2017-05-07

Scaling RC servo angles / ESC speed on the fly

Initial idea

When we started to play with our recently acquired RC cars, Benoit's kids wanted to try them. Unfortunately the cars are too powerful and too fast for kids, they can really be dangerous for them, and they can break them, so they were a bit frustrated by our refusals.

This led me to realize that such devices are missing a "training mode". I thought that maybe it would be possible to implement a speed limiter using an ATTINY microcontroller. After a bit of thinking, in fact it's really easy, considering that :
  • pulses are supposed to be 500 to 2500 microseconds long
  • pulses are 20 ms apart
  • accuracy is not a big deal for forward/backward speed
  • the signals are <= 5V amplitude
  • the 0 and 5V are present on the pulse cable
I wrote a small program consisting in a loop to measure the pulse width and to reimplement such a pulse afterwards. If the pulses were more frequent it would be a problem as they could overlap, but here after a pulse ends, we have at least 17.5 milliseconds remaining, of which at most 2.5 milliseconds will be used for the next pulse. So in the end, we have 15 ms left to do whatever we want. The program will have to loop through the following iterations :
  1. wait for a pulse
  2. measure the pulse width
  3. perform whatever computation needed, for less than 15 ms
  4. emit a new pulse
I started with some example servo code made for Arduino and placed it into an ATTINY85. I noticed there was some noise in the measure, as placing a servo on the output resulted in an unstable position. I understood that interrupt management and possibly other stuff outside the arduino's loop() were making the timing unstable. Last but not least, the code was huge and couldn't possibly fit under 1 kB for the smallest devices. But I could easily replicate the input pulse to the output. So it was time to get rid of the arduino environment and reimplement it in plain C.

Timing

The first important point is to be able to measure a pulse width and to create a pulse. We don't have a very high frequency so we want to waste the least possible cycles counting. I tried several constructs for a loop and ended up with 5 cycles per loop to measure a pulse, giving a resolution of +/- 0.625 microseconds at 8 MHz  (ATTINY85) and +/- 0.52 microsecond at 9.6 MHz (ATTINY13A). The code looks like this, with width giving the pulse width in CPU cycles :

uint16_t width = 0;
while (!(PINB & (1 << PB2))); // wait for beginning of pulse on PB2
while (PINB & (1 << PB2)) // wait for end of pulse
    width += 5;

To create a pulse, you need to wait for some time. Usually this is done using a volatile integer but here I noticed that it made gcc produce very poor quality code resulting in 14 cycles being spent per loop. Instead I used a barrier made of an empty asm statement that gcc couldn't optimize away. This resulted in only 4 cycles being spent per loop, which is much better :

PORTB |= 1 << PB3; // start pulse
while (--width) asm volatile("");     // wait width*4 cycles
PORTB &= ~(1 << PB3);       // end pulse

The width can be converted to microseconds by multiplying/dividing it by the CPU's frequency. Care must be taken to avoid integer overflows while sticking to 16 bits. For integral MHz frequencies it's trivial. For non-integral MHz frequencies, the conversion can be done on 32 bit while keeping 16 bit values in and out.

With only this done, we don't need the C++ nor arduino environment anymore and we can have a very compact C code.

Scaling pulses

I did a first scaling attempt by dividing the distance to the center by two. Given that the center is 1500 microseconds, the pseudo-code looks like this :

int16t width;
width = read_pulse() - 1500;     <0 = rear; >0 = front
width /= 2;
send_pulse(width + 1500);

It worked pretty well but I realized that I couldn't brake anymore by going backwards. In fact my car brakes before trying to go backward when it was going forward, and the braking force depends on how far I pull the trigger. Not being able to brake is not acceptable, so I had to implement the whole ESC's state machine.

State machine

I ran some tests and noticed the following :

  • at rest (initialization), the car can go backward
  • at rest, the car can go forward
  • when going forward and suddenly backward, it brakes
  • the car continues to brake until the trigger is released. In order to go backward, I have to release it and pull it again. This means that after braking and releasing the trigger, it goes to rest again.
  • if I only release the trigger when it's going forward, braking is possible for the first 2.5 seconds. Waiting longer will make it go backward. This means that after 2.5 seconds not accelerating it goes back to the rest position
  • it I pull the trigger again to go forward while braking it goes forward again
  • if I pull the trigger forward when it goes backward, it goes forward immediately

I ended up implementing the following state machine :
This state machine allows a different ratio to be applied to different states. The forward and backward speeds are cut in half, but the brake force is kept at full scale.

