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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 1: Learn the Components!
Task 1: Learn the Components!
In the worksheet on the right you will focuse on understanding how essential parts like the voltage regulator, amplifier, Bluetooth module, variable resistor, and speakers work together to create great sound.
Students will research their assigned component, learn about its function, how it operates, and its role in the overall system. Through this hands-on exploration, they’ll gain insight into real-world electronics and build a foundation for understanding modern audio technology.
Then present their findings to either the class or a group
Below are some information on the components to assist you in your learning
Task 2: Build the Speakers electronics!
Task 2: Build the Speakers electronics!
Circuit diagram for Bluetooth Speaker
Soldering Hints
Soldering Hints
When soldering the bluetooth module, it is difficult to keep the 3 pads from joining together. Here are a few hints to help with that
Keep wire insulation at the base of the board and use just enough bare wire
Pre tin all surfaces and wire
Don't hold Iron on for too long
On the amplifier make sure all of your solder points are keen and smooth and that the insulation touches the board
Task 3: Building a housing
Task 3: Building a 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
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)
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.
don't watch every video skip video 2 and 3
How to use parameters
COMPONENTS
An amplifier is an electronic device that increases the power, voltage, or current of an input signal.
PAM8610
This digital power amplifier board consist of the main integrated circuit, the PAM8610 with various capacitors and resistors to complete the design. This board cost about $1.50 from Aliexpress.
Technical parameters
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
Speakers
Speakers
Speakers are used to convert an electrical signal to an audio signal.
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
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.
Oval Speakers
Oval Speakers
These are the speakers we are using and the dimension for you Fusion 360 design is on the right.
There are rules for designing speaker boxes to get optimum sound. These websites are some starting points for the information you need:
Bluetooth Audio Receiver Board
Bluetooth Audio Receiver Board
The receiver consist of a Bluetooth antenna to pick up audio from your phone via Bluetooth. The output is the left and right channel.
Very important to understand that the supply voltage is limited to 3.7 to 5V.
Voltage Regulators
Voltage Regulators
A voltage regulator is a component that maintains a constant voltage at the output. Normally lower than the input voltage. This component allows for a larger power sources to be limited so that specific parts that require lower voltages don’t get damaged.
Why does our project need one?
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:
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