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Circular-led

Circular LED with ATmega324PA

32 red LEDs mounted in a circle with a diameter of 75 mm. Each diode has a resistor and is connected to one of the 32 port pins of an ATmega324PA. Each single LED can be switched on and off.

1 Properties

View of the clock device This small device can be used for two different applications:
  1. as programmable light band in a circle: starting from the left side, one, two, three or four LEDs move either clock-wise or counter-clock, steps, speed and direction can be programmed into a more or less large table and repeat endless,
  2. as clock: starting with the upper LED and then clock-wise seconds, minutes and hours are displayed and advanced. The minutes blink in slow motion, the hours even slower. The seconds start with LED 1 and advance very fast until their current value is reached.
Many different variations are possible:

Content

All drawings of this project can be downloaded as LibreOffice draw file here (including the PCB layout and the component placement drawing), all flow diagrams are as LibreOffice draw file here, all calculation tables are as LibreOffice Calc file here.

2 Hardware

The hardware for both applications is nearly identical. When applied as clock, an additional crystal and two ceramic capacitors are required.

2.1 Hardware of the light band

Schematic of the circular LED device This here is the boring schematic of the circular LED. The connections of the LEDs with the controller pins requires some attention in the software section, but eases the PCB design: the bits of the three ports C, D and B are in a different direction than that of port A.

The 6-pin IDC plug is necessary only if you either want to program the controller on the board or if you want to supply the device via the standard connector.

Variations

If you want more than ten of the 32 LEDs on simultanously, you can use low-current LEDs, e.g. for 2 mA, and increases the resistors (by default 82Ω), e.g. to 560Ω. You can then switch as many LEDs on as you want, without risking exceeding the current limits of 200 mA of the controller.

The same can be done when supplying the device from a battery.

2.2 Hardware of the clock

The clock uses the same hardware, but the crystal and the two ceramic capacitors of 22 pF hav to be added like shown in grey in the schematic. The clock uses the crystal to be more exact than with the internal RC oscillator.

Selection of crystals for the device By default I used a crystal with 2.097152 MHz, to which the software is also adapted. This crystal is suitable for a 16-bit TC as well as for an 8-Bit-TC. The software uses a 16-bit TC.

The picture shows for all crystals on the market, if those are suitable for this application. As can be seen, the 16-bit TC version works with more crystals than the 8-bit version. Please note that crystals above 10 MHz work only with 5 V operating voltage. But such high frequencies are not necessary for this application. The device and the software even work at frequensies such as 32.768 kHz. But, in that case, make sure that your programming adapter allows clock frequencies below 8 kHz, if you use such a low-frequency-crystal.

For the 8-bit-TC, higher frequency crystals use additional clocking with CLKPR. As can be seen, no crystals, that require additional CLKPR-dividing are suitable with an 8-bit-TC.

If you want to use a different crystal: the calculation sheet "clockxtals" in the LibreOffice-Calc-file here provides the opportunity to check its suitability. Those who really want to use a crystal above 4.5 MHz, can check if additionally using CLKPR as clock prescaler can probably offer an additional suitability case.

With the drop-down-field in cell B3 you can select one of the listed crystals. If that crystal fits the 8-bit- or the 16-bit-TC, prescaler and CTC-divider are provided as constants for export to the source code. Simply select the constants lines, press Ctrl-C to copy these lines to the clip board, then mark the respective source code lines and press Ctrl-V to overwrite those lines in the source code. If you assemble that, you can program the controller with that changed clock frequency.

LED currents at diverse operating voltages and resistors This table shows the LED currents for 5-mm-LEDs under different operating voltages and with different resistors. Listed are operating voltages between 3.0 V (two AA- or AAA-battery types), 3.3 V (from a power supply over ISP6 or a wall plug supply), 3.6 V (from two AA- or AAA-types rechargeable batteries), 4.5 V (three AA- or AAA-type batteries) and 4.8 V (four AA- or AAA-type rechargeable batteries). Additionally the upper tolerance voltage of a 5 V power supply is listed.

Calculation of the currents is not that simple because so, cannot be calculated with a simple linear function. Therefore the calculation in the spreadsheet "LED-Currents" uses 10 approximations per voltage/resistor. As can be seen from the sheet that the approximations for the 47Ω, and in part also for 82Ω, are not approaching a useful final value. Those values are not exact, but the others are.

