1. 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

2. Agenda 1.Project Goals and Objective 2.Engineering Requirements 3.Testing and Analysis 4.Current System State 5.Suggestions for Improvement 6.Project Lessons Learned

3. Problem Statement and Objectives Problem: 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

4. Customer and Sponsors Center for Electronics Manufacturing and Assembly Jeff Lonneville, Lab Technician Dr. Ramkumar, Director Scott Systems Rob Scott, Owner

5. Current System State

6. Engineering Requirements Specification (Metric)Unit of MeasureMarginal Value Ideal Value Physical Footprintft^3408 Weight of Machinelbs600300 Eliminate potential for injuriesBinaryPass Noise GenerationdBA<100<75 Minimum Width Between Traces Supportedinches0.0200.016 Manufacturing Cost$28002000 Minimum Tolerance to locating positions on boardinches0.0050.001 Feed Ratein/minute10100 Required Voltage for OperationVolts 5 ±.5, 12 ± 1.2, 24±2.4 5, 12, 24 Router Speedrpm1500030000 Debris Removal (Copper and Substrate)mg11.71.7 TIR (Total Indicated Run out)inches<0.0006<0.0004 Vacuum Table Forcelbs force1020

7. Successful Test Results Successful Test Results Specification (Metric) Unit of Measure Marginal Value Ideal Value Concluded Condition Physical Footprintft^3408 Marginal Pass Weight of Machinelbs600300 Pass Eliminate potential for injuriesBinaryPass Noise GenerationdBA<100<75 Marginal Pass Minimum Width Between Traces Supportedinches0.0200.016 Marginal Pass Minimum Tolerance to locating positions on boardinches0.0050.001 Marginal Pass Feed Ratein/minute10100 Marginal Pass Router Speedrpm1500030000 Marginal Pass TIR (Total Indicated Run out)inches<0.0006<0.0004 Marginal Pass Vacuum Table Forcelbs force1020 Marginal Pass

8. Successful Results TIR Test Maximum TIR (in) Router 10.005 Router 20.001 Router 30.0005 Width Between Traces Test Set 1Set 2Set 3 Width at location 1 (in) 0.010.0110.016 Width at location 2 (in) 0.0160.0170.023 Width at location 3 (in) 0.0190.0220.027 Average Width (in)0.0150.016670.022 Marginal Width (in)0.020 Difference (in)-0.005-0.0030.002 Average Width (in.)0.017888889 Vacuum Table Test Average ValueTotal Force on table (78 holes * force per hole) Force per hole (lbf)0.215.6

9. Failures and Undetermined Results Specification (Metric) Unit of Measure Marginal Value Ideal Value Concluded Condition Manufacturing Cost$28002000 Fail ($3450) Required Voltage for OperationVolts 5 ±.5, 12 ± 1.2, 24±2.4 5, 12, 24 Marginal Pass for 5V, 24V; Fail for 12V Debris Removal (Copper and Substrate)mg11.71.7 ?

10. Capabilities: Can we do what we set out to do? Elektor PCBA 110538-1: Radiation Monitor

11. 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 time Machine a level vacuum table sacrificial layer from non- porous, non-flexible material

12. Improvements (continued) Increased Debris Management ◦We’ll have a better idea of what to improve following remaining testing Disabled Signal debugging- software or connector issue Computer shut off issue Limit Switches ◦Recovering from a limit pause- implement hand crank ◦Improve board design

13. 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!

14. Project Lessons Learned: Project Management Planned expectations vs. Actual results ◦Scheduling ◦Budget ◦Designs ◦Test Results Development of Operating Procedures ◦ Time-consuming, but necessary and helpful