 300 mV. Specifically, it can only reach between 0.3 V and 4.4 V. Therefore to enable the output signal to reach GND potential, we have to generate a Vss  with greater than -0.3 V, and capable of supplying in excess of 100 mA (over OpAmp both channels).

I looked at a number of options for charge coupled devices, and decided that the cheapest and best way was to use two paralleled TPS60403 devices to each generate -5 V 60 mA from the 5V power rail. These devices don’t filter their output, but since we are not going to use the -5 V directly, this doesn’t matter.

GoldilocksAnalogueVccNegative

Following the generation of the -5 V supply, I’ve decided on a TPS72301 variable voltage 200 mA linear regulator, configured to generate its reference voltage -1.186 V, to provide a regulated Vss. Using the internal reference voltage saves a few resistors, and it still generates sufficient negative voltage to enable the OpAmp to easily reach true GND potential.

uSD Card Level Translation – TXS0104

Some further analysis of the voltage translation application revealed that the TXS0104 is designed to exactly suit the purpose of interfacing SPI bus at up to 24 MHz. As a side benefit it is a much smaller package, which recovers prototyping space back to the original Goldilocks benchmark. It is also cheaper than the general purpose OpAmps previously used.

Initially, the prototype used the TXB0104 device, but it was unsuccessful. The 4kOhm output resistance combined with less than optimal uSD card characteristics meant that the design failed. The TXB series cannot drive anything with pull-up or pull-down greater than 50kOhm. The uSD card is specified to have 10kOhm to 100kOhm integrated pull-up resistors, but in practice they all seem to be around 10kOhm. The schematic below will be updated to show TXS shortly.

GoldilocksAnalogueTranslate

The PCB Layout

The board layout has been completed, and a PCB ordered to this design.

More detail soon.

GoldilocksAnalogue

Top Signal Layer
GoldilocksAnalogueTopRatsnest

GND Signal Layer
GoldilocksAnalogueRoute2Ratsnest

5V Signal Layer
GoldilocksAnalogueRoute15Ratsnest

Bottom Signal Layer
GoldilocksAnalogueBottomRatsnest

 

 

As of June 2014, I’ve now got all the parts, and the PCB ready for a new prototype. This new version was  constructed late July 2014 and is awaiting basic testing.

Version 2 of the prototype

Version 2 of the prototype, fresh out of the oven.

 

As of August 2014, I have started testing. So far the analogue design seems to check out, with both the headphone (AC biased) circuitry and the OpAmp (DC biased) circuitry performing as intended. More testing soon, and a new post.

Goldilocks Analogue demonstrating a clean DC biased sign wave (to 0V) .

Goldilocks Analogue demonstrating a clean DC biased sign wave (to 0V) .

The spectrum at the output of the TS922A OpAmp is cleaner now than directly at the MCP4822 DAC output of the previous prototype iteration.

The nominal 12 bit DAC capabilities are able to achieve 72dB SNR. Target achieved.

Spectrum at the output of the OpAmp.

Spectrum at the output of the OpAmp.

Goldilocks Analogue – Testing

Introduction

This post follows on from the and gives some insight into the results of the first board prototype board assembled.

Updated - Goldilocks Analogue

Updated – Goldilocks Analogue

The information will develop over the next few weeks, as I add more information and test results.

I’ve built a new Goldilocks Analogue design and I have described the changes and additions.

Discussion

Well I’ve had my  Goldilocks Analogue on my desk now for a few nights, and I’m very impressed that it seems to generally meet the specification that was intended.

The code for setting the DAC levels is currently only optimised for setting two values at a time. Specifically, it is not a streaming function. Never-the-less, it is possible to achieve the stated goal for both DAC channels. The actual number achieved is 108 kSamples/second, shown below, or 18.8us to transmit 2 samples on 2 channels.

I’ve been testing the Goldilocks Analogue DAC stage and found (what I should have known) that I needed an output buffer op-amp able to do negative rail (0V) input and output to support the MCP4822 0v to 4.095V ranging DAC, so I’m going to order some soon.

Unfortunately the OPA4350 (rail to rail high current), at over $10 each, is nearly as expensive as the audiophile OPA4132 I specified previously.

There seems to be a pin compatible alternative, the TS924A, which is about $2 each, but several orders of magnitude worse in performance.