With resistors from 82Ω and higher the complete range of operating voltages produces acceptable currents. But e aware that currents above 20 mA through the SCK/MOSI/MISO pins can conflict with the ISP interface, if your programmer is not fit for such currents. And be aware that for all LEDs that are switched on simultanously a limit of 200 mA can be driven by the controller ATmega324PA.

Background in read signals currents below 5 mA, for which only low-current-high-efficiency LEDs are suitable.

On my real object, equipped with 82Ω and at 3.125 V, I measured a current of 10,6 mA, so the currents in the table are a little bit too low.

Currents for 3-mm-LEDs 2 mA Here the same has been calculated for 3-mm-LEDs and for 2 mA nominal current: as the forward voltages of such LEDs are smaller, the currents are higher than for the standard-5-mm-LEDs. So the resistors can be larger.
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2.3 Power supply

Power supply for maximum 4 LEDs The wall plug power supply is provided in two flavours: to the left a schematic for a maximum of four LEDs on simultanously, below for 200 mA as maximum permissible current from the ATmega324PA and for more than four LEDs on.

Power supply 0.5VA Power supply for four LEDs The smaller one can drive up to 80 mA LED current. The controller's current contribution is only 0.5 mA, so forget this.

Power supply 1.5VA Power supply for maximum 200 mA This is the larger version. The 200 mA are sufficient for more than ten LEDs at 20 mA each or for all 32 LEDs when low-current-LED-types and larger resistors are used (max. 6.25 mA per LED).

200 mA power supply This is the 200-mA-power-supply on a small raster board.

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3 Mounting

For three applications (light band and clock in a circle, rectangular and a mimimal space version) PCB's has been designed, because mounting that all on a raster board is not exact enough in respect to mechanical aestetics.

3.1 Printed cicuit boards

3.1.1 Circle-type PCB

PCB for the circular light band and for the circular clock This is the design for the PCB in a 80-by-80 mm format in .gif format. The PCB is single-sided.

Those who need it with enhanced resolution, can right-click on the drawing, select "Save target as" and save the file in enhanced resolution. Or you can use the LibreOffice-Draw file and produce a higher-resolution copy as gif- or png-file. Print this enlarged drawing to scale (e.g. with IrfanView).

3.1.2 Component placement circle type on the PCB

Component placement on the PCB That are the components and how to place them on the PCB. All drillings are 0.8 mm, excluding the four holes for the screws (2.5 or 3 mm) as well as the six holes for the IDC plug and the two holes for the power input (1.0 mm).

Those who want to program the controller via the ISP6-plug have to add three enameled copper wires for SCK, MISO and MOSI manually from the IDC socket to the controller.

Who does not need the ISP plug, neither for programming nor as power supply plug, can leave it aside.

If you do not need the clock feature, you can leave the crystal and the two 22-pF-capacitors out. In this case the controller runs with its internal RC oscillator and at 1 MHz clock. This is also the basis for the software.

3.1.3 Rectangular PCB

Rectangular PCB layout This is a rectangular version with the same PCB size.

Those who want it more squared than cuircular use this layout. No component placement drawing here, it is nearly the same. Right-click and use "Save target as" to have the drawing in a higher-resolution version.

The software works fine, the LED numbering starts in the middle of the left edge.

3.1.4 Minmal size PCB version

This version reduces the PCB size to a minimum.

3.1.5 Minimum size PCB

Minimum size of the PCB layout That PCB places the 32 LEDs as near as possible to the controller. It has a size of 65x50 mm. If you right-click on the PCB picture and "Save target as", you'll get the enlarged drawing. Components such as the ISP6 plug, the operating voltage plug and the crystal are placed to different locations.

3.1.6 Component placement on the mimimum size PCB

Component placement on mimized PCB The most relevant change compared to the circled version is that the resistors are mounted vertically. That reduces the size of the PCB substantially. No crystal is foreseen here. One bridge has to be soldered. And, if you plan to program the controller via ISP6, the MOSI pin has to be connected manually.

Minimum size version This is a minimum size version with 32 pieces of 2mA-3mm-LEDs and 470Ω, preferably for battery operation. The 4-Led-power-supply version is sufficient, if your software does not switch on more than ten LEDs at a time.