I found that the car was lacking a bit of "punchiness" when starting up, so I modified the FWD state to allow it to reach full speed for the first 300 ms. This allows it to deploy the full force to the wheels to make it drift and perform a U-turn for example, or to accelerate very quickly from rest, without permitting it to reach a high speed. In fact it even starts to become fun :-)

I also realized that knowing the current state makes it convenient to light some LEDs to indicate what is being done. We can have a set of brake lights made of red LEDs, and a backward light made of a white LED.

Centering

I found that the internal RC oscillator is not very precise so I implemented an automatic frequency adjustment at boot so that the car would not automatically start to advance or go backward. The idea is that when booting, the only signal we're supposed to see is the center position, so we average it over a few measures and compute the offset so that this one equals 1500 microseconds. This state is implemented at boot before going to the INI state.

Also the LED on PB1 (pin 6) which is present on some ATTINY85 boards is used as a debugging indicator. It is lit when we're not at the rest position. This eases centering on the transmitter because the led must be turned off by default.

Implementing the basic ON/OFF switch

Just similar to what was implemented from a disassembled servo a few months ago, it's possible to implement an RC switch from this controller by enabling/disabling a GPIO depending on the pulse width. So I added such a very simple test to connect to an output pin. After I realized that by implementing this on a $0.30 ATTINY13A, coupled with a $0.07 cable it could be 3 times cheaper than the previous solution, I ended up writing a simplified version of the program doing just that, called onoff.c. But the same function was implemented on its own pin on the main program so that pre-programmed chips can be use for both purposes without having to be reprogrammed.

Multiplexing LEDs

ATTINY13/85 only have 5 usable GPIO (well 6 if you reprogram the RST pin but I don't want to, it's too painful for development). With one GPIO for the input pulse, one for the output pulse, one for the centering LED, one for the ON/OFF LED, it leaves only one pin for the brake/rear LEDs. However there's a solution to solve this. If we put 2 red LEDs and 1 white LED in series, their total voltage is around 6.6V so they will not turn on on 5V. However it's possible to light either the 2 red ones or the white one by connecting their middle pin to the power supply or ground. The only thing is that to turn them off we need to disconnect the pin, which is equivalent to configuring it for input. It will only keep the internal pull-up which will be too weak to turn the LEDs on. We could use a single resistor connected to the GPIO, but it's safer to use one per set of LED so that in the event an over voltage would appear beyond their turn-on voltage, the drained current remains limited.
With all these features implemented, the code is only 642 bytes long for a 8 MHz ATTINY85, and 804 bytes long for a 9.6 MHz ATTINY13A.

Implementation

The device was implemented on an SOIC8 ATTINY13A soldered on an SOIC8-do-DIP8 adapter serving as a PCB. The GPIO pins were chosen on opposite sides of the device so that wires could easily be soldered without having to bend them too much :

A simple male-to-female connector was cut to provide both the connector to the RX and the connector to the ESC. An extra 5-pin connector was added to access the LED signals. There is no additional component, only the MCU and cables. All this was enclosed in heat shrink tube and could be placed inside the receiver receptacle in the car.

 

Improvements

Some improvements could be made. First, I forgot to solder a wire to the RST pin in case I'd want to reprogram the device. Second, it would make sense to support detecting a short-circuit on one of the GPIO at boot in order to disable the throttling. It could result in sort of an adult/kid switch. For example, the debug LED GPIO could be used for this since it's only used to debug the throttling.

It would also be nice to try to make the device learn the highest possible speed from the remote, but probably that it is not very easy to implement in that small code. There are only 220 bytes left on the ATTINY13A, so that's something to keep in mind.

Code

The source code is available here. The executables are so small that they can be dumped here. For ATTINY13A, the fuses to use are :
  • low: 0x7A
  • high: 0xFF
For ATTINY85, the fuses to use are :
  • low: 0xC1
  • high: 0xDD
  • extended: 0xFE
Hex code ready to be flashed is provided below. Just copy-paste it to a file and flash it as usual with avrdude after having set the fuses above.

