Anechoic Chamber Used for Electronics Testing

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Devoid of electromagnetic waves, an anechoic chamber (Figure 1) is a shielded room designed to provide an ideal environment for testing electronics. Anechoic means free from echoes—or non-reflective. These chambers are used in compliance testing. The surfaces of anechoic chambers are lined with carbon-based absorbing materials (Figure 2) and ferrite tiles in order to eliminate electromagnetic emanation, radiation, and reflection. Isolation from external interference enables design engineers to accurately test devices and electronic components like radar systems, antennas, sensors, and more. In an anechoic chamber, designers can also conduct a wide range of tests and measurements like thermal noise and military specification tests often conducted in certification labs.

Connected Development’s OTA pre-compliance anechoic chamber

Figure 1: Connected Development’s Over-the-Air (OTA) pre-compliance anechoic chamber used for antenna, radio, OTA, and RF testing. (Source: Connected Development)

Anechoic Chamber Inside

Figure 2: The inside of the chamber is lined with conductive carbon-coated material and is designed to make the chamber shielded and anechoic, meaning it is designed to prevent the signals from echoing or reflecting inside the chamber or from getting in from the outside–thus distorting RF measurements. (Source: Connected Development)

Electronic Device Certification Requirements

Regulatory and carrier requirements often present the need to test in RF and anechoic chambers. Any electronic device—wireless or wired—must meet certain governmental regulations, with requirements varying based on application and geographic location. Additionally, almost all products will need to meet government requirements for un-intentional emissions. Devices undergo anechoic or semi-anechoic chamber testing at an accredited certification lab to get certified or complete a Declaration of Conformity. Specifications may call out an Open Area Test Site (OATS) for testing but allow other calibrated chambers as alternatives. In these circumstances, it is best to undergo anechoic chamber testing rather than using an OATS site due to the controlled environment that anechoic chambers offer.

In the US, the Federal Communications Commission (FCC) requires that products meet FCC Part 15B if they contain a clock at 9kHz or higher, unless exempted (Title 47, part 15.05 Digital Device, 15.101). If the product includes a transmitter, additional radio-based testing is needed based on the spectrum the device operates in and other factors related to the product type.

For sales in Europe, the market requires a CE mark on the product. Part of the requirements contains an EMC directive or Radio Equipment Directive (RED), which has un-intentional emissions, spectrum efficiency, and immunity requirements.

What Is an Anechoic Chamber Used For?

Shielded from external interference, anechoic chambers offer a controlled environment for electronics testing. The following are key tests performed in anechoic chambers:

  • RF/Antenna Performance Testing: A key test performed in an anechoic chamber is RF/antenna performance testing. RF performance is critical, and the evaluation ties into final certification. An anechoic chamber enables measurements of transmitter performance, and designers can decide if any antenna circuit matching needs to be adjusted or if an antenna needs to be changed. The types of testing supported include RF testing and RF performance of devices for un-licensed radio areas like LoRa®, Wi-Fi, GPS, and BLUETOOTH®, and licensed areas like cellular.
  • Passive Antenna Pattern Testing: Anechoic chambers support passive antenna pattern testing for design, matching, or trimming an antenna. Testing the performance of antennas through the design phase is important, and in un-licensed certified modules, the antenna gain is limited by the certified module manufacturers’ limits or limitations presented by governmental bodies for the radio type and service. In cases where the antenna is designed into the PCB as a trace antenna, anechoic chamber testing can provide insights into the gain and efficiency of the design.
  • PTCRB/CTIA OTA Testing: In the US, cellular device approvals are generally required to meet OTA and Radiated Spurious Emissions (RSE) requirements set by carriers like AT&T and Verizon. OTA test methods are determined by certification programs such as PTCRB, CTIA, or the cellular carriers themselves.
  • Other Performance or Quality Testing: Other tests that can be performed in anechoic chambers include:
    • Pre-compliance testing throughout the development cycle to avoid costly re-work and redundancy in submission for final certification
    • Un-intentional radiated measurement testing
    • RSE testing for harmonics of the transmitter
    • OTA antenna testing
    • CE Immunity tests

How Is an Anechoic Chamber Constructed?

From small, mounted chambers to rugged military-grade chambers, anechoic chambers come in many different shapes and sizes. The size and weight of the device and frequencies to be investigated help determine the size and type of chamber needed (i.e., measuring an automobile vs. a cellular phone). The internal turntable needs to be able to handle the weight of the device and rotate freely. The distance between the device and the antenna needs to be large enough to measure down to the lowest frequency desired. Typically lined with carbon-based absorbing materials or ferrite tiles, anechoic chambers are constructed in one of two ways—fully anechoic or semi-anechoic:

Fully Anechoic Chambers

Fully anechoic chambers (Figure 3) have absorbing material, ferrite material, or both on all surfaces—floors included. The goal is to absorb all energy, allowing the test antenna to measure only the energy seen in a direct line from the product being tested. Fully anechoic chambers are used to test for emissions, immunity, antenna pattern, and transmitter and receiver testing–including OTA.

Fully Anechoic Chambers

Figure 3: Diagram showing placement of absorbing material in a fully anechoic chamber. (Source: Connected Development)

Semi-Anechoic Chambers

Semi-anechoic chambers (Figure 4) have absorbing material, ferrite material, or both on the walls and ceiling. For some test areas, absorbing material is placed between the test antenna and the product being tested, but is not present on all surfaces. Semi-anechoic chambers are used to test for emissions immunity testing.