For Example: OPA4350 vs TS924A
Gain Bandwidth Product: 38MHz vs 4MHz
Slew Rate: 22V/μs vs 1.3V/μs
Total Harmonic Distortion: 0.0006% vs 0.005%

Is it worth the difference, when working with a 12 bit DAC in the presence of mV of power supply noise? I’ll revisit this with the next design notes.

How about 5V?

To build an effective DAC I’ve learned that we need to have an effective quiet 5V power supply, with as little noise as possible. To put this into context, the 12 bit MCP4822 generates a 1mV per level difference. I noticed there is quite a few mV of noise on the 5V supply of the Goldilocks Analogue. Not what I was hoping to see, so I’ve gone back to see how that compares with predecessors.

All measurements are taken with a 100MHz Rigol DS1102E, with 150MHz probes grounded onto the USB socket of each board respectively. The probes are directly on the regulator output capacitor, which should be the quietest point on the board, and then directly off Vcc on the MCU for the DIL boards, or a nearby test point for the SMD boards.

First stop is a reference design Arduino Uno R2 board. As a starting point the Uno shows 16mV on the power supply, and 35mV on the MCU. Let’s see how some other boards compare.

Arduino_Uno

Arduino Uno

The Freetronics Eleven board also uses a linear regulator, similar (if not identical to) the Arduino Uno. However the capacitor arrangement must be somewhat more effective because the noise present on the output capacitor is less than 6mV. This is significantly better than on the Arduino Uno, and even measured against the Vcc pin the supply noise remains significantly lower than the Uno.

This Freetronics Eleven board was running at 22.1184MHz rather than the standard Arduino speed, but that doesn’t seem to affect the result.

Freetronics_Eleven

Freetronics Eleven

Next up is the Seeed Studio ADK boards is an ATmega2560 board running at 16MHz, which also uses a linear regulator. The ADK board exhibits the same quiet supply found in the Freetronics Eleven, and has very similar characteristics on the Vcc test point as well.

Seeed_ADK

Seeed Studio ADK

The Goldilocks v1.1 resulting from the Pozible project is my true point of reference. I hope to be able to do slightly better than this board, by better layout of the same SMPS circuit that is used across all of the Freetronics range of products.

In measurement, the Goldilocks v1.1 sets a very high standard to surpass. Even though there is a 500kHz SMPS running in the supply, the Vcc supply capacitor shows very low noise of only 5.29mV, and the Vcc noise on the test point is only 12.0mV.

GoldilocksV1

Goldilocks V1.1

The Goldilocks Analogue Prototype 1 uses the same SMPS circuit present across the entire range of Freetronics boards, but using an optimised (for this application) layout. Shorter internal tracks should result in slightly faster smoothing, and better regulation, although the effect at normal currents would be minimal.

In comparison with the  Goldilocks v1.1, there seems to be slightly less noise at the supply capacitor with less than 5mV showing, although this effect is marginal. The noise on the Vcc line seems to be similar.

Goldilocks_Analogue

Goldilocks Analogue Prototype 1

SMPS

Having looked at the power supplies at rest, and built a baseline of what to expect, here are some screenshots of the Goldilocks SMPS under load. Port D is being switched from 0x00 to 0xFF at 30kHz. The first screenshot shows one of the Port D pins on channel 1, and the Vcc (5V) line at the supply capacitor on channel 2. Note that there is 24mV of noise on the Vcc supply capacitor, even without drawing much current.

GoldilocksAnalogue_NoLoad_Vcc

This second screenshot shows the same set up, but with 8 LEDs being driven off the Port D. Channel 2 shows the variation in supply capacitor Vcc under the increased load.

GoldilocksAnalogue_8LED_Vcc_Macro

So the big question is whether the new layout of the SMPS has achieved anything. Well, based on this simple test, it would seem to have generated a fairly significant improvement.

The below two screenshots shows the trailing edge of the 8 LED power load being switched off. Note that on the supply Vcc there is some oscillation and instability as the SMPS recovers from the load reduction.

This first screenshot shows the Goldilocks V1.1 situation, with a ripple of 832mV peak to peak.

GoldilocksV1_8LED_Vcc_Micro

With the Goldilocks Analogue, the peak to peak ripple is reduced to under 600mV, which is a 25% improvement in this situation.

