Home-made 6-pin DIN-plug

Tascam Portastudio

For the restoration of an old audio mixer (Tascam Portastudio 424mkIII), the first task was to find a suitable power supply. It didn’t come with a supply, only a weird looking connector, with the words next to it: “~IN TASCAM PS-424mkIII ONLY”. It looks a lot like a DIN connector, but with 6 pins scattered in random places. Nevertheless and according to wikipedia it’s not random, but appears to be standard after all.

20200517_194255Some research on the internet showed, it is indeed a type of DIN connector with the pins placed at 0°, ±60° and ±120° instead of the usual ±45° and ±90°. And it requires 24V AC with a center tap, in other words 2×12V. I found a suitable transformer within a few minutes but unfortunately no such connector could be found in the junk bin. Of course I could search the internet for a vendor of the connector and wait for it to come but, hey, let’s see what we can do with stuff in the house.

DIN connectors

I disassembled a few normal DIN connectors from the junk bin and I thought, what if I could drill a few holes and place the pins in other positions. But of course that would become a mess, the pins wouldn’t sit sturdy and straight and it would be a failure.

But I’ve got a little computer controlled router! It’s the dirt cheap (€160) 3018 cnc router from Banggood, that I use for crude, home made pcb fabrication. Looks ideal for this project and has enough precision for such a plug.3018 cnc router

I figured out that a stack of three layers of pcb material would be just the right thickness to replace the plastic thing holding the pins in an existing DIN Plug. I pulled the pins out of the existing DIN plug to re-use them, together with the housing and cable relief thing.

CADsoft Eagle

Device

I started like a normal pcb design project. I am used to CADsoft Eagle, so I designed a Symbol, a Package and a Device (that’s the way Eagle works) and then a Schematic and a Board (again, that’s the way Eagle works). Then I used pcb-gcode.ulp, a User Language Program that converts a pcb into gcode commands that the router will understand. It generates a bunch of files, but for this project I only needed:

  • plug.bot.etch.tap
  • plug.bot.drill.tap
  • plug.bot.mill.tap

“plug” is the name of my project, “bot” stands for bottom, which means that the cnc instructions are for working on the bottom side (copper side) of the pcb. “tap” stands for gcode instructions. The “etch” file contains instructions for scraping away the thin copper, as if it were etched in a chemical process. The drill file contains instructions for drilling holes for through-hole components. The mill file contains instructions for milling. I wanted to use milling for routing out the circumference of the pcb. It would be a round pcb with a diameter of 12mm.20200517_133000 - kopie

The etching and drilling part went fairly smooth. It is no different from manufacturing any pcb. I use grblControl for this work. The hardest thing with the etching process is finding the optimal routing depth. Too shallow, and the copper is barely touched but not completely eaten away. Too deep, and too much copper is removed. I’m using a 30° V-shaped bit for this work. On large pcb’s, there is the possibility to make a “height map”, which should correct for wobbling pcb’s, but that is not needed for a pcb of only 12 mm in diameter.20200517_133953 - kopie

After the etching, came the drilling of holes. I used a 1.4mm routing bit (with 3.175mm shaft), since I have no drill of that size. It is always very satisfying to see the cnc router drill holes exactly in the centre of the pads that were created earlier. I can’t help thinking of days long gone when I tried to hand drill holes in imperfectly etched home-made pcb’s. And now, today there is… perfection!

Gcode

Final step was supposed to be the milling of the circular outline of the pcb. But alas, nothing happened. It turns out that pcb-gcode.ulp will only produce milling instructions for straight lines, not for circles. Would it be hard to write your own gcode to make a circle? So, time to take a deep dive into the world of gcode.

Milling

It turns out to be fairly easy. I took the mill file that pcb-gcode.ulp had produced and added a few commands. I turns out that gcode has a simple command for routing out a circle segment. In my case:

G0 X-3.2 Y10                ; move to the starting point
G1 Z-1 F200                 ; move down
G2 X-16.8 Y10 I-6.8 J0 F100 ; half a circle
G2 X-3.2 Y10 I6.8 J0 F100   ; the other half circle
G1 Z2.5                     ; move up

That does the trick. In this way I made three similar pcb’s.