Semi Anechoic Chambers

Figure 4: Diagram showing placement of absorbing material in a semi-anechoic chamber. (Source: Connected Development)

Conclusion

To ensure optimal performance and compliance with governmental regulations, electronics must undergo thorough testing. Anechoic chambers provide a means to take repeatable RF measurements and eliminate reflections and outside interference. Testing is supported for both unlicensed and licensed radios. Anechoic chamber testing provides detailed insights into the performance of devices. It ensures the device's antenna performance meets the needs of the device, addresses governmental compliance, and assists in troubleshooting design modifications.

About Author

"Darin Hatcher is a Certification Manager at Connected Development with previous experience as a Radio Characteristics and Regulatory Engineer. Darin specializes in radio access stack, radio characteristics, FCC, and 3GPP type approval. His expertise spans IoT M2M areas for Cellular (5G, 4G including Cat-M and NB-IoT, 3G and 2G), Wi-Fi, Bluetooth, GPS, and LoRa®. In his current role, Darin oversees the certification process and testing for government regulations, (FCC, ISED, CE) and carrier requirements (OTA, PTCRB, CTIA, AT&T, Verizon, etc.)"

Originally Posted on Mouser

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Build Your Own Power Bank

A power bank is a portable rechargeable battery that allows you to connect to an external charging source when you don't have access to a wall charger. The market for power banks has exploded, making it one of the most popular electronic products available. However, such a fantastic device comes with an equally astounding price tag. Fortunately, we will go over a step-by-step approach in this post on How to Make a Rechargeable Power Bank (4500mAh) Using 3.7V DC Batteries at Home.

Typically, there are three basic components that make up a power bank that is created for sale. A Li-ion (Lithium Ion) or Li-Po (Lithium Polymer) rechargeable battery, a DC-to-DC converter module, and a battery charger module (often based on TP4056 IC). To connect the power bank to any external device, you will also need a Micro USB cable.

Components Required for Power Bank

  • 3 x Li-ion Cell (18650 3.7V 1500mAh)
  • 1 x Power Bank Module
  • 1 x Micro USB Cable

Making A Power Bank: Step-by-step Guide

DIY Power Bank Circuit

Step 1

Connect the 18650 Lithium-ion cells in parallel, which will make it a 4500mAh 3.7V Pack.

Step 2

Connect the Power Bank module to the battery pack as indicated above.

B+ Positive of the battery pack.

B- Negative of the battery pack.

Enclosure for the Homemade Power Bank

To safely keep all the circuitry enclosed, we designed an enclosure with all the cut-outs on Fusion-360 and 3D printed them.

Power Bank Enclosure

You ought to have a power bank that is securely sealed after putting everything together.

Easy to Build DIY Power Bank

18650 Battery based Power Bank Circuit Working Explanation

This circuit's operation is rather straightforward. A DC power reservoir is provided by the 3.7V battery. Considering that the battery typically provides 3.7V DC. The charge controller module protects against overcharging while ensuring optimal charging. A consistent 5V/2A DC output is provided by the inbuilt DC to DC boost converter module found on the charger circuit board.

The onboard SMD LEDs on the charge control circuit board's bottom give charging-status signals when the circuit is linked to either an external output device or a wall outlet for charging.

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The Biggest Challenge for T&M Industry to Keep up with Stringent Quality Checks and Right Use of Equipment

One of the biggest challenges faced by the testing and measurement (T&M) services and solutions is to adapt to the changing times and new equipment that are flooding the market. The increased product complexity has prompted growing demand for precision testing at every stage of the product life cycle and companies have to be ready for the demand.

5G Is Not Just Good for Consumers, the IoT Will Benefit Too

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5G will not only boost mobile telecom but also the IoT with technology such as DECT-2020 NR.

Mobile communications has followed a development path signposted by “generations”. It forms an interesting history kicking off with the retroactively applied ‘0G’ label used to describe analog systems that predated the cellular approach.

Things really got going with the analog/digital technology of the late 1970s and early 80s; ‘1G’ was based on cellular mobile coms that used analog radio for calls but digital systems for backhaul. ‘2G’ arrived in the early 1990s as an all-digital system. Before the turn of the century, we saw ‘3G’ (building on enhancements introduced by 2.5G and 2.75G) which introduced higher throughput to support the emergence of the smartphone. Enhancements to 3G boosted speeds such that it could handle mobile internet and streaming video.

4G is based on the Long Term Evolution (LTE) standard and was introduced in Scandinavia in 2009. It has since been deployed over much of the planet and is the mobile technology with which we are most familiar today. It offers a maximum throughput of 100Mbps (compared to around 15Mbps for 3G) and can support high-definition video, online gaming, and video conferencing.

Next is 5G. The standard was introduced in 2016 and 5G networks are being rolled out. It promises a staggering maximum speed of 32Gbps (downlink) and 13.6Gbps (uplink). Once fully deployed, 5G will be directly competitive with fiber cable solutions for internet support. The technology also offers lower latency, better coverage, and improved spectral efficiency compared to 4G.    

So 5G is like 4G then, but just a bit bigger and better. Actually, that’s far from it; 5G also ushers in lots of new technology that’s of little benefit to users of Zoom, Netflix, and TikTok but will prove critical to the growth of the IoT.