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3.2 Parts list

Parts list for the light band and the clock This is the complete parts list for both applcations as well as for the two power supplies. The order numbers and prices, as of 12.10.2021, are for Reichelt.

The controller and the 32 LEDs determine the total price. Note that low-current-LEDs instead of standard LEDs increase the price a bit.

3.3 Supply current analysis

Power supply currents Two cases have been analyzed:
  1. the light-band with 5mm-LEDs, designed for 20mA current, supplied by the 200mA-power-supply,
  2. the minimum size light-band with 3mm-LEDs, designed for 2mA current, supplied by the 4LED-power-supply.
As can be seen from the table, a maximum of 22 LEDs can be on simultanously without reaching the maximum load of the power supply and without reaching the maximum current of the ATmega324PA. The last line with the 23 LEDs in the first case exceeds this limit by 10%, but the ATmega324PA worked fine even under these circumstances.

First of all: regulators for 3.3 V do not work as exact as 5V-regulators. They only work fine at very low currents, where no LEDs have to be driven. Especially in the mid-range of current loads both regulators are on their knees, with a maximum of 0.6 Volts missing. In the higher current areas they again go up with their voltage but they never reach their nominal voltage again.

Astounting is the current if no LED is on. With 0.51 and 0.88 mA both currents are quite different, even though both ATmega were measured at the same clock frequency and without interrupt servicing.

The average currents are fine, but the voltage drops of the regulators cause very different currents.

Conclusion: a battery is a much better regulator. And: do not trust semiconductor producers, they sell machines with very different properties than what is printed on the outside.

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4 Software

The software is written completely in assembler and is well documented, so that own adaptions and changes are possible.

The flow diagrams are available here as LibreOffice-Draw file.

4.1 Software for the circular light band

4.1.1 Download assembler source code for the circular light band

The assembler source code for the light band can be downloaded from here and can be viewed in the browser here. No further include files are necessary. Please change the fuses during programming.

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4.1.2 Setting the fuses for the circular light band

Fuses Original ATmega324PA Fuse-Umstellung Zirkular-LEDs To the left are the original fuses when the ATmega324PA is shipped, to the right are those fuses that are to be set to have a correct functioning of the circular LED.

Only the JTAGEN fuse has to be switched off. Otherwise the LEDs L13 to L16 would not work correct. All other fuses remain the same.

4.1.3 How the software for the circular light band works

Flow diagram of the Compare-A-Interrupt-Service-Routine The light band's software works as follows:
  1. The timer TC1 runs with a prescaler of 64 in CTC mode with the compare value in Compare-A.
  2. After the timer reached the compare value, a compare-match-interrupt is executed. The Interrupt-Service-Routine shifts the complete 32 bit wide output value either to the right (if the direction bit is zero) or to the left (if it is one). The shifted registers are written to the ports A, C, D and B.
  3. If all (32 or whatever) shifts are executed and rRnd is zero, the number of repeats in (rRpt is decreased. If this is also zero, the next combination of values is read from the control table (Load next table values). The control table consists of eight 16-bit-words: the first two words hold the start values of the LEDs (1 is LED off, 0 is LED on, byte 0: Port A with LEDs L1 to L8, byte 1: Port C with L9 to L16 reversed, byte 2: Port D with L17 to L24 reversed, byte 3: Port B with L25 to L32 reversed), the third word holds the Compare-Match-Value (the lower the faster), the fourth word consists of the LSB, which is the number of repeats, and the MSB, which is the number of rounds between 1 and 128 as well as the direction bit in bit 7.
  4. If the table end is reached, the next table address is set to the beginning of the table. The table can use the complete rest of the flash memory, sufficient for roughly 4,000 table entries.
The LEDs of the Ports C, D and B are reversed, which means that L9 is PC7, L10 is PC6, etc. When constructing the table those bits are to be defined different: 0x7F to C turns L9 on, 0xFE turns L16 on.

