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The purpose of this project is to learn how to make an audio amplifier that are created by assembling various subsystems. This is a makers project. Your main goal will be to use soldering to construct the audio amplifier system and Fusion 360 to design the housing.
Task 1: Learn the Components!
Task 1: Learn the Components!
Before you start building your Bluetooth audio amplifier, you need to understand the key subsystems and components.
Use this carousel to work through each part.
For each component, you must research and record in your document:
An image of the part
What it does in the audio amplifier (its purpose/usage)
Its key specifications (voltage, current, power, etc.)
How you connect to it (inputs, outputs, power pins, etc.)
Components - Extra Info
Components - Extra Info
PAM8610 Technical parameters
PAM8610 Technical parameters
Power Supply:
Supply voltage - DC 6V-15V. Recommendation voltage: DC12V 2A
Standby current - 20mA
Speakers:
Output power: 10W * 2 (8Ω) 15W * 2 (4Ω)
Channel type: Double Channel
Output Impedance: 4-8Ω
Other specifications:
SNR: 90%
Working mode: Class D Amplifier
Frequency range: 20Hz-15KHz
Input impedance: 15K
Amplifier board size: 28mm * 22mm * 2.5mm
Voltage Regulators: Why does our project need one?
Voltage Regulators: Why does our project need one?
We plan to use a 9v battery to allow our system to be portable but a 9v battery might damage the receiver system. Electronic components are only rated to be able to handle a certain level of voltage, because of this we need to be able to reduce the voltage to 5v therefore we will use a voltage regulator because it guarantees that only 5v will be given to the system.
We have chosen to use a 78L05 Voltage regulator (image to the left) due to it not only outputting the necessary 5v but also has a maximum current of .1 amp or 100 milliAmps. Due to the receiver only using about 20 milliAmps this will provide plenty of current that might be needed.
Input voltage range: 7 to 30V.
Extra Information on voltage regulator:
Speakers Extra Info
Speakers Extra Info
This is a simple design of a speaker, and it shows the working parts.
We provide electricity to the coil which vibrates back and forth. This is because when a coil is electrically charged it becomes an electromagnet.
Depending on the controller the coil is repelled by the permanent magnet moving the coil and cone back and forth in specific ways causing sound to be produced. The polarity of the coil is constantly reversing via the positives and negative charges on the coil swapping.
When the voice coil is moving back and forth it pushes the diagram back and forth creating the sound waves. The system is designed to move via a supportive suspension.
The speed and rate of the diaphragm makes the sound come out in different ways depending on the sound needed. This is all depending on the controller and how the coil is charged.
Other parts of the speaker
Other parts of the speaker
Dust cap – Protects sensitive electrical components from dust
Cone, surround and spider – these are the parts that hold the cone in place while still allowing them to move
Voice coil – The electromagnet that moves
Basket – Provides a structural base for the whole speaker
Top plate, pole, and rear plate – Surround the permanent magnet to focus magnetic waves
Magnet – The permanent magnet
There are rules for designing speaker boxes to get optimum sound. These websites are some starting points for the information you need:
Task 2: Assemble the Bits!
Task 2: Assemble the Bits!
The purpose of this project is to learn how to create an audio amplifier that are created by assembling various subsystems. This is a makers project. Your main goal will be to use soldering to construct the audio amplifier system and Fusion 360 to design the housing.
Task 3: Test your BT Speaker
Task 3: Test your BT Speaker
Step 6: Test the Circuit
Power the circuit with the 12V supply.
Pair the Bluetooth module with a device and play audio to test.
(Teacher note: Encourage students to check connections before powering on to prevent errors.)
Optional: Add a Mute Switch
Wire a switch to the mute pin on the PAM8610 module for silencing the speakers.
(Teacher note: This step is optional, depending on time and student experience.)
Task 2: Building the Housing
Task 2: Building the Housing
In this task, you’ll design a housing for your Bluetooth audio circuit and prepare it for laser cutting. The housing will protect your components, provide access to buttons and controls, and make your speaker look great! You have two options to choose from.
Option 1: Pre-Designed Box with Custom Buttons
Option 1: Pre-Designed Box with Custom Buttons
Use a box maker tool to generate a basic housing design (provided DXF file).
Import the DXF file into Fusion 360 and modify it:
Use this file to speaker cutouts - LINK
Add cutouts for buttons, switches, and ports.
Create decorative patterns or engravings to personalize the box.
Ensure your design still works for laser cutting.
Make sure size is appropriate.
Option 2: Custom Housing Design (Extension)
Option 2: Custom Housing Design (Extension)
Design your own unique housing from scratch using Fusion 360.
Focus on creating a personalized shape or structure that fits your circuit and speakers.
Consider:
Internal space for the components (amplifier, Bluetooth module, speakers).
Ventilation openings for heat dissipation.
Placement of buttons, ports, and switches.
Use this laser cut file for a start box. It a Lightburn file .
Extra Resources
Extra Resources
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