Welcome to New Radio

The 3GPP, a unification of seven telecoms standards development organizations, has worked hard to ensure 5G is not only built for demanding consumers, but also for the future requirements of enterprise organizations and the IoT. Behind the scenes, engineers have methodically put together the document that details the International Mobile Telecommunications (IMT)-2020 specifications. IMT-2020 is the bible of 5G, detailing how it will be built and how it will meet the exacting demands of consumers and industry. The specification includes an initial peak data rate of 20Gbps; a typical user data rate of 100Mbps; one-millisecond latency; an “area traffic capacity” of 10Mbps per square meter, and a connection density of one million devices per square kilometer.

These guidelines clearly demonstrate how the 5G network is being built for a combination of high speed (for consumer and commerce applications) and high device density (for the IoT). 4G is more consumer-oriented (although suitably modified networks can support cellular IoT technology such as NB-IoT and LTE-M). The magnitude of the challenge for 5G can be appreciated when considering, for example, conventional device density. Tokyo has an average population density of over 6,000 people per square kilometer and most people own a least one mobile device. If they all wanted to access the internet, the local network could still cope. That’s impressive, but it’s two orders of magnitude lower than the planned device density of 5G.

A clue to how 5G will cope with the twin demands of consumers and the IoT is hidden in the detail of IMT- 2020. The document describes two elements: 5G LTE technology for traditional users and new radio (NR) for other use cases, including the unique demands of the IoT. Engineers refer to these elements as “radio interface technologies” (RITs).

Between them, the LTE and NR RITs fulfill all the technical performance requirements across the five anticipated use cases:

  • indoor hotspot (using enhanced Mobile Broadband (eMBB))
  • dense urban (eMBB)
  • rural (eMBB)
  • urban macro (Ultra Reliable Low Latency Communication (URLLC)
  • urban macro (massive Machine Type Communication (mMTC))

The last two, URLLC and mMTC (related), use cases primarily support the IoT.

LTE and NR operate in frequency bands below 7.125GHz identified for IMT use, but NR can also use the IMT frequency bands above 24.25GHz. The so-called upper mid-bands (3.3 to 7.125GHz) are the key 5G resource and offer satisfactory throughput and range for consumers and commerce. The ‘high bands’ above 24GHz offer support for both high device density and extreme throughput.

5G, But Not As We Know It

It turns out that 5G doesn’t even have to be cellular technology. Buried in the IMT-2020 document is a reference to what’s been labeled “the first non-cellular 5G standard” - DECT-2020 NR. It makes the grade by offering support for one million devices per square kilometer and although not strictly cellular, it does borrow a lot of technology from cellular systems.

DECT 2020 NR is an interesting technology that demonstrates how comprehensive IMT-2020 is in identifying the scope of 5G. The technology uses the global—and, unusually for 5G operations, license-free—1.9 MHz band and will support mMTC on wireless mesh and other types of networks. These networks typically underpin IoT applications with very high deployment densities, high reliability, and low latency demand—such as thousands of compact sensors/actuators in industrial automation applications.

DECT-2020 NR stacks up well against other wireless IoT technologies used for mMTC. For example, when supporting node densities up to its maximum capability, the technology offers a top performance of 100kbps throughput with sub-10ms latency. That’s ideal for typical IoT applications.

5G is the first generation of cellular (with a sprinkling of non-cellular) mobile technology that was designed from the outset to support not only traditional mobile telecoms, but up-and-coming wireless technologies such as the IoT. 6G is already in the works and is said, perhaps not surprisingly, to be significantly faster than 5G. The plan is to use frequencies ranging from 100GHz to 3THz and support will extend from consumers and the IoT to new sectors such as AI and fully immersive VR. Based on the decade-long beat rate for introductions of new generations of mobile wireless technology, expect to see 6G-capable smartphones in the stores in 2030.

About Author

Steven Mouser

"Steven Keeping gained a BEng (Hons.) degree at Brighton University, U.K., before working in the electronics divisions of Eurotherm and BOC for seven years. He then joined Electronic Production magazine and subsequently spent 13 years in senior editorial and publishing roles on electronics manufacturing, test, and design titles including What’s New in Electronics and Australian Electronics Engineering for Trinity Mirror, CMP and RBI in the U.K. and Australia. In 2006, Steven became a freelance journalist specializing in electronics. He is based in Sydney."

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How to build a 12v Battery Pack using Li-ion Cells

We'll be making a 12V 2000mAh Li-ion Battery pack in this post. We'll start by designing a 3s battery pack, then connecting the BMS to it to execute all of the BMS's functions. Li-ion cells are increasingly used as battery packs for many applications due to their high energy density and rechargeable characteristics. However, we must link a Li-ion cell with a BMS to safeguard the circuit from being destroyed or reducing the cell's life. In this tutorial, we'll construct a simple 3s battery pack and connect it to a 3s 6Amps BMS circuit.

About 18650 Li-ion Cells

The 18650 battery is a lithium-ion battery with a diameter of 18mm and a height of 65mm. Its height and diameter are both greater than the AA size. They are not compatible with AA or AAA size batteries. Because of its high-level capabilities, such as 250+ charge cycles and increased energy density, the 18650-battery type is useful in rechargeable and high current draining devices. Because of its versatility, the 18650 Li-ion battery may be found in various applications, including electric cars/scooters, power banks, and utility devices such as emergency lighting, torchlights, etc.