Code for ATTINY13:
:1000000009C021C020C01FC01EC01DC01CC01BC015
:100010001AC019C011241FBECFE9CDBF10E0A0E661
:10002000B0E0E2E2F3E002C005900D92A236B10723
:10003000D9F710E0A2E6B0E001C01D92A736B107E3
:10004000E1F702D06CC1DCCFEF92FF920F931F93C8
:10005000CF93DF938BE087BBC0916500D0916600A2
:1000600000916200E0906400F090630010916000E5
:1000700088B3110F8D7F182B18BBB299FECFB29B9E
:10008000FECF60E070E002C06B5F7F4FB299FCCFA3
:1000900080E090E02AE030E040E050E0DED020E672
:1000A00030E040E050E005D1B901C19825E0683763
:1000B000720714F4C09801C0C09AFB01EC5DF540D2
:1000C0000023A9F0EC0FFD1F023009F451C00330EA
:1000D00030F4002361F0013009F057C023C0043030
:1000E000C9F1043048F1053009F04FC041C0CF01DB
:1000F0008C509E4F895E934010F0FA9446C089E080
:100100008F1538F4F7FF03C0CE1BDF0B02C0CE0FF4
:10011000DF1F23E12F15C8F5CE016AE070E0B6D0ED
:10012000EB0131C0E832F105C4F58FEFE93DF80786
:1001300064F502E0FF243AC02FEFE93DF2074CF1ED
:10014000CF0187968F34910500F583E08F15E8F491
:1001500004E024C0E832F10504F52FEFE93DF20791
:10016000C4F08CE78F1588F401E0FF2411E021C072
:10017000E832F10594F4CF0187968F34910528F485
:1001800023E02F1510F401E009C010E0053061F400
:1001900008C005E0FF2410E004C003E0FF2410E0E5
:1001A00008C0BC9AC49A27C0023019F4BC9AC498FB
:1001B00025C0BC98033018F4002389F12BC003300C
:1001C00019F0053039F517C081E0EC32F80734F04A
:1001D000E3942EE02E1514F43EE1E32E81E0E039A5
:1001E000F8071CF02EE02E15DCF4CF0162E070E081
:1001F0004DD0FB0114C081E38F1590F4CF01880F1F
:10020000991F63E070E042D0FB01EA94E7FE07C06B
:10021000EE2405C0EA94E7FE03C0EE2401C011E01D
:10022000E452FA4FBF0180E090E020E630E040E089
:1002300050E013D028E230E040E050E03AD02F5FA9
:100240003F4FC39A00C021503040E9F7C3982FEFC9
:10025000F21609F40DCFF3940BCFFF27EE27BB273F
:10026000AA2760FF04C0A20FB31FE41FF51F220FCF
:10027000331F441F551F969587957795679589F786
:100280000097760771F7CF01BD01089597FB092EFE
:1002900007260AD077FD04D02ED006D000201AF40D
:1002A000709561957F4F0895F6F7909581959F4FD2
:1002B0000895A1E21A2EAA1BBB1BFD010DC0AA1FA7
:1002C000BB1FEE1FFF1FA217B307E407F50720F0BF
:1002D000A21BB30BE40BF50B661F771F881F991F3A
:1002E0001A9469F760957095809590959B01AC0183
:1002F000BD01CF010895AA1BBB1B51E107C0AA1F76
:10030000BB1FA617B70710F0A61BB70B881F991FB6
:100310005A95A9F780959095BC01CD010895F89460
:02032000FFCF0D
:020322000100D8
:00000001FF

