After our laser cut CMS stencils, this afternoon we ran tests to get masks to cover the holes from unused module slots in the DTPlug boxes or cover the space around the module connectors.
The tests took place on local FabLab (fabrique d’objets libres) laser cutting machine.
Some shots of the results : [Gallery not found]
We received the first batch of mass produced DTPlug boxes this afternoon from the injection moulding plant in California (USA).
The 17 shipping boxes take up a lot of space but we’re happy to see the fruits of a project we’ve been involved in for so long and we’ll finally be able to start selling those DTPlugs :)
We’re slightly disappointed by the quality of this batch which is a bit bellow that of the pre-series but nothing to worry about, it’s still good enough to keep the dust out :)
This afternoon I tested the laser cutting CMS stencil technique at Lyon’s FABLab (Fabrique d’Objets Libres), that will be used to build the development modules. These stencils will be part of the development module kit I’m working on: an autonomous module allowing you to test your boards before building them.
The plastic stencils (rhodoïd – 150 micrometers thick) work great, at least as good as steel ones and are perfect for laser cutting. Tin sticks well to the PCB once the stencil if removed and transparency makes positioning easier.
You need to watch your pad size though, due to the cutting width: as much as 40% smaller for CMS components in CMS 0402 boxes, SOT-363 boxes or even LQFP boxes like the LPC1224′s otherwise you’ll get shot circuits.
And now, the pictures:
Just to tell you that we received the first, fresh from the mold, DTPlug boxes. The rest is still in production. These are for mechanical validation of the mold. Except for a few minor aesthetic details, they meet our expectations :)
Here’s a few pics:
With Friday’s delivery of boards (test in progress) we’ll soon be able to deliver our first products, so order yours now!
The DTPlug is now operational and we started it’s production.
The DTPlug is available in our online store
The first 100 controller boards have been received, as well as 110V-230V~/5V power supply blocks with all the cables and connectors.
The full box version is also available, as we received the first production batch for the case (no less than one thousand cases !).
The plastic injection has been done in the USA, and the pieces present some more shrinkage due to cooling than the prototypes we got from the mold maker in china, but this is very light and does not affect the mechanical caracteristics, and only produces some effects on the surfaces in a few spots.
The cooperative company Techno-Innov is an eager supporter of free software and applies this principle to its products whenever possible (a SCOP is a company and needs income to pay its employees).
All Techno-Innov created elements for DTPlug are under Creative Commons CC BY-NC-SA Attribution-NonCommercial-ShareAlike License.
What does that license entail?
- Any physical person can use the plans, schematics and any other technical data we publish to create their own DTPlug.
- Any physical person who wishes to may modify our plans and schematics to create a modified DTPlug for their personal use.
- Any physical or moral person who wishes to publish plans, schematics or any other technical data pertaining to DTPlug, in their original or modified version, must do so under our chosen license (CC BY-NC-SA) and name the original author: the Techno-Innov cooperative company.
- Producing DTPlugs, completely or partially, and selling them without our authorisation is forbidden, even with a simple compensation or share of production costs, whether or not profit is made.
- You are not allowed to produce DTPlugs for commercial use even if you don’t sell them.
- These restrictions also apply to modified version, whoever their author may be.
In order to boost the diffusion of DTPlug, we allow DTPlugs purchased from Techno-Innov to be resold, modified or not, at the seller’s entire responsibility.
This exclusion is intended to allow installers to make commercial use of DTPlugs they have purchased from us.
You’ll find on this page all the DTPlug related documents. You can download and use them as long as you abide by the license they’re under.
All of the hardware created by Techno-Innov for DTPlug is under Creative Commons CC BY-NC-SA Attribution-NonCommercial-ShareAlike License. For software, check the licensing of each element.
Make sure you understand the implications of this License as outlined in: What does that license entail?
