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I received a pair of Apem AV09C7L3D2006 momentary pushbuttons from
Hawk Electronics (hawkusa.com).
These have 2V red LEDs (hence needing a 1K resistor in series if
driven from 12V). I wanted yellow, but I can't seem to find them
anywhere on-line and in-stock.
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I ordered a pair of Apem IPR3FAD2LOS pushbuttons from
Mouser Electronics. The
AV09C7L3D2006 are very cool, but don't fit terribly gracefully into
console blanks. They're also relatively expensive and the lens
doesn't permit much light from the LED.
Mouser doesn't have the IPR3FAD2LOS in stock, so I've no idea how long I might have to wait for them.
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Mouser shipped my Apem IPR3FAD2LOS pushbuttons. They should be here
next week.
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The Apem IPR3FAD2LOS pushbuttons arrived from
Mouser Electronics. They're very
nice, and two of them will easily fit in a console blank.
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I ordered some 2.5W bulbs for the instrument cluster indicator.
P/N 62-11-1-391-260
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The current PCB design is 0.9" x 1.65". It has inputs for the
DSC button and a separate Sport Mode button. It has outputs for
DSC, Sport Mode, the Sport Mode cluster lamp, and an LED for Sport
Mode.
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Bell BMW shipped the bulbs for the Sport Mode indicator in the
instrument cluster.
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I picked up eight DME pins (P/N 61-13-0-005-197) and the connector
that's used to hold the same pins on the DSC button wiring
(P/N 61-13-8-380-696, which superceded P/N 61-13-8-377-238). My
dealer had them in stock.
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A microcontroller Hotchip Motherboard, Mini Board, output
relay module, output MOSFET module and an input module shipped
from ucpros.com.
This is for my code testing and is not what will be installed in
my car; it's too big. It should arrive December 4, 2003.
I ordered components from Mouser Electronics for my "Mini" version of the Sport Mode microcontroller module.
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For future reference, I ordered a pair of
ITW Series 57 pushbutton switches
from newark.com. These look to
be of equal quality to the Apem AV series, but are small enough to
fit well in a center console blank. They were in stock, so they
shouldn't take too long to arrive.
I also ordered components to make 2 more Sport Mode Mini modules. That brings my total to 4 modules. Once I have tested the fitment, I will order boards.
- Components shipped from Mouser Electronics. The Apem IPR3FAD2LOS pushbuttons are on back-order, and expected to ship on December 15, 2003. Not a big deal, I already have a pair of them and will also have the ITW Series 57 pushbutton switches this week.
- The ITW Series 57 pushbutton switches arrived from newark.com.
- I submitted my PCB order to custompcb.com. 16 units are expected to ship on December 9, 2003. Total cost was $104.00 (including shipping).
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I ordered Delrin bar stock, #3-48 1" screws and nylon-insert locknuts from McMaster-Carr and had it shipped to Randy's address so he can try making a pair of cases.
- Parts arrived from
MicroController Pros.
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Components should arrive from
Mouser Electronics.
- An 8-pin SOIC to DIP adapter arrived from logicalsys.com. It's part number PA8SO1-2006-3. This will let me pre-program the microcontroller before soldering. It's almost exactly the same as the PA20SO1-2006-3 I used for the 20-pin AT90S2313, but only uses 8 pins in the adapter and only has 8 DIP pins.
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Printed circuit boards shipped from
custompcb.com.
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IDC cables arrived from
Mouser Electronics.
These will let me make use of the modules I got from
MicroController Pros.
- Three Apem IPR3FAD2L0S pushbuttons should arrive from Mouser Electronics.
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Woo woo! PCBs arrived early; I might get to assemble one this
weekend.
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I assembled one complete module and tested it on the workbench.
It seems to work well for Sport mode. I haven't tested the
DSC part yet. The programming header works too, with my STK500
programming board and a 6-pin IDC cable.
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I assembled a second unit (#2) for Randy, and half of another (#3) for
Drex.