GoldilocksAnalogue_8LED_Vcc

Sine Waves

I’m using my new Red Pitaya to analyse the output of the Goldilocks Analogue output state, with a 43.066Hz Sine wave (1024 samples played out at 44.1kHz) as the input to the DAC.

MCP4822 DAC

This shows the sine wave generated at the output of the low pass filter (23kHz -3dB single pole design). This is almost exactly as we would like to see.
Post Filter 43Hz Sine - Oscilloscope
Looking at the lower segment of the sine wave below and the image above, it is almost perfect to 0V and to 4.096V peak to peak.
Post Filter 43Hz Sine - Oscilloscope Segment
Looking at this sine wave on the spectrum analyser across the band up to 7.6kHz, we can see the noise floor is 70dB down from the signal exiting the DAC. It seems the DAC performs as advertised.
DAC 43Hz Sine - 7k6Hz
Looking across the band to 61kHz, we can see the peak at -70dbm from the 44.1kHz sampling noise. Unfortunately, the single pole filter doesn’t do much to suppress this noise source.
DAC 43Hz Sine - 61kHz
To get an idea of whether the 23kHz filter is working as expected, we need to look out to the 976kHz band. The next two images contract the signal before and after the Filter.
DAC 43Hz Sine - 976kHz

The lower image shows that noise peaks out to 200kHz have been properly suppressed, so the filter is working but it is too slow to hit the 41kHz noise.

Post Filter 43Hz Sine - 976kHz

Op Amps

The Op Amp selection was a mistake. Rather than thinking about the application correctly, I simply sought out the best “musical” Op Amp. The audiophile OPA4132 is absolutely not the right tool for this job. And these images show why.

Driving into a 1kOhm resistance, the output of the OPA4132 is shaved off as the op amp output amplifier saturates as it approaches the 0V rail (or Ground rail). The top of the waveform is OK, as we are still 1V from the Vcc rail. Under higher loading, such as headphones at 32Ohm, the signal is worse, much worse.

OpAmp 43Hz Sine - 1kOhm - Oscilloscope

Looking at this (initially as an open circuit) view and then with the 1kOhm loading imposed, we can see the difficulty the op amp has with the signal.

OpAmp 43Hz Sine OpenCircuit - 953Hz

The noise peaks (created by the flattening of the sine wave) are at least 10dB greater under a small load. As the load increases the situation gets worse.

OpAmp 43Hz Sine 1kOhm - 953Hz

OpAmp 43Hz Sine 1kOhm - 7k6Hz

OpAmp 43Hz Sine 1kOhm - 61kHz

To fix this issue, I will need to use a rail to rail high current op amp, and also make sure that I create a small negative rail (-o.23V using a LM7705) to allow the op amp to reach 0V effectively.

Amongst the Burr Brown range the best alternative seems to be the OPA2353, which can support almost 40mA of current, and can effectively drive 75Ohm loads. Unfortunately the OPA2353 (rail to rail high current) costs about $6 each,

There seems to be a pin compatible alternative, the TS922A, which is about $2 each, but several orders of magnitude worse in performance. However, it can supply 80mA and effectively drive 32Ohm headphones.

For Example: OPA2353 vs TS922A
Gain Bandwidth Product: 44MHz vs 4MHz
Slew Rate: 22V/μs vs 1.3V/μs
Total Harmonic Distortion: 0.0006% vs 0.005%

Errata

Reset button can be moved closer to the edge.

AVcc supply capacitors are too close together, and need to have bigger pads.

Use the DAC out header spare pin to pin-out the AVcc, for testing or use on prototyping area.

AVcc inductor is not correct footprint (device much larger).

AVcc ferrite bead is not correct footprint (device much smaller).

Remove analogue potentiometers, unnecessary as DAC is extraordinarily accurate.

Put pin-out on DC output, and headphone socket on AC output 100uF capacitors.

Replace Analogue Op Am with LM7705 and TS922A. This generates 0V to 4.096V required to properly buffer the MCP4822 DAC. LM7705 can’t sustain 80mA, but for small DC signals (up to 20mA) we will have accurate buffering of the DAC, and for headphones, it is an analogue signal anyway.

Replace uSD Op Amps with TXB0104, more suitable for the purpose.

These errata have been addressed in the new Goldilocks Analogue design and I have described the changes and additions.