The table entries again:
  1. First word: LSB = Port A (bits normal), MSB = Port C (bits reversed),
  2. Second word: LSB = Port D (bits reversed), MSB = Port B (bits reversed),
  3. Third word: CTC compare value, 1 MHz / 64 = 15.625 kHz, per round these are 488.28 Hz or 2.048 milliseconds,
  4. Fourth word: LSB = Number of repeats 1..256, MSB = Number of shifts 1 .. 128, Bit 7 = 1 is backward shifting.
Die voreingestellte Tabelle hat folgenden Inhalt:

Table:
  .dw 0xFFFE,0xFFFF, (10000*cSecondMult+500)/1000-1, 1+32*256 ; One LED, 1 time right, round time 10 seconds
  .dw 0xFFFE,0xFFFF, (2000*cSecondMult+500)/1000-1, 20+32*256 ; One LED, 20 times right, round time two seconds
  .dw 0xFFFF,0xFF7F, (2000*cSecondMult+500)/1000-1, 10+256*(32+cLeft) ; One LED, 10 times left, round time two seconds
  .dw 0xFFFE,0xFF7F, (1000*cSecondMult+500)/1000-1, 10+32*256 ; Two LEDs, 10 times right, round time one seconds
  .dw 0xFFFF,0xFFFF, (500*cSecondMult+500)/1000-1, 1+32*256 ; All off for half a second
  .dw 0xFFF0,0xFFFF, (100*cSecondMult+500)/1000-1, 100+(32+cLeft)*256 ; Four LEDs in a row, 100 times left, round time 0.1 seconds
  .dw 0xFFFF,0xFFFF, (2000*cSecondMult+500)/1000-1, 1+32*256 ; All off for two seconds
TableEnd:

The constant cSecondMult allows to define the duration of a 32-shift round in milliseconds. In lines 3 and 6 of the table you can see how the shift direction can be reversed. The lines 5 and 7 demonstrate a "quiet" round, with none of the LEDs on.

You can see from the flow diagram, that all runs though the ISR require between 26 and 43 clock cycles (the red numbers in the diagram are clock cycles). This is the reason for selecting a prescaler value of 64: even when the CTC compare value is zero, one complete execution cycle fits within and no timer interrupt is missed.

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4.1.4 Video of the circular light band

... are available here as 1280-by-720 and here as 640-by-360.

4.2 Software of the circular clock

The software of the clock application is also written in assembly language.

4.2.1 Download assembler source code for the clock

The assembler source code for the clock can be downloaded here and viewed in the browser here. No additional include files are necessary.

In the section "Adjustable const" of the source code all parameters controlling the clock can be adjusted. Many of those adjustments can use the spreadsheets in the the LibreOffice Calc file here, can be copied from the spreadsheet and can replace the corresponding lines in the source code file.

After assembling and burning the hex code to the flash memory the Fuses of the ATmega324PA need adjustment, otherwise the clock runs too slow (or much too fast if you plan to use a 32.768 kHz crystal).

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4.2.2 Adjusting the fuses for the clock

Fuses Original ATmega324PA Fuse-Umstellung bei der Uhr Prior to or after programming the controller the fuses of the ATmega324PA have to be adjusted to use the external crystal. To the left the original fuses can be seen, to the right the adjusted fuses are marked in red sqares.

The JTAGEN-fuse (otherwise the LEDs L13 to L16 remain dark), the CLKDIV8-fuse (otherwise the clock runs too slow by a factor of eight) and the SUT_SCKSEL-fuses have to be changed (otherwise the clock runs too slow by a factor of roughly two).

The SUT_SCKSEL-fuses are displayed here for a crystal of 2.097152 MHz. If you want to use a 32.768-kHz crystal and if you imported the respective lines from the spreadsheet in the LibreOffice file you'll have to change this setting to a Low-Speed-Crystal entry.

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4.2.3 How the software for the clock works

Flow diagram of the clock software The dewsign of the software is not as trivial as the hardware, because The complete timing therefore is not simple and straight-forward:
  1. The second's pulses have to make 32 steps in a minute or in 60 seconds. That is 32 / 60 steps per second or 0.5333333 steps/s or 1.875 seconds per step. To enable a dynamic second movement, these 1.875 seconds are subdivided by 32. Each of these steps lasts 1.875 s / 32 = 58.59375 milli-seconds. Each of these sub-steps shifts the second's LED one step further if it is smaller or equal the current second position, otherwise it remains there for the rest of the 32-step-cycle.
  2. The minute pulses divide one hour by 32, so that 32 steps are to be absolved in 60 minutes. The step speed is 32 / 60 steps per minute or 32 / 60 / 60 per second = 0.0088888 steps/s or 112.5 seconds per step. Related to a sceond's step duration of 1.875 seconds these are 60 "seconds", compared with a sub-duration of 58.59375 milli-seconds these are 1,920 single steps.
  3. The hour pulses divide a half day by 32, so that 32 steps are absolved in 12 hours. Here we have 32 steps in 12 * 60 * 60 seconds or 1.350 seconds per step. Compared with a sub-duration step of 58.59375 milli-seconds these are 23,040 single steps.
The flow diagram of the TC1-Compare-A-Interrupt-Service-Routine shows all this. The ISR is called every 58.59375 ms. On its end (lower part of the diagram) this routine outputs the current states of the four rLedN registers. The minute's (rMinN) and the hour's (rHrN) LEDs are ANDed with these registers, depending from two bits of the sub-counter, so those blink with a different rhythm.