20200517_143108 - kopie

Temporary pin holder

Then I made a temporary pin holder out of wood. For that purpose, I manipulated the drill file a little bit, so that the holes would be 8mm deep. Now I can stick all six pins in the pin holder and be sure that everything is exactly straight.

20200517_145118 - kopie

Assembly

I put the middle pin in one of the pcb’s and soldered that pin on, using the wooden pin holder to get it straight. I widened the middle hole of the second pcb to 3mm, to make room for the solder. Then I put the second and third pcb on and the rest of the pins. Then I soldered all the pins to the third pcb only.20200517_151527 - kopie

To my dismay, the whole pcb stack wouldn’t fit in the DIN plug enclosure. Sigh. Using sandpaper, I removed a couple of micrometers until it would fit. Now the whole thing came together. What a beauty. Looks like a bought one!

20200517_152339 - kopie

The product V0.1

The final DIN plug fits perfectly in the power inlet of the Portastudio. But a new problem emerged soon. The way I constructed the plug makes that the metal plug housing is in electrical contact with the centre pin (pin #6). Inside the Portastudio, the housing is connected to ground and pin 6 to 12V AC. So it makes a short. Bummer! At this moment I’m using the plug without the housing, and it works fine. But I’ll still have to come up with a construction that doesn’t cause this short. The easiest solution is probably to cut off the center pin, as it’s doubled with pin 3.

Up to now, this was already the most expensive plug in my life, counting hours. But then again, it’s a hobby and it’s a lot of fun!

20200517_160743 - kopie

Files

plug.bot.etch.tap
G21
G90
G00 X0.0000 Y0.0000
M03
G04 P2.000000
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G01 X-14.5590 Y9.0035
G01 X-14.4475 Y9.1965
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G01 X-14.1543 Y9.5309
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G01 X-14.7310 Y11.6386
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G01 X-14.7019 Y12.0824
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G01 X-14.6133 Y13.1376
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G01 X-13.1826 Y14.4500
G01 X-12.8794 Y14.4500
G01 X-12.5780 Y14.4160
G01 X-12.5428 Y14.4080
G01 X-12.4984 Y14.5349
G00 Z2.5400
G00 Z5.0000
M05
M02

plug.bot.drill.tap (adapted for drilling 8mm deep pin holding tool)
G21
G90
M05
G00 Z5.0000
G00 X0.0000 Y-5.0000
M06 T01 ; 1.4500
G01 Z0.0000 F200.00
M06 T01 ; 1.4500
G00 Z2.5400
M03
G04 P2.000000
G00 Z2.540000
G00 X-6.9690 Y8.2500
G01 Z-8 F100
G01 Z2.540000
(R2.5400 P0.500000)
(G00 Z2.540000)
G00 X-6.9690 Y11.7500
G01 Z-8 F100
G01 Z2.540000
(G00 Z2.540000)
G00 X-10.0000 Y10.0000
G01 Z-8 F100
G01 Z2.540000
(G00 Z2.540000)
G00 X-10.0000 Y13.5000
G01 Z-8 F100
G01 Z2.540000
(G00 Z2.540000)
G00 X-13.0310 Y8.2500
G01 Z-8 F100
G01 Z2.540000
(G00 Z2.540000)
G00 X-13.0310 Y11.7500
G01 Z-8 F100
G01 Z2.540000
T01
G00 Z5.0000
M05
M02

plug.bot.mill.tap

G21
G90
G00 X0.0000 Y0.0000
M03
G04 P2.000000
G00 Z2.5400
G0 X-3.2 Y10
G1 Z-1 F200
G2 X-16.8 Y10 I-6.8 J0 F100
G2 X-3.2 Y10 I6.8 J0 F100
G1 Z2.5
G00 X-9.5000 Y4.4000

G1 Z-1 F200
G01 X-10.5000 Y4.4000 F100.00
G00 Z5.0000
G0 X0 Y0
M05
M02

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