This battery is famous in the electronics industry because of its safety features, high output current, and energy capacity.

18650 Cell Dimension

The standard size of a 18650 battery is 18x65mm.

  • The 18650 battery is 65mm long
  • The 18650 battery has an 18mm diameter

More specifically, it measures 65mm in length and 18mm in diameter; however, technically, the 18650-battery size is permitted with some length and diameter tolerance. On the datasheet and characteristics of Li-ion cell, you could see specifications such as 18±0.3mm 65±0.5mm. Remember that 18x65mm is a standard size, and the rest will be handled by device and battery designers and manufacturers. Because different gadgets or devices restrict other locally created technology, the size of the 18650 battery is permitted. That may not be able to produce the correct length and diameter of batteries or battery holding space to fit the device or 18650 Lithium battery, respectively.

About the BMS

A battery management system (BMS) monitors a battery pack, a collection of cells electrically grouped in a row x column matrix to supply a specific range of voltage and current for a set period response to projected load scenarios. A BMS's supervision often involves the following:

  • Calculation of the state of charge
  • Over-voltage and under-voltage protection for the cell.
  • Balance Charging.
  • Battery Pack charge management.
  • Temperature monitoring of the pack.

The name "battery" refers to the entire pack. Still, the monitoring and control functions are applied to individual cells or groups of cells known as modules in the whole battery pack assembly. Lithium-ion rechargeable cells offer the highest energy density and are used in battery packs for various consumer items, including computers and electric cars. While they function well, they may be harsh if used outside of a relatively narrow safe operating area (SOA), with repercussions ranging from battery performance degradation to outright danger. The BMS has a complex job description, and its total complexity and supervision scope may include electrical, digital, control, thermal, etc.

For more information on the BMS, refer to this article.

Now that we have adequate information about the 18650 Li-ion cell and the BMS, let's begin making a battery pack.

Material Required for a 12V Li-ion Battery Pack

  • 18650 Li-ion Cells x 3
  • 3S 6Amp BMS (Battery Management System)
  • 0.15mm Coated Nickle Strips
  • Barallel Connector
  • JST XH 2.54 Female 4-Pin Connector
  • 100mm PVC Heat Shrink Sleeve

Connections for 12V Battery Pack with BMS

Cell Connection in Series

Every 18650 cell can be charged up to 4.2V; we need three cells in series to make a 12.6V battery pack. In the figure above, the connections are indicated.

12V Battery Pack with BMS Module

The BMS is to be mounted as indicated above.

Marking On the BMS

Connection with the BMS

P+

Connection to the battery pack's positive terminal for charging and attaching the load

P-

Connection to the battery pack's negative terminal for charging and attaching the load

B-

Negative terminal of the 1st cell

B1

Positive terminal of the 1st cell

B2

Positive terminal of the 2nd cell

B+/B3

Positive terminal of the 3rd cell

To balance charge the battery pack, an extra set of wires must be attached to the battery pack with a JST XH female connector.

BMS Module with Battery Pack Connection

To seal the battery pack for safety and sturdiness, we use a 100mm PVC Heat Shrink Sleeve and shrink it around the battery pack. After it's done, the battery pack will look as indicated below.

12V Battry Pack

Performance

To test the battery pack's performance, we hooked it up to a Constant Current DC Load, whose details can be found here.

We set the current to a constant 1 Amp, and below is the result for the test.

  • Unloaded Battery Voltage-12.45V
  • Battery Voltage Under 1Amp load -12.20V

From the above graph, it can be observed that when a load of 1A is connected to the battery pack, the voltage drops to 12.20V from 12.45V. It keeps on dropping till 9.2V before the BMS turns off the pack to prevent over-discharging of the cells.

Frequently Asked Questions

Q. How long do Li batteries last?

According to most manufacturers, lithium-ion batteries are expected to last at least 5 years or 2,000 charging cycles. On the other hand, lithium-ion batteries may last up to 3,000 cycles if properly cared for and utilized.

Q. Do lithium batteries lose charge when not in use?

Even when the battery is not in use, it will drain the charge, regardless of the kind or substance. Lithium-Ion batteries, too, will deplete when not in use.

Q. What is amps in BMS?

The BMS rating is in amps (a unit of current/flow), whereas the battery capacity is in amp-hours (a unit of capacity/stored energy). The BMS is solely concerned with the maximum amps flowing through it, not with the amp hours.

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What is Helping the Growth of the Global Cellular IoT Module Market?

Smart meters along with automotive, router/CPE, industrial, PC and POS are the major IoT based cellular applications that helped in generating large revenue, but router/CPE, PC, and drones are the key three growing segments

For the international deployments of IoT, cellular connectivity is known to be the impeccable and trustworthy connection option. There are no requirements to craft new-fangled infrastructure nor adding of further network gateways to support deployments remotely. It implies that cell towers are simply getting connected that already existed. Another thing that can be looked upon is cellular roaming. As the cellular IoT ventures move from location to location there must be an agreement or an association between partner carriers and your cellular providers to allow seamless connectivity throughout the regions devoid of changing the SIMs. Now, the point to be noted is that as the cellular network utilizes SIM cards for authentication, it becomes very intricate to find the identity of the product. In the IoT ecosystem, if any sole device is under security risk then all the products related to it are at risk severely. In order to assure the security of the device is safe, the cellular keeps on separating every device from every other device.

