IronVale & Breadboarder
IronVale IronVale
Hey, I’ve been crunching the numbers on a new high‑efficiency battery pack for the next exoskeleton model, but I’m curious how you’d keep an old‑school analog control loop alive under that power budget. Got any vintage tricks that still make sense today?
Breadboarder Breadboarder
Sure thing. For a budget‑conscious exoskeleton, keep the loop analog the way I used to build my old radio receivers. Start with a 741 or a TL071 op‑amp for the feedback stage—those babies are still solid and I’ve got a few in my drawer. Feed it a 4.5 V reference from an LM317 set up as a low‑noise regulator; that gives you a tidy, clean reference without pulling a bunch of current. Use a 10 k potentiometer for the gain, a 100 nF capacitor across the feedback resistor to tame any oscillation, and a 2N3904 or 2N2222 transistor to drive the motor driver. If you need a pulse for timing, wire a 555 in astable mode and let it pulse at whatever frequency you need—clean 20 % duty is pretty common. Keep the traces wide on the power side, use a metal‑core cable for the supply, and you’ll have an analog loop that respects your power budget and still feels like a piece of the past. Trust me, if I had to touch anything, I’d solder it myself.
IronVale IronVale
Nice rundown, but that 741 setup will chew up power faster than the battery can spare. If we’re targeting a 300‑mile march, I’d replace it with a rail‑to‑rail op‑amp and keep the bias current under 20 µA. Also consider a low‑dropout regulator instead of the LM317; it’ll let the rest of the system sit tighter on the margin. Think about adding a simple current‑sense resistor on the drive transistor so you can shut the loop off if the motor draws too high. Keeps the whole rig efficient and still gives that analog feel you’re after.
Breadboarder Breadboarder
I hear you. Switch that 741 for a TLV9025; it’ll stay below 20 µA and still let you hit the rail‑to‑rail sweet spot. Grab a low‑dropout like the MCP1700 so you only lose a millivolt off the supply, keeping the whole thing lean. For the sense resistor, a 0.1 Ω, 1 W will give you a few millivolts at 10 A, then feed that into a comparator that trips a MOSFET to cut the loop. That way the old‑school feel stays, the battery lives, and you still get that nostalgic hiss of a genuine analog circuit.