Units #1 and #2 both passed basic bench testing. They each now have a coat of silicone conformal coating on the top and two coats on the bottom. Another coat on the top and I can send one out to Randy.
I ordered components to assemble six more boards.
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Components arrived to populate 6 more boards.
I tested a module in the car. Seems to work as expected.
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I ordered pass-thru pin headers to make my harness adapter for
the DSC connector. I need to pick up more DME pins and the
DSC connector from my dealer.
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I received 3 cases from Randy. See the case
page.
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I ordered more cluster lamp bulbs from Bell BMW (order #11187434).
I ordered AWG20 wire in various colors from Digi-Key to make color-coded harnesses. I also ordered a new Paladin stripax Pro 6 stripper, to replace the stripper I lost years ago in a move. Order #12693693.
I ordered a pair of Snap-On soft-grip stubby ratcheting screwdrivers (one for me and one for Randy for being gracious enough to make cases for me). I ordered a handful of bits for each of us too (3 Philips ACR, 3 flat tip, 3 Torx).
Four modules are in-progress for Drex, z3scot, Mpire and MarkL. The boards are assembled, and the conformal coating is drying. I need to test them one they're dry. I only have cases for the first three; MarkL's will have to wait until Randy finishes the case.
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I drove to Cleveland and back (1.25 tanks of gas) with a module in
my car. Seems to work very well. I toggled Sport mode and DSC
several dozen times, and restarted the car at every opportunity
(including traffic lights). I left Sport mode on for the entire
return trip.
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Mouser contacted me today to tell me there's been yet another
delay on the Apem IPR3FAD2LOS pushbuttons. They're now saying
that my last order (placed December 15, 2003) won't arrive until
the third week of February. Sadly, this appears to be the
situation from other suppliers as well, and Kim @ Mouser told me
that it's not a minimum order issue; Apem is backlogged on all
of the LED-illuminated IP pushbuttons.
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I ordered flame-retardant braided sleeve (to wrap the harnesses)
from cableorganizer.com.
I thought I had some of the normal stuff (not flame-retardant),
but I could only find pink, blue, red, yellow and green in my
stock. I want black. I also ordered more adhesive-lined
heatshrink tubing.
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I ordered center console blanks (P/N 51.16.2.492.136) and more
cluster lamp bulbs from
Bell BMW.
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I ordered 10 more ST VND600SP drivers from
Digi-Key.
Mouser has none in stock
and the ETA is unknown. I also ordered 4 large diodes (15A, 400V)
to do the fix for my HID ballasts (JonM posted this on bimmerfest).
Order #12718294, FedEx tracking number 630284930439.
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The braided sleeve and heatshrink tubing will ship from
cableorganizer.com.
- After months of waiting, Mouser has finally shipped more
IPR3FAD2LOS pushbuttons. They should arrive on February 23rd.
- I created a simple test rig using LED bulbs to re-test modules
I created, and test any future modules. I re-tested one of the
modules, and will be testing more tonight. I have a couple of
harnesses made, and a couple of center console blanks prepared.
I need to double-check the harness lengths.
- Since my Windows XP machine is dead, I had to fire up my old
ThinkPad to run the AVR tools since I can't seem to get uisp
to program fuses. What a hassle... crusty Windows 95, and
I had to disable a bunch of hardware to get the serial port to
work with the STK500.
I tried testing a second module, and it failed. The one I tested yesterday (#5) looks fine. From visual inspection, I'm guessing the problem is the ground pin on the microcontroller. So right now I've got two working modules available, and one dead one. In the future I will do more rigorous testing before conformal coating. I need to assemble a few more modules, which I'll do this week.
- I ordered parts from Mouser to make one more module for Mark in
Sweden. Right now, Fairchild NDS355AN MOSFETs are not available
from Mouser or Digi-Key, so I ordered FDN357N instead.