Now, the reliability of the cellular device is another criterion. As cellular connections gained massive traction and popularity all over the world, the Cellular IoT protocols can grab the advantages or the benefits of the existing characteristics and benefits. In the licensed bands, the cellular works that state the reliability and performance of the communication. However, cellular also offers a huge volume of connections per tower, which are monitored and supervised separately thus offering success and guarantees on reliability and services. If you look back closely at history, a significant limitation for cellular adoption has been battery life and power usage. The cellular protocols of this generation would make it easier for cellular IoT modules to cut power costs when they are not being used and transmit a small volume of data with the slightest power usage. In this regard, both NB-IoT and LTE-M have been designed exclusively to provide top-notch operation from a power source driven by a battery. As the data throughput is not largely available, lesser intricate radio modems and easy signal modulation schemes are massively required, leading to lesser power requirements. On modern hardware, improvements in sleep/wake modes provide the benefits mentioned above.

New Role of Technology in Cellular IoT Module Market

Now, according to various telecommunication experts, the connectivity landscape in China is completely different from other parts of the planet. Now, if you look at the countries outside China, the piercing of LTE-Cat 1 is much higher, for instance, the perforation of narrowband (NB)-IoT. In China, only 12 percent of penetration is done by LTE-Cat 1, while the same offers 23 percent penetration outside China. According to an exclusive report of IoT Analytics, back in 2020, the Cellular/licensed low-power wide-area (LPWA) shipments (NB-IoT and long-term evolution-machine type communication LTE-M) offered only 10 percent of the market outside China. The country is mostly focused on improving NB-IoT and 90 percent of this shipment appeared from China itself.

Highlighting the importance of cellular IoT modules, Satyajit Sinha, Senior Analyst, IoT Analytics said in his research report, "The rise of LTE-Cat 1 started in North America a few years ago. That is when LTE-Cat 1 started to become the go-to alternative for 2G and 3G IoT applications as 2G networks were retired by network operators. The massive migration from 2G/3G to LTE-Cat 1 started in 2018. Telit, Thales, and Sierra Wireless, for example, have collectively shipped more than 40 million LTE-Cat 1 modules in the last three years in the outside-China region. As evidenced in the data, the decline in shipments of 2G/3G modules was directly proportional to the increase in shipments of LTE-Cat 1 modules outside of China."

In the past few years in China, for 2G IoT applications, NB-IoT has turned out to be the new substitute. Therefore, in China, NB-IoT has turned out to be the licensed low-power wide-area network (LPWA) technology of choice. Nonetheless, the technology LTE-M is not present in China and certain technical hindrances within NB-IoT have spearheaded the escalating demand for a new-fangled segment, which is low-cost LTE-Cat 1 bis modules that are centered on 3rd Generation Partnership Project’s (3GPP) Release 13. The technology is optimized for lesser power applications and a sole antenna. "This is in contrast to the LTE-Cat 1 standard adopted in North America, which is defined by 3GPP’s Release 8 and is supported by two receive (Rx) antennas. 3GPP’s Release 8 LTE-Cat 1 is based on Intel and Qualcomm chipsets, whereas 3GPP’s Release 13 LTE-Cat 1 bis is driven by UNISOC 8910DM. The Release 8 LTE-Cat 1 modules cost, on average, $10 more than the Release 13 LTE-Cat 1 modules," added Sinha in his research.

Cellular IoT Module Market

Growth of Global Cellular IoT Module

A new research report of Counterpoint stated that in the final quarter of 2020, the growth in revenue of international cellular IoT modules escalated to 58 percent YoY. China is claimed to be the fastest adopting this technology and managed to grab more than 40 percent of the profit. India is said to be the fastest-growing cellular IoT module market with a market share of 324 percent YoY, which is then followed by 4G Cat 1 105 percent. Router/CPE, PC, and industrial were the leading applications for 5G. Highlighting the importance, Senior Analyst of Counterpoint Soumen Mandal opined that MeiG, Quectel, and Telit managed to grab the top three stands in the worldwide cellular IoT module market. In Q4 2021, these firms offered around 40 percent of the revenue, whereas the revenues and the shipments of this technology reached 57 percent and 59 percent YoY.

MeiG is one of the leading Chinese firms in this domain that is looking for constant enhancement and development and has now finally reached the top three standings on the cellular IoT module cluster both in terms of revenue and shipment. The company is carrying out more development and research on AIoT and smart module-based higher-end applications such as router/CPE, intelligent cockpit, video recordings, industrial PDAs, drones, and AR/VR. Now, in 2021, the company entered into the business of lower-end applications. This product amalgamation of low-priced and flagship modules assisted the company to augment revenue by more than 100 percent in Q4 2021.

Quectel's recently launched ODM brand, Ikotek, which will throw tough competition in the US. Again in Q4, 2021, the revenue in the same segment escalated to 100 percent YoY. Experts are now speculating that this firm would make its entry into the Latin and North American markets. According to the said requirement of a venture, the products can be customized and designed accordingly. On the other hand, Telit made a strong comeback after relatively weaker performance in recent history. For quite a few years, Telit is constantly increasing its solutions and services, which is helping its growth, whereas, Telit NExT is offering seamless connectivity schemes throughout the 190 countries to grab the benefits of growing business models and wiping out key bottlenecks for several IoT vendors, mostly device based. In Q42021, the company largely focussed on Latin America to assist customers from migrating to 4G cat modules. The strategy helped the company to become the major supplier of modules in the country and it ultimately maintained its key position in the North American market.