Code for ATTINY85:
:100000000EC028C027C026C025C024C023C022C0DF
:1000100021C020C01FC01EC01DC01CC01BC0112499
:100020001FBECFE5D2E0DEBFCDBF10E0A0E6B0E05E
:10003000E0E8F2E002C005900D92A236B107D9F7D0
:1000400010E0A2E6B0E001C01D92A736B107E1F7CB
:1000500002D014C1D5CF0F931F93CF93DF938BE0C2
:1000600087BBC0916500D09166004091620000910D
:100070006400109163002091600088B3220F8D7F8F
:10008000282B28BBB299FECFB29BFECF80E090E038
:1000900001C00596B299FDCF63E0969587956A9564
:1000A000E1F7C19825E08837920714F4C09801C0A1
:1000B000C09AFC01EC5DF5404423A9F0EC0FFD1F54
:1000C000423009F44DC0433030F4442361F04130F4
:1000D00009F052C021C04430B1F1443038F145300C
:1000E00009F04AC03DC0CF018C509E4F895E9340BD
:1000F00010F0115041C01A3038F0F7FF03C0CE1B8A
:10010000DF0B02C0CE0FDF1F1431B0F1CE016AE069
:1001100070E08DD0EB012EC0E832F105ACF58FEF29
:10012000E93DF8074CF542E010E037C02FEFE93D1C
:10013000F20734F1CF0187968F349105E8F414303B
:10014000D8F044E022C0E832F105F4F48FEFE93D45
:10015000F807B4F01D3780F041E010E021E020C046
:10016000E832F1058CF4CF0187968F34910520F4A5
:10017000143010F041E009C020E0453061F408C0BF
:1001800045E010E020E004C043E010E020E008C0BB
:10019000BC9AC49A24C0423019F4BC9AC49821C0B5
:1001A000BC98433018F4442369F127C0433019F058
:1001B000453019F514C081E0EC32F80724F00F5FE8
:1001C0000F300CF00EE181E0E039F80714F00F3049
:1001D000D4F0CF0162E070E02AD0FB0113C01233EB
:1001E00090F0CF01880F991F63E070E020D0FB01F1
:1001F000015007FF07C000E005C0015007FF03C022
:1002000000E001C021E0E452FA4FCF01A0E0B0E0ED
:10021000880F991FAA1FBB1F0196C39A00C00197A0
:10022000F1F7C3981F3F09F428CF1F5F26CF97FB34
:10023000092E07260AD077FD04D00CD006D0002066
:100240001AF4709561957F4F0895F6F79095819512
:100250009F4F0895AA1BBB1B51E107C0AA1FBB1FDC
:10026000A617B70710F0A61BB70B881F991F5A9542
:10027000A9F780959095BC01CD010895F894FFCF22
:0202800001007B
:00000001FF



2017-02-26

Injecting power into mains

This title sounds scary. In fact it really is :-)

I have long been experimenting with various solar panels initially to try to make some devices more autonomous (eg: self-recharging hexapod robot, long-lasting outdoor camera, etc) and noticed that solar panels have become very cheap and that low quality batteries can also be reasonably cheap. I started to think "what if I used a lot of batteries to power some of my home appliances like servers, water heater, etc?".

Let's do some math. Looking at my electricity invoice, I'm using on average 800W between february and august, and 1400W between august and february. I don't have more details, and both periods include some cold periods where the heating is used. I suppose that taking heating out of the equation I probably need
about 400W on average (light, PCs, water heating).

In order to deliver 400W 24 hours a day with 8 hours of charging, I'd need to charge at 1200W and to store 9.6 kWh of energy. A correct LiPo cell stores 2.6Ah at 3.7V, or 9.6Wh. Thus I'd need 1000 such batteries just to store the required energy. At about $2-3 a battery it's not interesting.

But I thought, why would I need batteries ? Two thirds of my consumption are during the day and one third at night. And these are differently priced so that the day is more expensive (15cts/kWh during day, 10cts at night). So by using 400W of direct solar energy I could expect to be able to cut the day consumption in half, resulting in a 37.5% overall saving on the daily bill.

This approach sounds interesting because it uses 3 times less solar panels and no batteries. But how to power devices on irregular energy sources ?

My idea was that if it were possible to inject the solar energy directly into the mains synchronized with the alternating current, I could in fact offload the energy provider from the energy I harvest from the sun, so that I don't have to care when a cloud passes. But it's possibly very hard to keep in sync with mains...

Then I started to think about some ZVS induction heaters I've made in the past, these ones are resonant self-oscillating circuits. Wouldn't it be possible to do this with mains ? That is, monitor the mains voltage to decide what polarity to send into a transformer ? After all in order to monitor the mains, I just need another independant transformer that's not too much affected by the power I feed into the secondary coil. Thus I ran an experiment with two miniature transformers (12V/1.2VA each) installed behind a 12/230V DC/AC converter (I prefer to use this than real mains during experiments like this). Impressively this worked pretty well out of the box, I could cancel the power consumption of the primary transformer.

That immediately made me think about these old transformers I salvaged from a dead UPS, I remembered they had some additional windings. I took one of them, a 400VA model, measured the voltage across its terminals and found that it matched the markings : 8V symmetric on a 50A circuit (designed to take 12V peaks on its input to produce the 325V peaks), and 14.5V on a low power circuit. This last one would be used to monitor the mains polarity. As long as I don't feed too strong a current, mains will always win and impose its polarity, and this monitoring winding would force the mosfets to reverse the current.