CAD Files for the box:
- 3D Printing version: bottom and top.These aren’t the final files, which include clearances for the release from the mold after plastic injection, but the last version used for 3D printing on an Ultimaker 3D printer at the Fabrique d’Objets Libres (Free objects manufacture), Lyon’s FAB-Lab.
- The final version will be available as soon as we’ve validated the mold.
Controller board schematics:
- Schematics for DTPlug’s controller board (currently produced version is v1.1) provided as an archive with all files, including the components libraries. You’ll find the schematics in KiCad native format and the placement/routing file (also in KiCad native format).
- Technical manual for DTPlug is not yet available
- Technical data for the main components (NXp’s LPC1764 de NXP, Ethernet PHY, ….) is available in this directory. Be aware that more up to date versions may be available on the manufacturers’ websites.
Available on the “Software” page.
DTPlug’s technical data:
Controller board hardware:
Micro-controller: NXP’s LPC1764
- ARM Cortex-M3 core
- Core freq: 100MHz
- Flash: 128Ko integrated and fully onboard programmable
- SRAM: 32Ko
- Ethernet MAC
- USB gadget 2.0 full-speed (device) only
- UART, SPI, I²C, GPIO, ADC, PWM, …
Interfaces and Features :
- Cortex-M3 nicro-controller running at 100MHz, 32Ko of SRAM, 128Ko of fully onboard programmable Flash (through UART0, need UART-to-USB adapter on board version 1.1).
- 12 MHz main Osc. + 32.768 kHz RTC Osc.
- Ethernet RJ45 10BASE-T/100BASE-TX port using SMSC’s LAN8720A ethernet transceiver.
- USB gadget 2.0 full-speed port on micro-AB connector.
- SD card socket.
- Reset and ISP buttons, programming header on 2.54mm pins.
- Two USB charging ports (power only, no data), type A connector, 30W available, requires provided USB cable.
- 4 internal UEXT connectors (specified by Olimex) to add modules for home automation, including two with 5 GPIO + 5V power extension.
- 1 internal “CPL” connector to add CPL specific modules.
- ARM JTAG 20pins and GPIO extension (not populated).
The DTPlug is already available in box version (docking station for DomoTab will be added later):
- Robust plastic case, easy to open.
- 110-230V 50-60Hz IEC320C7 power input (euro-connector)
- Power switch
- MeanWell EPS-35-5 power supply, 5V – 30W.
- 4 openings with blinds for home automation modules connectors.
- Controller board PCB (excluding connectors) (l x L x H) : 65mm x 118mm
- Populated controller board (l x L x H) : 68mm x 121mm x 25mm
- Box (including connectors and switch) (l x L x H) : 78mm x 124mm x 70mm
- Full version: 280g
- Controller board: 50g
- Box (3D printing) : 125g
- Box (injection) : 110g
- Power supply + internal cables: 105g
DTPlug is an extension box for DomoTab intended to provide a bridge between the tablet versions and wired networks.
Originally planned as a simple extension card to be integrated in the tablet’s power supply, we finally decided to make DTPlug a stand alone product. Like DomoTab, this is a modular product that can be used independently, uses the same module format and an ARM Cortex-M3 micro-controller,NXP‘s LPC1764.
While the LPC1764 doesn’t have a lot of memory (128KB of flash memory, 32KB of SRAM), it has enough to control an IP stack (such as lwip), a mini OS (such as CoOS) and all connected modules.
On top of its Ethernet 10/100 Mbps, USB Device port and SD card slot (to store temperature readings or read configuration data for instance), DTPlug has 4 UEXT extension ports (two of which have extra GPIOs) and a PLC port (power line communication).
In order to fulfil its primary function (power or recharge the DomoTab tablet), DTPlug includes a MeanWell EPS-35-5 Power supply which can provide 30W of useful load, shared between the USB charge sockets. When used with our custom USB charge cable, DTPlug can provide up to 5A of charging current, as defined by USB Battery Charging Specifications (be aware that D+ and D- signals aren’t connected on those two ports).