- I started building 3 more modules. If they all work, these
will satisfy the waiting list from months ago. I finished the
reflow soldering on the bottom of all three. Here they are fresh
out of the oven:
I loaded code onto the 6 microcontrollers I had on hand. I'll finish assembly of these three modules tomorrow. I have not yet started to build the module for Mark in Sweden. He wants slightly different code on the microcontroller, which hopefully I'll get to this weekend.
- I forgot to program the RCEN bit (enable on-board oscillator)
on the microcontrollers when I was loading code onto them last
night. I just did that, and am now woriking on reflowing the
second side of the modules that are in-progress.
I need to pick up more supplies today; I'm nearly out of small diameter heatshrink tubing, and I need more male and female insulated disconnects for the runs to the DME and instrument cluster.
Hmm, the first one's ISP header isn't working. I accidentally loaded the wrong code on the microcontroller before soldering (the old plain 'sportmode.hex'), and need to reprogram. It's unclear what's wrong here, I need to check the ISP header soldering. It looks fine, and I've never had a failure of this kind. Perhaps the microcontroller was damaged when cleaning up bridges with the solder wick. I'll pull it from the board and test it in my socket adapter on the STK500.
I reloaded all of the other microcontrollers with the correct code.
- I ordered the following, which are mating connectors for
the DSC harness. These will let me eliminate the somewhat
hokey setup of the gender changer I'm using right now.
P/N Description Unit Price Qty. Total 61.13.8.377.229 universal pin terminal uncoded, 4-pole $0.59 12 $7.08 61.13.0.005.198 pin contact (0.2-0.5mm) $1.04 48 $49.92 61.13.1.387.173 universal pin terminal uncoded, 4-pole, schwarz (black) $0.59 12 $7.08
- I received the parts I ordered on March 12, 2005. Looks like I'll no longer need the Sullins gender changer trick.
- The voltage regulator went belly-up on the controller in my car. I have a newer design with a beefier regulator, but haven't placed a PCB order. For the interim, I should order an AVR I/O board from microcontrollershop.com/. It's big, but it's cheap and robust (opto-isolated inputs, etc.). I will probably locate it over by glove box, since there's room there and it would make access easier than what I have now.
- The AVR I/O board shipped from microcontrollershop.com. USPS 9101805213907525117111
- I think I'm done with the next-gen sport mode module design. I should do one more parts check and then place a PCB order. The module is about 1.75" x 1.75", which means I'll probably get 12 of them in one PCB order.
- The AVR I/O board arrived from
microcontrollershop.com. The relays are rated for 15A at 24V DC.
- There are a couple of drawbacks to using this board. One is that it we need pairs to the inputs since the inputs are opto-isolated, and need +12V and ground to pull the input pin low. Another is that the power connector is not secure enough for in-car use.
- I started tweaking my code to run on the AVR I/O board.
- I started playing with loading code on the AVR I/O board. What works with the
SP Duo programmer:
avrdude -v -p t2313 -c stk500v2 -U flash:w:sportmodeavrio.hex - I committed code that seems to work fine. I now just need to clean it up, and start thinking about case and wiring.
- I ordered some parts from Digi-Key. they let me order Apem IP switches in quantities of 1, so I ordered one with a black plunger and green LED, one with a green plunger with green LED, and one with a red plunger and red LED. We'll see which ones I decide to use, but I'm leaning toward keeping one of my existing ones with black plunger and red LED for DSC, and using the black one with green LED for sport mode.
- I also ordered 10 VND600SP high-side drivers from Digi-Key, since Mouser doesn't let me order in small quantities. Worth noting that they also carry the VNQ600, which is a quad high-side driver in SO-28 form. That'd be handy for my later more generic design.
- I ordered some garolite sheet, PVC C-channel and standoffs to make a simple case for the AVR-IO board.
- I need to work on a wiring diagram. Ideally I put a modular jack in the case, so it's easy to unplug it and remove it.
- I need to order a power plug for the AVR I/O board. 5.5mm OD, 2.1mm ID.