Global Cellular IoT Module Vendor Shipment Ranking

According to a report by Counterpoint Research, the other important firms in this segment are Sierra Wireless, Rolling Wireless, Fibocom, Thales, and Sunsea and among all the companies, LG and Rolling Wireless mostly catering to the automotive segment. Thales is centered on industrial applications, smart meters, and healthcare mostly in Japan, North America, and Europe. Fibocom is said to be working exceptionally well in 4G Cat 1 bis technology, but the company failed to include itself in the top five standings in module vendors due to its inferior performance of the NB-IoT module. Sunsea on the other worked quite well in the worldwide IoT module market, but still, its shares went down. Sierra Wireless’s and Rolling Wireless’s profits soared to 87 percent and 105 percent respectively. After rolling out from Sierra’s automotive segment last year, Rolling Wireless swiftly included itself in the top ten module vendors list.

Senior Research Associate Neil Shah said, “Back in Q4 2020, the global module vendors did not perform well, but in the same quarter of 2021, the same companies performed exceptionally well. In terms of profit in China, Sunsea, Quectel, and MeiG turned out to be the top IoT module firms. But, other than China, Thales, Quectel, and Telit were the top three players in the market. Quectel is ruling the sector in Japan, Latin America, and India. But, these same regions have a very diminutive share of cellular IoT modules, and hence, they do not have much impact. Japan has a preference for LTE-M, which is against the business model of Quectel.

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Build a 300W Pure Sine Wave Inverter

Nowadays we can’t even imagine a world without power. Even an intermittent power failure is so inconvenient. As we depend on electricity in many important areas of our life, it is important to take persuasion against power failures and that’s where the inverter plays an important role. There are multiple types of inverters in the market, such as square wave inverters, modified sine wave inverters, and pure sine wave inverters. The cheapest options would be square wave and modified sine wave inverters. But the difference between modified and pure sine wave inverters is that these types of inverters are not suitable for inductive loads such as motors, fans, etc. that’s where pure sine wave inverters come into play. They output a pure sinewave at line frequency so that it won’t affect such inductive loads.

So, in this project, we are going to build a pure sine wave inverter with a rating of 300W or 800VA. Let’s look at the components needed for this project.

Components Required

  • EGS002 SPWM module
  • IRF3205 N Channel MOSFETs
  • 90N03 N Channel MOSFET
  • LM7505 Voltage regulator
  • FR207 Diodes
  • S8050 Transistor
  • 12V fan
  • 10 Ohms resistors
  • 1 KOhms resistor
  • 1 KOhms resistor
  • 10 KOhms NTC
  • 10 KOhms Preset
  • 0.1uF capacitors
  • 2.2uF 650V Capacitor
  • 10uF capacitors
  • 2200uF capacitor
  • 0-9V Transformer with a rating of 400W or higher
  • Heat Sink
  • Connectors
  • Wires
  • Copper Clad / Perfboard
  • Soldering Kit

300W Pure Sine Wave Inverter Circuit Diagram

The complete circuit diagram for the Pure Sine Wave inverter is given below.

300W Pure Sine Wave Inverter Circuit Diagram

Now let’s have a look at each section.

The power section consists of reverse polarity protection based on an N Channel MOSFET and an LM7805 voltage regulator along with some filter capacitors. The input from the battery is connected to the power input and then the positive is directly connected to a switch and the H-bridge. The negative is connected through an N Channel MOSFET for reverse polarity protection. LM7805 generates the necessary 5V for the EGS002 Module.

Pure Sine Wave Inverter Power Section

The temperature and fan control circuitry consists of a 10K NTC for temperature measurement and an NPN transistor to drive the fan. The temperature reading and the fan control are done by the EGS002 module itself.

Temperature and Fan Control Circuitry

Next, the H-Bridge and EGS002 control circuit. The H-Bridge is made up of four IRF3205 MOSFETs. The control lines from the EGS002 are connected to the MOSFETs through the gate resistors. The transformer is connected to the points TR1 and TR2.

H-Bridge and EGS002 Control Circuit

The feedback circuit consists of a bridge rectifier and a voltage divider. The variable resistor VR1 is used to adjust the output voltage by adjusting the feedback voltage. The AC voltage from the transformer is connected to the input of the bridge rectifier and the step-down voltage is connected to the VFB pin of the EGS002 module. The module will adjust the SPWM duty cycle with respect to this feedback voltage, to keep the output voltage stable.

Sinewave Inverter Feedback Circuit

The transformer is connected to the H-Bridge at TR1 and TR2 points. In the output, a 2.2uF 650V capacitor is connected to filter out any high-frequency component from the SPWM. This filtered output is then connected to load and a feedback line of the EGS002.

Sinewave Inverter Transformer Circuit

Building and Testing the Pure Sine Wave Inverter Circuit

You can either build this project in a perfboard or you can make a PCB with the files from the link at the bottom of the page. Both PDF files for the toner transfer method and the Gerber file for the manufacturing are included. Here is the PCB layout for the inverter.

EGS002 Driver Board

And here is the PCV view for the same.

EGS002 Driver Module

Once you made the circuit with all appropriate connections, connect the battery and turn on the switch. If the inverter turns off after a few seconds with the LED on the EGS002 blinking three times, it is because the output voltage is not calibrated. Connect the output to a TrueRMS multimeter and adjust the variable resistor till the output voltage is set correctly.

