Low Noise USB Audio Device
A dual-channel, broad-spectrum, USB sound recording device for recording environmental sound, specifically for investigating industrial noise pollution.
Technical Highlights
Opportunity
Atkinson & Rapley Consulting developed the SAM Scribe Mk I device to record audio in the infrasound and audible range (0.1 - 20,000Hz). The device, launched in early 2016, enabled non-specialists to record and analyse soundscapes with laboratory-accuracy.
After having success in the Australian market, Atkinson & Rapley Consulting looked to develop a second generation unit with the following requirements:
- Designed for ease of manufacturing
- Additional features - including advanced analogue signal switching
- Strong bias toward "intuitive-use" (Human Factors design)
- Ideally an increase in SNR performance
- Ideally lower overall cost
Atkinson & Rapley Consulting considered a few R&D consultants and in the end engaged Beta Solutions as its product innovation partner. This was primarily due to its friendly approach and proven experience in the field of audio electronic design.
Design Phase
The first step was to work with Atkinson & Rapley Consulting to understand its needs and its customer requirements. It was immediately evident that the product had to incorporate a strong human factors design element. That is, it was vital that the product not only performed well, but also looked good and was as straight-forward to operate as possible.
Once the layout and specifications were agreed upon, we undertook some SPICE simulations to validate the initial design calculations. As can be seen in the graph below, one requirement was that the bandpass had a low-end cut off frequency of only 0.1Hz. This was somewhat challenging, as the vast majority of off-the-shelf solutions has a band pass low-end cut off frequency of >10Hz. Every component in the audio path had to be capable of passing through the 0.1Hz - including the various coupling capacitors and analogue-to-digital circuitry.
The PCB was designed using the very latest version of Altium Designer which - in addition to the standard 2D PCB layout - enabled us to create 3D models of the intended circuit board. We then used these 3D models to cross check that the PCB would meet our required clearance constraints for the intended mechanical aluminium enclosure.
Noise Minimisation Design
A very strong emphasis was placed on designing the circuit to minimise electrical noise from external and internal sources. This involved selecting all components (including capacitors, OpAmps, power supplies, and ADCs) correctly - carefully ensuring the components' datasheets specified the required low noise characteristics. Additionally, any "noise generating" (digital) circuitry was kept well away from any sensitive analogue audio paths, with solid PCB copper ground planes being used extensively (on multiple layers) to help shield the circuitry from unwanted conductive and radiated emissions.
Prototyping and Testing Phase
Once the design was completed, a prototype PCB was produced. The fully-functional prototype allowed us to validate the design, ensuring it met the required specifications. Various audio tests were undertaken utilising our specialist diagnostics and test equipment - including oscilloscopes and spectrum analysers.
Atkinson & Rapley Consulting undertook the final Acceptance Testing, and the prototype was found to have exceeded expectations, out performing their original Mk1 device by 5dB on average.
Decibel Scale Reference
For those who are not familiar with the acoustical dB scale:
Noise Floor Performance
The SAM Scribe Mk II's noise floor (in one particular mode) is less than 0dB (SPL) between 100Hz and 1000Hz (approx). Essentially this means that electronics produce less than the signal from a microphone responding to a 20 micro-Pascal air fluctuation.
Production Phase
Just as with the R&D phase, Atkinson & Rapley Consulting has turned to Beta Solutions to assist with the PCB production aspect of the project. We have been able to produce the required quantities in the shortest possible time. As with all of the products that we produce for our clients, we undertake all the required programming, assembling and testing before giving the product the "QC Sticker" stamp of approval.
Success
Atkinson & Rapley Consulting is thrilled that we have been able to deliver this project on Spec, on Time and on Budget. The SAM Scribe Mk II has now completed the first commercial production run and sales continue to increase as the demand for these fantastic products rises. More information about Atkinson & Rapley Consulting's SAM Scribe product can be found on its website.
"It is rare to find the combination of high-technology technical expertise, practical hands-on skills with sophisticated and friendly customer service, yet Beta Solutions has these. When we approached Beta Solutions to partner our product development, they were able to combine analog and digital design skills with a deep understanding of human interfacing that allowed them to design a stunning product from our technical brief.
Beta Solutions project management skills and communication with the client has always been superb and any problems that surfaced were dealt with quickly and efficiently, and at the lowest possible cost to the client.
Beta Solution's combined talents are exemplary. That Beta Solutions have such a comprehensive team to focus on each project has meant that the overall R&D operation was smooth and effective from inception to finished product. The high-tech knowledge and state-of-the-art facilities make them a one-stop-shop for electronic product design and manufacture. Atkinson & Rapley Consulting cannot recommend them highly enough.
All content in this article, including imagery, has been approved by our client for publication on this website.