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Blinky Ball (RGB)

An ever evolving LED project

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A sphere of LEDs with PCBs as structure.

In 2012 we did a Blinky Ball, it was 384 white LEDs with a 800mah battery and had a run time of a couple hours.  I was a great project, we tried to kickstart it but we came up short.  We ended building a dozen of them and they are still going strong.

About a year later, in late 2013, I started an RGB version.  Each slice had 24 common cathode RGB LEDs and three TLC59xx LED drivers.  There were a couple of problems with this... first it was very expensive.  At the time the TLC drivers were about 4 bucks in qty, so it would have cost ~$200/per ball for just that one part.  Also I couldn't find a RGB LED that looked good at low power, with 24 LEDs per slice, 3 junctions per LED at 20ma... its 1.4A per slice or ~22Amps for the whole ball, just for the LEDs.  So the project got shelved like so many other projects.

Four years later... 2017, my infant baby girl takes a shine to the original white Blinky Ball in my office.  And since my wife was making the baby clothes for her first birthday, I thought I would do what I do, and make something blinky for her.  

So here we are, 6 years later revisiting the blinky ball.  The first prototype was huge and wired (no battery) after quite a bit of effort charliex got the software running all 1152 LED elements.  After a couple of false starts and a couple of melted wires we got it to look OK at 1 Amp and it looks great at 1.8 Amps (peak amp numbers).  Since that was well within the range of being battery powered, the next prototype had an 18650.  It runs for about 4 hours, it's smaller and my daughter loved it, even if it was a month after her birthday (It's OK she just turned one.)

That one was 20 LEDs per slice with 16 slices. We are going to make ver 3.0 with 24 LEDs per slice that should have a similar run time.  And since people complain that I never document anything... here we go.

sch - 958.87 kB - 06/27/2018 at 22:00

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  • 384 × 5mm PTH ws2812 LEDs
  • 1 × CYC4245 Cypress PSOC4
  • 1 × IRF9358 Dual P-Channel FET
  • 1 × ESP-WROOM-32
  • 1 × IP5209 Power SoC

View all 11 components

  • A small video break

    mmca06/27/2018 at 18:47 0 comments

    A small video intermission as we wait for PCBs to come back from board house.

  • Evolution of the Main Slice

    mmca06/27/2018 at 18:42 0 comments

    In our first Blinky Ball all 16 slices where the same PCB.  You would build out the main slice with MCU, Bluetooth, battery charger and the other slices just got LEDs and a driver chip.  I was super happy with this and was constantly patting myself on the back about it.

    But as we moved to the RGB ball and especially when we got to the battery powered RGB ball all the slices started to get specialized. 

    This is the driver slice with Cypress PSOC4 and an logic level shift (the PSOC is a 3v3 device and the LEDs expect 5v signal).  In this version all the colors/patterns are done in PSOC4.  In the next version the heaving lifting will be offloaded to another processor.

    This is the power slice, It takes USB power and charges the 18650 and boosts the 3.7v of the battery up to 5v.  We are using the IP5209, a highly integrated power management SoC, it isn't the best documented chip, but we are figuring out all its little oddities.  It is a great little chip, you add a couple caps, resistors and an inductor... good to go.  Unfortunately there is no easy way to disconnect the 5V from the circuit, so the next revision has bits for that.

    Behind that mess of wires is the ESP32 slice.  We had the ESP8266 for some of the early protos but after using the EPS32 on the 2018 L1 badge, it made sense to switch.  This slice also has an i2s microphone and DAC.

    And here is the speaker slice.  That is a little speaker from a Lenovo monitor, they are available oinline from a factory buy out.

    What we wanted to do for the third revision was bring all the parts together back on to one slice.  Bringing it back to the original vision.

    This is what the main slice looks like now... ESP32, LED driver, mic, DAC and all the power bits.  It is off at manufacturing now, fingers crossed. 

  • Connecting all the slices

    mmca06/27/2018 at 04:59 0 comments

    In the first Blinky Ball we used wires to move the power and signal around the ball between slices.  It was a little clunky and time consuming to build but seem to work OK.  

    For the RGB ball we wanted something a little cleaner, more elegant.  So we combined the structure and the signal path.  The little slots that are soldered together to make the ball also carry the signals and power.

    The top cap pass the signal from slice to slice connecting the DOUT from one slice to the DIN of the next.  The bottom cap works in a similar manner but is just 5V and GND. 

    Unfortunately there are still a couple wires in the build.  There are user buttons on the bottom cap and some sensors in the top cap that need to be wired.  The battery is connected to the power slice by wires and that slice is in turn connected to the power distribution cap (bottom). 