Pure Sine Wave Inverter

Once the voltage is set the inverter will work without any errors. The EGS002 Module has a Low Voltage cut-off, so if the input voltage is reduced below minimum voltage the inverter will shut down automatically. Similarly, the module is featured with overcurrent protection and over-temperature protection. Let’s have a look at the EGS002 Module and its features.

PCB And Main Components

Here is the PCB I have made, and the components used. You can see that the number of components is the bare minimum. The input is given through a high gauge wirer to reduce the voltage drop due to the resistance of the conductor. A tank capacitor of 2200uf is added to the input. The 5V for the EGS002 module is generated using the LM7805 voltage regulator and the filter capacitors. As already mentioned, the AC feedback circuit consists of a bridge diode made of four FR207 diodes, a voltage divider made of two 100KOhms resistors and a 10KOhms pre-set and a filter capacitor of value 10uF.

Pure Sine Wave Inverter Module

Here is the H-bridge circuit made of four N channel MOSFETs. You can use IRF3025 or any compatible ones for the H-Bridge circuit.

H-Bridge Circuit Setup

The below image shows the bottom side of the PCB. The bottom side only has one component. And that is an N-Channel MOSFET for the reverse polarity protection. The power traces are reinforced with solder for better current handling. All other traces are covered with solder to avoid the oxidisation on the home made PCB tracks.

EGS002 Module

EGS002 Module

EGS002 is a driver board, designed for single-phase sinusoid inverters. It uses ASIC EG8010 as the control chip and IR2110S as the MOSFET driver chip. The driver board integrates functions of voltage, current and temperature protection, LED warning indication, and fan control. We can use jumpers to configure the following settings, Output frequency (50/60Hz), soft start mode, and dead time.

Here is the pin description table for the EGS002 module-

EGS002 Module Pin Description

Jumper Configurations

As already mentioned, the EGS002 can be configured with the onboard jumpers. Let’s take a look at those. The following table shows the function of each of these jumpers.

EGS002 Module Jumper Configuration

LED Indications and Error Codes:

The EGS002 module can give error codes with the onboard LED. Here are the error codes and their meanings.

Normal: Lighting always on

Overcurrent: Blink twice, off for 2 seconds, and keep cycling

Overvoltage: Blink 3 times, off for 2 seconds, and keep cycling

Undervoltage: Blink 4 times, off for 2 seconds, and keep cycling

Overtemperature: Blink 5 times, off for 2 seconds, and keep cycling

Working of the 300W Pure Sinewave Inverter

The below gif shows the working of the pure sine wave inverter. The GIF showcases the soft start of the inverter.

Here is the waveform view of the inverter output.

Pure Sinewave Inverter Output Waveform

You can increase the inverter power by adding more MOSFETs and changing the transformer. All the files necessary to build this project can be found in the following GitHub repo.

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There is a 90% Decline in Solar Cost Trend in India in the Last Ten Years

Of late, Mordor Intelligence, a market research firm stated that the market for solar energy in India is speculated to reach a CAGR of 8 percent from 2020 until the end of 2027. In fact, experts also highlighted that the COVID-19 pandemic failed to impact the market in India because a sufficient volume of growth was already viewed in the solar PV installed capacity in 2020 compared to 2019.

Teardown of 3S, 6A Lithium Ion Battery Management and Protection Module (BMS) with Schematics, Parts List and Working

In this article, we will be learning about the features and working of a 3S 6A lithium Battery Management System or BMS along with checking out the components and the circuitry of this module. Furthermore, we have done complete reverse engineering of the module by removing all the components from the PCB and measuring all the PCB traces with the multimeter. For testing the BMS and the circuit, we have built a battery pack and we will charge and discharge the battery pack with it. 

Protection Features Offered by JW3313S based 3S 6A BMS Module

A BMS is an essential component for any battery pack not only because it protects the battery from overcharge and over-discharge conditions but it also extends the service life of a battery by keeping the battery pack safe from any potential hazard. For this, we are using a 3S, 6A battery pack which houses a JW3313S Battery Protection IC. The protection features available in the Battery Management System are listed below.

  • Overcharge detection
  • Over Discharge detection
  • short circuit detection voltage

Overcharge Condition:

When a lithium battery is charged beyond a safe charging voltage, the cell heats up extremely and its health is affected and its life cycle and current carrying capacity get reduced. To protect the cell from these types of conditions, a good battery management system must have an overvoltage built-in, and for the JW3313S IC, this is no exception. In our testing charging of the battery pack cut off almost at 12.75V which represents 4.25V for each cell.

Over Discharge Condition:

The same can be said true for the over-discharge protection. When the battery voltage goes below a certain threshold, the lithium cells get affected and the life cycle of the cells gets reduced. To protect this from happening, every BMS should have over-discharge protection and this IC is not an exception. In our testing, the cell voltage gets as low as 2.7V for each cell, and then the protection features kicked in and cut the output.

Short Circuit Condition:

Overcurrent protection in a BMS is necessary to safeguard the battery from high current load or short circuit conditions. When a short circuit condition occurs the current draw is way higher than the maximum rated current of the battery pack. This condition can affect the cell’s health or even cause damage to the cell leading to fires. This is also why there is an overcurrent and short circuit protection built into the chip.