So I came up with the following diagram :

The primary (left part) of the transformer is connected to a power meter and to a 8W/230V lamp. The power meter is connected to the 12/230 converter for now. The assembled circuit looks like this (the MOSFETS are IRFB4110, they are directly mounted on the transformer terminals) :



The wave across the 14V monitor winding looks like this :



It's obvious that my 12/230 converter doesn't provide a sine wave, it's almost a square one! That's optimal to drive the transistors but it doesn't reflect reality. Since I had no smoke and I could manage to cancel the power usage by adjusting the DC voltage, I restarted the experiment plugged to real mains this time after double-checking every connection. The wave across the 14V winding looks much better :



The power meter showed that the transformer alone draws 4W of power and the lamp draws another 8W, leading to 12W total :



I progressively adjusted the input DC voltage until I saw exactly 0W on the power meter. The DC input showed 8.8V and the amp meter showed 2.26A, that's 19.9W total consumed power to produce 12W of power needed to power the lamp and the transformer losses resulting in 0W on the power meter  (I'm not cheating here, except by carefully adjusting the voltage to reach exactly 0, and the white reflect on the LCD comes from the lamp, entirely powered by my circuit) :



Note that some of these 19.9W are in fact injected into the mains, this explains why almost nothing heats here and why a higher current was needed to cancel consumption when connected to mains than to the DC/AC converter. Pushing the DC voltage higher results in the power meter showing a positive power again, indicating that I'm sending even more power into the house. At this point I stopped the experiment.

So yes, it is technically possible to re-inject some power into mains with a simple enough circuit. At this point one difficulty is to find the proper input DC voltage to cancel the mains without sending too much, because I don't want to dissipate too much power nor to send power back into the grid (with even the risk that it would make the disc spin again and charge me for the power I offer). Probably that producing only the minimum of any day's power usage would be a very simple way to solve this. Otherwise maybe a current meter on the mains connection to the grid could make it possible to have some feedback and regulate the injected power.

It's worth noting that during this experiment the delivered current was not very clean. On the image below it's visible that there were short peaks at each zero-crossing, caused by the short period during which none of the MOSFET is conducting, I even had to change the scope's time base because it couldn't stabilize on it :



But these artefacts should be very easy to cancel using a small capacitor across the transformer's terminals connected to the MOSFETs and it will also increase the efficiency and limit the MOSFET heating. Note that during this experiment, the MOSFETs were barely warm. Another improvement could consist in using a voltage comparator to always saturate the MOSFETs during the switch but given that the voltage is low at this moment it's not even certain that this is needed. I should also possibly use a choke in series with the central point of the transformer to absorb current impulses during the polarity inversion. But all this is very cheap and just a matter of experimenting a little bit.

Good solar panels having about 20% efficiency are found around $1/W nowadays, so for $400 it's possible to build a 400W array. Feeding 400W of power into the mains 8 hours a day every day at peak energy cost would save 175 EUR/yr, so the panels and circuits would be amoritzed in 2.5 years approximately.

Note that I thought about charging batteries at night and re-injecting the power during the day, but the cost difference and the inevitable losses would not make this worth, and it would take decades to amortize the batteries cost.

Has anyone successfully tried such a design ? Suggestions welcome.

Because the world runs on 5V

The success of USB as a power source is amazing.

15 years ago my friend Benoit Dolez told me "why not run a whole house on low voltage and avoid the risks of electric shock for everyone ?". I remember I responded "no, that wouldn't be practical, you'd need a very high amperage for this, it would require very thick cables and would cause too many losses". "Oh too bad" he said.

Of course I was wrong. Not on the technical side of things. On the social one. I didn't count on the possible success of portable devices making almost any device vendor provide a USB connector to receive some power.  Some even just draw copper lanes imitating the USB connector on their PCB. And this success wouldn't have been that huge without all those fantastic smartphones who stopped competing on how long they last on battery, and instead compete on how large the screen is and how fast their CPU can process pixels, even if that only lasts a few minutes before having to be plugged to the mains again (no single smartphone lasts as long as our 20-years old so-called cordless phones which could run on Ni-MH batteries for 8 hours talking).

All of this madness has resulted in the need for USB everywhere, instead of its usefulness. And when there is a need somewhere, there is a market, and there are innovations, products and progress.

