p14311: pcb isolation routing system final presentation team members: matthew clark, marley collier...
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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
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Agenda
1. Project Goals and Objective2. Engineering Requirements3. Testing and Analysis4. Current System State5. Suggestions for Improvement6. Project Lessons Learned
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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
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Customer and Sponsors
Center for ElectronicsManufacturing and Assembly
Jeff Lonneville, Lab TechnicianDr. Ramkumar, Director Scott Systems
Rob Scott, Owner
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Current System State
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Engineering RequirementsSpecification (Metric) Unit of Measure Marginal Value
IdealValue
Physical Footprint ft^3 40 8Weight of Machine lbs 600 300
Eliminate potential for injuries Binary Pass Pass
Noise 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 Volts5 ± .5, 12 ± 1.2,
24±2.4 5, 12, 24
Router Speed rpm 15000 30000
Debris Removal (Copper and Substrate) mg 11.7 1.7
TIR (Total Indicated Run out) inches <0.0006 <0.0004
Vacuum Table Force lbs force 10 20
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Successful Test ResultsSpecification (Metric)
Unit of Measure
Marginal ValueIdealValue
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
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Successful Results
TIR Test Maximum TIR (in)
Router 1 0.005Router 2 0.001Router 3 0.0005
PCB 1
PCB 3
PCB 5
78
82
86
Sound Levels per sample PCB
dBA Reading 1dBA Reading 2dBA Reading 3Average
PCB Sample #
dB
A
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 0.002
Average 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
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Failures and Undetermined Results
Specification (Metric)Unit of
MeasureMarginal Value
IdealValue
Concluded Condition
Manufacturing Cost $ 2800 2000 Fail ($3450)
Required Voltage for Operation Volts5 ± .5, 12 ± 1.2,
24±2.4 5, 12, 24Marginal Pass for 5V, 24V;
Fail for 12V
Debris Removal (Copper and Substrate) mg 11.7 1.7 ?
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Capabilities:Can we do what we set out to do?
Elektor PCBA 110538-1:Radiation Monitor
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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
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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
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Project Lessons Learned: Technical Items
“It’s always more complicated than it seems…” ◦ The design became complex very quickly
Read documentation for purchased parts before implementing
Through-hole components require solder on bottom- can’t solder through plastic!
Safety is important!
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Project Lessons Learned:Project ManagementPlanned expectations vs. Actual results
◦ Scheduling◦ Budget◦ Designs◦ Test Results
Development of Operating Procedures◦ Time-consuming, but necessary and helpful