- I ordered some power plugs for the AVR I/O board. 5.5mm OD, 2.1mm ID. I also ordered a new benchtop power supply, an Extech 382202.
- I took a quick measurement in the e-box. There's at least 6"x7"x1.5" of space to work with.
- Parts arrived from McMaster-Carr to make a simple case for the AVR-IO board.
- I need to work on a wiring diagram. Ideally I put a modular jack in the case, so it's easy to unplug it and remove it.
- I picked up a pack of 500 resistors from Radio Shack, so I have some to wire in-line with the LEDs in the Apem IP pushbuttons. 1K ohm should work fine.
- I wired a modular jack to the AVR-IO board. I also fabricated a simple case.
- I ordered some heatshrink from Mouser, as well as a Wahl ISO-TIP soldering iron for Randy and a couple of new tips for myself.
- I need to order some longer #4-40 screws. The ones I have are too short. McMaster-Carr 91770A113 (3/4"), 91770A096 (1/2") and 91770A108 (3/8").
- I also need to order some BMW connectors for the cabin.
P/N Description Unit Price Quantity Total 61.13.8.377.072 3-pole receptacle $1.00 6 $6.00 61.13.6.931.929 3-pole plug $1.34 6 $8.04 61.13.6.909.058 6-pole receptacle $0.78 2 $1.56 61.13.6.913.635 6-pole plug $1.86 2 $3.72 61.13.0.005.197 bushings for .738 and .058 $1.22 40 $48.80 61.13.0.005.198 pins for .213 and .307 $1.22 40 $48.80 TOTAL $127.48 - The 3-pole connectors are for the instrument cluster. The 6-pole connectors are for the harness that runs from the cabin to the e-box.
- I assembled the red and green Apem IP pushbutton harnesses, and installed the buttons in a console blank. I'm using the BMW connectors, and wired 1K resistors in for the LED in each button so I don't have to think about it when driving them. They light up fine with as little as 3 milliamps, should I someday drive them from 5V. worst-case they're going to see about 14 milliamps, which is safely within their range. I tested them, they work fine.
- I need to look over my wiring diagrams and finalize my order for BMW parts. See avrioCabin.obj in my embedded/MRoadster/SportMode/tgif directory.
- I ordered connector parts from the local BMW dealer.
- Note that if I want to draw more power for the controller board, I can tap any of the fuses that are fed by the engine control module relay in the e-box. Those ware red/white wires, pins 2, 4, 6 and 8, fuses 201 through 204. See 0670.2-01 in the ETM.
- The cabin harnesses will look something like the picture below.
- I still have the question of the current draw for the AVR-IO board, worst case. The relay coils each use .36W of power, but I'd only have one latched more than briefly. The microcontroller consumes microamps, might as well be called neglible. The instrument cluster lamp is 1.5W. So I think we can assume we'll be using about 2W of power. At 14V, that's 143mA. That's well within the range of AWG24 wire and our voltage drop will be less than 1 percent if the wire is 8 feet or shorter. Max for AWG24 would be around .6A if being very very conservative (700 circular mils per amp rule). That would be 7.2W, which is way above what we'll be using. Realistically, we're talking about short runs and could hence probably use a 300 mils/amp rule, or even 200 mils/amp. AWG24 is 404 mils, which would yield 1.33A with a 300 mil/amp rule; way more power than we'll use).
- I picked up the harness parts at the dealer. I assembled the center section of the harnesses, which was the hardest part.
- I put together enough of the rest of the harness to test in the car. It seems to work fine. I tweaked my code, pulled the cat5 cable to the e-box, etc. I should be buttoning it up soon.
- I finally ordered new test leads for my HP 54501A oscilloscope, as well as leads for my function generator so I can fix my speedometer error.
- I have Bud PT-11664 enclosures on the way from Mouser for all of the AVR-IO-M16 boards. They should arrive on Tuesday. I need to order some console blanks from the local dealer.