I remember saying around 2008 in a shop "hey look they've put a USB connector on this wall plug, that's neat!". Right now in 2016 people visiting you at home routinely ask "where is the closest USB plug?". "The closest?". Not only it became obvious you have one, but you're even supposed to have many, all easily accessible! And that's true, we see USB-equipped power plugs everywhere. We even see USB-only power plugs. There are certainly more USB-equipped homes than WiFi equipped homes now. And that's what proves Benoit was right and I was wrong. No need for thick wires, just put a power supply into each and every plug and you're done! I tried to count the number of USB connectors I have at home and it's not easy given that every simple appliance has at least one. Counting those able to deliver power immediately or by just pressing a button or putting them in a very close plug is more meaningful. That seems to be around 20-60 on average, there are already 54 around my desk under power right now due to the PC, power plugs and the build farm. These days, small 5V power supplies cost around $1 shipping included and are cheaper than the equivalent high gauge cable you'd need to connect to the central panel under 5V. And a 6-10 port 60W USB power supply costs between $10 and $20.

But there's an area where it's less convenient to have 5V. When you're moving. Then you find lithium batteries coming in 1, 2, 3 or 4 cells, selling milliamps-hours. And all are lying since they advertise the cumulated mAh at the battery voltage instead of 5V, but since everyone does it, the first one not to do it would lose. What matters are Watt-hours (Wh), a unit for energy, they are the product of the voltage and the capacity in amp-hours. Batteries are thick and heavy (though lithium batteries are much lighter than lead or NiMH batteries). You tend to have as many as the places where you need them. I have one in my bag, another one with my laptop, another one in the room where I'm doing some hacking, another one with my bike serving for the front light (which is USB-based too, strangely). But with many batteries, you often have many nearly discharged batteries.

Thus this idea : why not have a very small battery in the pocket like you have your keys or your USB stick ? After all, most often you don't need the full capacity of your battery, and if you need it it's never large enough and you'd have preferred a larger one. So let's ignore heavy usages and go back to the most common ones : lighting a portable torch for a few minutes in the garage, recharging your phone to pass an quick call, powering a small WiFi router to connect your phone to a local network, recharging a bluetooth speaker or your TV's remote, having some light on your bike to go back home at night, etc... We all know such usages. And we'd be fine with a very small battery that's constantly in our pocket.

I decided to attack this idea with pretty good results. I ordered various small cheap batteries from a few Chinese vendors. I picked some models made for small drones because these ones are very cheap and support high charge and discharge rates (up to 5C charge and 20C discharge). I bought various capacities and tried to pick models that would be resonably small compared to the power conversion module. I ordered 100, 160, 240, 300, 380, 500, 680 mAh.

The reference on the batteries often have 6 digits such as "751517" on the 100mAh battery below. The first two digits correspond to the thickness in 1/10 millimeters. The 3rd and 4th one are the width in millimeters. The last two are the length in millimeters. This 100mAh battery is 7.5mm thick, 15mm wide and 17mm long. Yes that's tiny!



Then I ordered a few power conversion modules. These ones are made for the large 18650 lithium batteries. they're only 1.5 times larger than the USB connector and are both a step-up voltage converter (3.0-4.2 to 5.0V) and an adjustable lithium battery charger (often 0.5 to 1 amp output current) :



I started to build a few small devices by connecting the batteries to the modules and protecting them with heat shrink tubes. The 160mAh battery is as small as the PCB. The assembly was complicated because in order to save space, I had to desolder the USB connector and move it to the other side, so that I'd get a flat area at least on one side. It also required to modify the battery to move one wire to the other side :





The devices looked great but there was a lot of wasted area, especially on the largest ones (300mAh and more). On both photos below, the left one is the 160mAh version and the large one is the 300mAh one. Also I noticed that the modules were unable to deliver more than 800 mA, and my bike's front light needs 1.3 to 1.6 amp peak. More importantly, it always starts at the highest level which means that if the converter is not strong enough and cuts off, it's impossible to reach the lower power level.
 


