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Documents Tinkering vs Engineering: Can You Build a Laptop from Scratch? -- Episode-640
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  • Author Author: tariq.ahmad
  • Date Created: 22 Jan 2024 5:16 PM Date Created
  • Last Updated Last Updated: 31 Jan 2024 7:56 PM
  • Views 2114 views
  • Likes 7 likes
  • Comments 17 comments

Tinkering vs Engineering: Can You Build a Laptop from Scratch? -- Episode-640

Clem's latest project takes a deep dive into laptop design, merging various components, such as a BLE keyboard, compute module, mouse, and a universal diagnostic screen into a custom-built laptop. However, the path to success wasn't without its challenges. 

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Downloads | Bonus Video | Bill of Material | Discussion

The project required a unique power system. For that, Clem opted for multiple 2000mAh LiPo cells, instead of a single large one. To achieve the necessary voltages (3.3V@1A, 5V@2.5A, and 12V@0.5A), Clem faced the complexity of generating multiple voltages from a single-cell source. This involved designing a switching converter, a task he had never done before.. 

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Troubles arose when attempting to parallelize the step-up converters. Clem's initial approach faced issues with voltage regulation and load-induced voltage drops. The struggle to balance multiple step-up converters led to unexpected challenges, impacting the overall system's stability. Despite successful testing of the charging circuit, integrating the system with an actual computer brought about further complications. 

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Clem wanted to use a Sudosom module; however, development wasn’t quite complete. This prompted a switch to a Raspberry Pi Compute Module 4. However, the step-up converters failed to deliver sufficient current, causing the voltage to drop and the computer to brown out. Even switching to a CM4 Lite did not resolve the problem. 

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In a last-ditch effort, Clem used resistors in an effort to control the voltage, but realized that the project demanded more expertise in power supply construction than he currently possessed. The undertaking highlighted the distinction between tinkering and engineering, emphasizing the need for precise measurements and in-depth knowledge in the latter. 

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Clem's rapid one-month endeavor revealed the importance of a well-planned and fresh design for such complex undertakings. 

Downloads and Links:

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Bonus Video:

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Bill of Materials:

Product Name Manufacturer Quantity Buy Kit
MICROCHIP Power Load Distribution Switch IC, Active Low, 1 Output, 5.5 V in, 700 mA, 0.14 ohm, SOIC-8 MICROCHIP 5 Buy Now
MOLEX HDMI Connector, 19 Contacts, Receptacle, PCB Mount, Surface Mount Right Angle MOLEX 2 Buy Now
MIKROELEKTRONIKA Rechargeable Battery, 3.7 V, Lithium Polymer, 2 Ah, JST MIKROELEKTRONIKA 3 Buy Now
BOURNS Power Inductor (SMD), 10 µH, 2.1 A, Shielded, 2.5 A, SRR0745A BOURNS 6 Buy Now
TOREX DC-DC Switching Synchronous Step-Up Regulator, 0.65-6V in, 5V out, 0.5A out, 3MHz, SOT-25, 5Pin TOREX 6 Buy Now
TEXAS INSTRUMENTS DC-DC Switching Boost Step Up Regulator, Adjustable, 2.7V-14Vin, 600 kHz, 2Aout, SOT-23-5 TEXAS INSTRUMENTS 2 Buy Now
MICROCHIP Battery Charger for 1 Cell of Li-Ion, Li-Pol battery, 6V input, 4.2V / 500mA charge, SOT-23-5 MICROCHIP 3 Buy Now
TOUCHSCREEN 10.1 MULTICOMP PRO 1 Buy Now
MOLEX FFC / FPC Board Connector MOLEX 6 Buy Now
 

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Top Comments

  • Jan Cumps
    Jan Cumps over 1 year ago in reply to baldengineer +1
    Quote from an SMPS book I bought today:
  • gendragonfly
    gendragonfly over 1 year ago in reply to mayermakes +1
    Thank you Clem, for all the great videos & projects! For someone who is learning as they go, you really tend to pick the most challenging projects
  • mayermakes
    mayermakes over 1 year ago in reply to gendragonfly

    I indeed try to challenge myself with every video, thanks for noticing.

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  • gendragonfly
    gendragonfly over 1 year ago in reply to mayermakes

    Thank you Clem, for all the great videos & projects! For someone who is learning as they go, you really tend to pick the most challenging projects Blush

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  • mayermakes
    mayermakes over 1 year ago in reply to gendragonfly

    it is still a project that I would like to complete one day, and yes the power system needs a tota lreconsideration of how it should be configured, I see the 2s benefit.

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  • gendragonfly
    gendragonfly over 1 year ago

    Please don't give up on using a CM4 or equivalent for this project. The Raspberry Pi foundation is going to release a CM5 that will very likely be pin compatible. You could create a real fully functional ARM laptop design! I know it's challenging, but it's not impossible to build a stable power supply and BMS that generates all the required rails: 3.3v, 5v and 12v for all the different components. Going with an ESP32 as a base for your laptop design is just trading one problem for another, as it lacks the compute power to do much. Especially if it's already driving a large screen.

    It would be a good idea however to use an ESP32 to do the power management of all the rails Wink

    The biggest choice/obstacle your facing is what battery configuration to use: 1S, 2S, 3S or 4S. I'd recommend going with a 2S battery system. You can buck down for 3.3v and 5v which will draw the most current and boost up for 12v which shouldn't draw much. This should give a high overall efficiency. The disadvantages are: you'll need to use a dedicated 2s charging chip, matching cells for the 2S battery and if you want to charge from 5v you'll need a boost converter to get the voltage high enough. Alternatively you can charge the 2S from 9v with USB-C PD.

    I recommend reaching out to Texas Instruments for advice on what components to use, and for help in creating a basic but functional power management and BMS design Slight smile

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  • baldengineer
    baldengineer over 1 year ago in reply to mayermakes

    Copper Pour = Zone.

    Click on a copper layer and then use the Zone tool. When you start to draw it, you can select which net it connects to.

    You could also leave it as "no net" and draw it until you're happy.

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  • beacon_dave
    beacon_dave over 1 year ago in reply to mayermakes

    I guess it depends if you can leverage fast or partial updates ?

    https://www.youtube.com/watch?v=pTCyJAUGWYg

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  • mayermakes
    mayermakes over 1 year ago in reply to DAB

    I have thought about epaper but dismissed it due to the super slow refresh which would make a terminal probably unusable on it. an alternative would be the sharp memory displays but they are to expensive and to small for what I want to do.

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  • mayermakes
    mayermakes over 1 year ago in reply to baldengineer

    thanks for the info.
    how do you conncet the planes to a net? is it just a pour plane but with the specific net selcted for the pour? or is there a different tool for that job?

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  • mayermakes
    mayermakes over 1 year ago in reply to koudelad

    the point that I WOULD LIKE to get towards is kinda proving that we do not need much to do computing on the go..so maybe aminimalist laptop is just what the world has been waiting for _)

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  • DAB
    DAB over 1 year ago

    Very entertaining Clem.

    Yes, laptop design is hard, that is why the manufacturers have large teams of engineers making them.

    Have you considered using Epaper for the monitor?

    That could cut your power needs and still give you a reliable output device.

    If you keep it simple with a not too demanding application, you could come up with a useful device.

    You just have to resign yourself to something that is going to be SLOW by modern standards.

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