Note: Please note that along with all the protection features, the JW3313S features hysteresis. When the overcharge protection kicks in, the battery gets disconnected and stops charging the battery. This causes the battery voltage to go slightly lower than the cutoff voltage. Now the battery will start charging again and the process will continue infinitely. Adding some hysteresis will prevent this.

Components used in 3S 6A BMS Module

Before we take a look at the schematic, here is the list of components that are required to build the 3S 6A BMS module. The main controlling IC of the board is the JW3313S Protection IC which is an 8-pin IC designed and developed by a Chinese manufacturer joulwatt. On the board, we have two FL3095K MOSFETs and a 0.005R Resistor. Other than that, we have a few resistors and capacitors as you can see in the image below. The list of components needed to build this module is shown below.

3S,6A Lithium Ion BMS Module Components

  • JW3313S low-power battery protection IC -2
  • FL3095K Mosfets - 2
  • 1N4148 - 1
  • 0.1uF Capacitors  - 5
  • 0.15uF Capacitors  - 1
  • 1K Resistor - 4
  • 10K Resistor - 3
  • 2M Resistor - 1
  • 1uF Capacitor - 1

Circuit Diagram of the 3S 6A BMS Module

The schematic of this BMS is designed using Eagle PCB Design Software. As you can see from the image below, it's not that hard to understand the complete circuit diagram of the 3S 6A BMS circuit.

3S 6A Lithium Ion Battery Management and Protection Module (BMS) Schematic

As you can see, we have the JW3313S chip that controls all the operations of the device. If you carefully observe the module, you will see separate connection terminals for P+ and B+. On the board, P+ stands for positive power input and output and B+ stands for Battery Pack Positive Input. In the PCB, these two terminals are connected to each other so we have named the connection P+B+. Next, we have the CO and the DO pins of the IC, which are pin 8 and 7 of the IC., which controls two MOSFETs. The CO gets high when an overcharger condition occurs. The DO gets high when an over discharge condition occurs. Next is pin 6 of the IC which is marked VM in the schematic and with this pin, the IC sets the over current protection of the device. This IC was designed so that it could use the internal resistance of the MOSFETs to detect the current but in this case, as you can see the manufacturers used a separate current shunt because they are using a Mosfet with high internal resistance. Pin 1 of the device is the power pin that supplies power to the IC and pins 2,3, and 4 are individual sense pins of the BMS module, and pin 5 is the ground pin of the module. Other than that, there are a couple of resistors and capacitors which are used for filtration and current limiting.

BMS Connection with Battery Pack - Fritzing Schematic

The BMS module has 4 terminals that will get connected to the four different points of the battery pack. This way the BMS module can separately monitor three individual cells and protect them from overcharging or over discharging. The schematic diagram of the BMS is shown below.

BMS Module with Battery Pack Connection

The BMS acts like three individual protection modules for three individual cells but it's a single IC that integrates all the features together to make the BMS that is able to deliver recurrent up to 6Amps.

Testing the 3S6A BMS Module for Overvoltage, Undervoltage & Short Circuit

Let's test the BMS and see if the BMS module is working as advertised in the datasheet. We are using a 3S 6A BMS module that uses a JW3313S Battery Protection IC and this IC is designed and developed by Joultech which is a Chinese manufacturer. You can check out Joulwatt website for more information on the IC.

Overvoltage Protection Test:

We started our test by arranging the battery packs in 3S configurations and started the charging process with a constant current of 600mA.

According to the datasheet, the charging process should have stopped when the pack voltage reached 13.125V that is 4.375V/Cell but to our surprise the battery got overcharged and started heating up then we stopped the charging. We don't know if this was the problem with our particular BMS board or not. We repeated our test with a new module but the result was exactly the same. You can see the testing process in the gif above.

Undervoltage Protection Test:

when the battery pack was fully charged (In our case it was overcharged), we started our undervoltage protection test.

As you can see in the above image for the under-voltage test we have removed one battery from the battery holder and replaced it with our Regulated Power Supply(RPS). Now we are decreasing the voltage and as you can see from the above gif, the BMS cuts out the load below 2.8V which means there are two protection systems that are working simultaneously. First, the BMS is monitoring the pack voltage and second, the BMS is monitoring individual cell voltage. If any one cell gets damaged the BMS will cut power.

Short Circuit Protection Test:

When the over voltage and under voltage protection test was done we need to check if the BMS was able to protect the battery pack from short circuit and overload conditions.

For that, we have connected a multimeter with the output of the BMS module, and as you can see when we short circuit the output of the module with the multimeter probe, the voltage goes to zero and you cannot see anything that is catching fire. This indicates that the short circuit safety mechanism is functioning properly.

Conclusion

The 3S 6A BMS module is a cost-efficient and highly effective module to protect LI-PO or LI-ION cells from damage. The 6A power capacity makes this device very versatile because not only this device can be used for three series packs, but it can also be used to make three series and two parallel battery packs that can be useful for many projects.

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Semiconductor Industry is Expected to Reach the Trillion-dollar Mark by the End of this Decade

For the past few years, India’s semiconductor industry has been transforming at a massive scale with the help of various schemes and initiatives unleashed by the government. But, when we speak of infrastructure, the nation has only one foundry and OSAT. There are infrastructure challenges (continuous power, water) in maintaining such manufacturing units. The PLI scheme can help build more foundries and OSATs in India to support end-to-end solutions development.