Then I had another idea. I realized that this 5 volt frenzy is interesting, because nobody uses the 5V power line as is anymore. It's always converted to a lower voltage, sometimes 3.3V, sometimes 1.8V, or several intermediary values. In fact the USB bus itself requires 3.3 V pull-ups. I even observed that many USB webcams and WiFi adapters work pretty fine at any voltage between 3.3 and 5.0 V, and consume the same current, hence consume less power at lower voltages thanks to the LDO regulator inside which is only here to produce heat from any extra voltage above 3.3 V . Since each and every device comes with its own regulator to reconvert the 5V to something else, we could have imagined seeing a new trend of lower voltage devices or even better, wide range inputs. But that doesn't seem to be the case yet. So I tried to design my own such battery. The smallest one (160 mAh) was directly connected to the USB connector, without any PCB at all. It is pretty small :




My bike's front light liked it pretty much (a white led is 3.2V approximatively), however I found a few devices which couldn't run off it, often those which need to boost the voltage, because generally they employ low-Rdson MOSFETs which are not saturated below 4V which which leak a lot of power. So I stopped the experimentation there, still frustrated that I didn't have the ultimate universal battery.

After searching I finally found another module, based on a TP5400 chip, which can deliver about 1.2 amps on 5V from a fresh battery. I ordered two (just in case I'd kill one).

It's pretty well designed for my use case. Very little wasted space. One side has only low-profile components and the micro-usb connector, the other side has the USB connector, the inductor and the integrated circuit. It is possible to solder the 100 mAh battery on the flat side so that it doesn't increase the module's width at all.

Since the battery is only 100 mAh, I changed the charging resistor from 1.2k to 3.3k to limit the charging current to about 330 mA (about 20 minutes). This device is capable of powering my bike's light, and even to power my Clearfog base ARM-based server via a USB-to-12V converter. The module heats, but the device runs and works fine even with the Gigabit Ethernet cable plugged. Of course it will not last long, maybe 10 minutes only, at this rate. But sometimes it's useful. Just like my bike, at half light intensity (as I normally use it), it should last about 8 minutes. That's enough to cut through the woods at night when going back home... And I think I could put the 160 mAh battery there with a bit of effort. However, I noticed that my bike is pulling hard from this module, and if it had not been charged recently, it will cut off.

Finally I think I found a very good solution a few weeks ago, eventhough from an implementation perspective it's not optimal yet. Recently some powerful 3V-to-5V DC/DC modules have started to appear on the net, like this 5V/2A step-up module : http://www.ebay.com/itm/122122888739

It's important to note that they do not include the charger, but I already have plenty of TP4056-based chargers. So I ordered two of them and started again to try to assemble them. Interestingly this module extended with one USB connector is exactly the same dimensions as the TP4056, which is also the same dimensions as a 240mAh LiPo battery, and both modules are single-sided so they could be sandwiched to take less space :

   
I just had to surround it with some transparent heat shrink tube and fill every hole with some hot glue and this results in a reasonably strong power cube which easily accepts being dropped on the floor :


After a few tests, it appears very powerful. I could draw slightly more than 2 Amps from it, that's 10 Watts!
In addition I forgot to reprogram the TP4056 for a lower charge current, so it charges under 1A (which the battery supports as it's supposed to support 5C hence 1.2A), and is fully loaded in 15-20 minutes. The power conversion module eats a bit of power even when idle. I measured around 100 microamps, meaning that the battery will be depleted after 3 months not being used. But given that I have it every day in my pocket now it's not a problem. And it has already served me many times since I've built it! I've used it to power some development boards while I had no more USB port available, and last night to have some light on my bike when the original 2.2Ah battery gave up mid-trip. I managed to get at least 15 minutes of light, I don't know if it will give more but that was enough. The purpose was perfectly filled since I had it available in my pocket as every day now.

It's much smaller and lighter than the original 2.2Ah battery as can be seen below :




So what's the next step now ? I'm not interested at all in trying to create a business around this, but I'm pretty sure that many people would love to have a very small power reserve in their keychains. These devices are small enough to be arranged with the connectors inline opposed to each other and the battery in the middle. Just add a small keychain ring and you're done. I'd love it if one day I can buy a small keychain looking like this. Let's hope all the makers of programmable door remotes and USB flash keychains copy this idea and allow us to bring 5V everywhere with us with real power (at least 2A). I thought about using the same micro-USB connector as an input and an output but it would cause a cable issue as micro-usb to micro-usb is very rare. And using a male micro-usb connector would make it too fragile.

For the long term, it would be nice to see an evolution of the USB norm allowing certain categories of device to *officially* run from 3 to 5V. These ones would be advertised as "green power" or something like this because they don't require a conversion module which comes with losses, and would even smaller power blocks to be made (or with higher energy by converting the PCB space to battery space).