    Still needs some cleaning up but its getting there.

  • Attaching LEDs to edge of PCBs

    mmca06/26/2018 at 21:55 0 comments

    On the earlier Blinky Ball with single color LEDs we just placed the holes near the edge and bent the LEDs over, it was easy and made for a very strong connection.

    When we moved to an common cathode RGB LED with four legs it got a little trickier.  It need to have four signals going to it, so I had this crazy notion of putting half the leads on one side of the PCB and the other two leads on the other side.

    This worked pretty well, its very strong and the LEDs line up directly on the middle of the PCB edge.  The main issue with this technique is that its a real pain to bend all the leads to fit on the PCB.  Each LED had to have its leads formed, then clipped to length.

    Next we moved to a WS2812 based addressable LED.  It still has 4 leads, but they get daisy chained together.  So in the current ball the PTH LEDs are just soldered in on their sides.

    At first I thought this would be an issue as the LEDs aren't centered on the PCB edge, but you really cant tell.  I also had concerns of the LEDs ripping off the pads, but it seems having 4 long pads is plenty strong.  (Yes, that's a speaker... more on that later.)

  • Recycling some LayerOne badges

    mmca06/26/2018 at 06:57 0 comments

    Our first blinky ball was monochromatic and run by an AVR driving some TLC5947s.  It worked very well but was a little expensive as each slice needed its own TLC IC.

    If we had done the same setup for the RGB ball it would have been 3 times the cost in driver ICs as each 5mm LED has three light emitting junctions. 

    For the LayerOne 2015 conference badge (and again in 2016) we had a PSOC4 driving WS2812 LEDs.  (Fun fact, the circuit comes from charliex's Christmas lights in 2014... when we like a circuit we really milk it.) This was great as you can make a 'serial block' on the PSOC4 that drives the LEDs and you get an ARM core all in one package.

    Now if only you could mount the 5050 WS2812 LEDs on the edge of the PCB or if they made WS2812 LEDs in PTH that I could mount on the edge of the PCB.

    Well it turns out they do make WS2812 LEDs in a 5mm PTH.  I got a couple of those and soldered it on to a LayerOne badge, and Yay! it worked perfectly.  First little part of the puzzle solved.

    Next we need some power, the WS2812 LEDs need 5 volts the PSOC4 needs 3.3v and I want to use a 18650 Lithum Ion that runs a nominal 3.7v.  So what I would normally do is go through the TI catalog looking for a boost IC and a charger chip.  In fact that is what I did for the 2017 LayerOne badge.  It was a great power circuit, it let you charge the battery from USB and boosted the voltage to a nice steady 5V.  Unfortunately it cost about 10 bucks for just that little power section.  Charliex pointed out that what we needed was a battery bank and from there we tracked down some highly integrated power bank ICs that do boost/charge all in one chip.   So the Blinky Ball uses the same power section as the 2018 L1 Badge (same idea as the 2017 power section, with a less finicky power SoC).

    And speaking of the 2018 L1 badge, the blinky ball has the same ESP-WROOM-32 for bluetooth and wifi connectivity and a mic and speaker.... for reasons.

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B1tl0rd wrote 07/12/2018 at 13:06 point

could you upload the source code?

and if it is not available, you can buy the complete kit
Thank you.

  Are you sure? yes | no

mmca wrote 07/12/2018 at 17:28 point

Nothing finalized yet. Still waiting on next run of prototype PCBs

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mpinner wrote 06/27/2018 at 21:03 point

any extra boards? i'd love to try this latest

  Are you sure? yes | no

mmca wrote 06/27/2018 at 21:59 point

Hey!

No extras as I've been ordering just enough to build out two at a time (about 40 PCBs each time).  But I think this next revision is going to get kitted up.  Will definitely let you know.

mpinner built one of our original blinky balls, one of only 12 that ever got made.

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Kurt Van Kelst wrote 07/06/2018 at 17:21 point

13........i made one too 

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Kurt Van Kelst wrote 06/27/2018 at 18:58 point

no schematics?   files

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mmca wrote 06/27/2018 at 19:02 point

Our hackerspace's svn server had a massive break down a little while ago.  All files will be moved to a more robust solution soon.

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Mike Szczys wrote 06/26/2018 at 17:43 point

I would recognize this blinky ball anywhere! I loved the earlier version and am glad to see you're continuing to riff on this. It looks fantastic!

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mmca wrote 06/27/2018 at 05:08 point

Hey Mike,

Yup, it all started because of that LED ball post on Hackaday all those years ago.

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