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

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

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

Current System State

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

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

Successful Results TIR Test Maximum TIR (in) Router Router Router Width Between Traces Test Set 1Set 2Set 3 Width at location 1 (in) Width at location 2 (in) Width at location 3 (in) Average Width (in) Marginal Width (in)0.020 Difference (in) Average Width (in.) Vacuum Table Test Average ValueTotal Force on table (78 holes * force per hole) Force per hole (lbf)

Failures and Undetermined Results Specification (Metric) Unit of Measure Marginal Value Ideal Value Concluded Condition Manufacturing Cost$ 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)mg ?

Capabilities: Can we do what we set out to do? Elektor PCBA : 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 time Machine 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 issue Computer shut off issue Limit 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 quickly Read documentation for purchased parts before implementing Through-hole components require solder on bottom- can’t solder through plastic! Safety is important!

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