p14311: pcb isolation routing system
DESCRIPTION
P14311: PCB Isolation Routing System. Final Presentation. Team Members: Matthew Clark, Marley Collier Sears, Sarah Duman, Richard Kalb, Joseph Post, Zoe Rabinowitz, Kevin Richard Guide: Vincent Burolla. Agenda. Project Goals and Objective Engineering Requirements - PowerPoint PPT PresentationTRANSCRIPT
P14311: PCB Isolation Routing SystemFinal Presentation
Team Members:Matthew Clark, Marley Collier Sears, Sarah Duman,
Richard Kalb, Joseph Post, Zoe Rabinowitz, Kevin Richard
Guide:Vincent Burolla
Agenda1. Project Goals and Objective2. Engineering Requirements3. Testing and Analysis4. Current System State5. Suggestions for Improvement6. Project Lessons Learned
Problem Statement and ObjectivesProblem: Develop an in-house prototyping system to create wiring patterns
and component holes on printed circuit boards (PCBs).
Objectives:• Handle boards up to 5” x 5”• Reliably and accurately drill and mill patterns with ± .001”
tolerance• Easy and safe for operator use
Customer and Sponsors
Center for ElectronicsManufacturing and Assembly
Jeff Lonneville, Lab TechnicianDr. Ramkumar, Director Scott Systems
Rob Scott, Owner
Current System State
Engineering RequirementsSpecification (Metric) Unit of Measure Marginal Value Ideal
ValuePhysical Footprint ft^3 40 8Weight of Machine lbs 600 300
Eliminate potential for injuries Binary Pass PassNoise Generation dBA <100 <75
Minimum Width Between Traces Supported inches 0.020 0.016
Manufacturing Cost $ 2800 2000
Minimum Tolerance to locating positions on board inches 0.005 0.001
Feed Rate in/minute 10 100
Required Voltage for Operation Volts 5 ± .5, 12 ± 1.2, 24±2.4 5, 12, 24
Router Speed rpm 15000 30000Debris Removal (Copper and Substrate) mg 11.7 1.7
TIR (Total Indicated Run out) inches <0.0006 <0.0004Vacuum Table Force lbs force 10 20
Successful Test ResultsSpecification (Metric) Unit of
Measure Marginal Value IdealValue Concluded Condition
Physical Footprint ft^3 40 8 Marginal PassWeight of Machine lbs 600 300 Pass
Eliminate potential for injuries Binary Pass Pass Pass
Noise Generation dBA <100 <75 Marginal Pass
Minimum Width Between Traces Supported inches 0.020 0.016 Marginal Pass
Minimum Tolerance to locating positions on board inches 0.005 0.001 Marginal Pass
Feed Rate in/minute 10 100 Marginal Pass
Router Speed rpm 15000 30000 Marginal Pass
TIR (Total Indicated Run out) inches <0.0006 <0.0004 Marginal Pass
Vacuum Table Force lbs force 10 20 Marginal Pass
Successful ResultsTIR Test
Maximum TIR (in)Router 1 0.005Router 2 0.001Router 3 0.0005
PCB 1
PCB 3
PCB 5
788286
Sound Levels per sample PCB
dBA Reading 1dBA Reading 2dBA Reading 3Average
PCB Sample #
dBA
Width Between Traces Test Set 1 Set 2 Set 3
Width at location 1 (in) 0.01 0.011 0.016
Width at location 2 (in) 0.016 0.017 0.023
Width at location 3 (in) 0.019 0.022 0.027
Average Width (in) 0.015 0.01667 0.022Marginal Width (in) 0.020 0.020 0.020
Difference (in) -0.005 -0.003 0.002Average Width (in.) 0.017888889
Vacuum Table Test Average Value Total Force on table (78 holes * force per hole)
Force per hole (lbf) 0.2 15.6
Failures and Undetermined Results
Specification (Metric) Unit of Measure Marginal Value Ideal
Value Concluded Condition
Manufacturing Cost $ 2800 2000 Fail ($3450)
Required Voltage for Operation Volts 5 ± .5, 12 ± 1.2, 24±2.4 5, 12, 24 Marginal Pass for 5V, 24V;
Fail for 12V
Debris Removal (Copper and Substrate) mg 11.7 1.7 ?
Capabilities:Can we do what we set out to do?
Elektor PCBA 110538-1:Radiation Monitor
Suggestions for Improvement Implement automatic functions(no operator involvement)
◦ Homing functions in all three axes◦ Spindle Variable Speed Control
Mach3 Upgrades◦ Create macros in Mach3 to improve system flow◦ Buy full version
Optimize tool path to minimize machining timeMachine a level vacuum table sacrificial layer from non-
porous, non-flexible material
Improvements (continued)
Increased Debris Management◦ We’ll have a better idea of what to improve following remaining testing
Disabled Signal debugging- software or connector issueComputer shut off issueLimit Switches
◦ Recovering from a limit pause- implement hand crank◦ Improve board design
Project Lessons Learned: Technical Items“It’s always more complicated than it seems…”
◦ The design became complex very quicklyRead documentation for purchased parts before
implementingThrough-hole components require solder on
bottom- can’t solder through plastic!Safety is important!
Project Lessons Learned:Project ManagementPlanned expectations vs. Actual results
◦ Scheduling◦ Budget◦ Designs◦ Test Results
Development of Operating Procedures◦ Time-consuming, but necessary and helpful