The minute registers rMinN are rotated every 1,920th step (counter in XH:XL), the hour registers rHrN every 23,040th step (counter in YH:YL). If after rotating all four bytes a zero rotates out, this zero is copied with AND to the beginning of the four registers, so that minutes and hours re-start again.

The flow diagram starts with shifting the seconds LEDs. This shifting of the rLedN is stepped over, if the round down-counter in rCntRnd is larger or equal to the seconds down-counter in rSec.

If the round counter in rCntRnd reaches zero, the LED registers re-start with the first LED and the round counter re-starts with 32.

The end of a 60-second-period cannot be used to advance the minutes, because the minute's LED only increases after 1.875 minutes. Therefore the minutes and the hours are derived from the 16-bit counters in XH:XL and YH:YL and have nothing to do with the second's clock.

The shifting of the seconds in rSec, which occurs every 1.875 seconds, is clocked separately with the 8-bit-counter TC0. This counter runs with a prescaler of 1,024. The overflow interrupt of this counter, which occurs after 256 prescaled clock cycles, decreases a software counter in rSecDiv by one (down from 15), which then decreases rSec if it is zero. If rSec reaches zero, it is re-started with 32.

In red letters all clock cycles within the ISR are documented. As can seen, a maximum of 76 clock cycles is required. Even at a crystal frequency of 32.768 kHz only these are 4.0% of the time when the next TC1 interrupt occurs. The software therefore is suitable even for this very low clock frequency.

The number of consumed clock cycles plays an additional role: the operating current of the controller depends from that. As outside the ISR the controller is send to sleep, it doesn't consume relevant current. At 2 MHz clock the sleep share is 99.3%, at 32.768 kHz this share is 96.1%. The current consumption of the controller therefore is irrelevantly small, as compared to the LEDs.

The minute and hour switching times of the LEDs If you want to start the clock not at 00:00:00 but, e.g., at 20:20:00 (or 08:20:00), you'll have to do that in the source code. As the uneven times of minutes and hours in this clock require some calculation, the spreadsheet in the LibreOffice Calc file "clockstart" provides some assistance for this. That spreadsheet took me several hours of hard work until it functioned correct, so use it properly.

The times at which the next minute or hour LED is to be rotated, can be seen from this table. n is the round number from 0 to 32. The columns Minute and Hour show the times. The column Bit show the portbits to be activated (different rowing for port A and C/D/B). The LED numbers in white on red background refer to the numbering in the schematic.

As nearly all minute and hour times are fractional, the start at a certain time requires to set the minute counter in XH:XL and the hour counter in YH:YL to certain values. If the start time would be 20:20:00, the hour LED would have to be LED22 (bit 1 in port B). The next shifting would have to be at 20:25:00. The 20 minutes will have to switch portpin PD45 active, the next minute LED would be activated at 20.625 minutes.

Start time 20:20 In the spreadsheet "clockstart" just input the hour and the minute of the starting time into the two cells with green background. This calculates the LED number and the port bits and displays this as hex number (and below in 32-bit binary). As the next shift of the hour and minute registers is only parts of a whole division, the sheet also calculates the rest of the counter time (as part of the 1,920 resp. 23,040 full counter stages). These rests can be used to start the XH:XL and YH:YL counters.

Constants for export Those four constants in the source code can be copied from the spreadsheet by highlighting those cells, Ctrl-C to copy those to the clipboard and Ctrl-V to replace those line in the source code file. After assembling and burning the clock starts at this point.

4.2.4 Video of the circular clock

... are available at here in 1280-by-720 resolution and here in 640-by-360 resolution.

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