Electronics Production

 

Principles and Practices, Project Management

 

ASSIGNMENT

Individual Assignemnt

make an in-circuit programmer by milling the PCB, then optionally trying other processes

Group assignment

characterize the specifications of your PCB production process

 

 

WORK FLOW

The first step to do is to download the basic FILE (FabTinyISP) that we can make readable and set for the machine through (FabModules)

FTS_MINI_TRACES FTS_MINI_CUT

 

 

Entered on FABMODULES we make the input (input format) of our files that will be in PNG format and we have to convert them in RLM (Roland mill).

CONVERSION

 

 

Let's then set the PROCESS, that is what type of tip we will use. In our case it will be PCB outline 1/32.

2

 

 

After setting the "PROCESS" will appear some parameters that we will have to complete with the values we need:

ORIGIN OF X-Y-Z

 

 

Once the parameters have been set, in the item below "PROCESS" click on "calculate" so that the SoftWare calculates the revolutions that the tip will have to make when cutting. Once finished, click on "save" and the file will be automatically downloaded to our computer.

CALCULATE BUNNON

 

We repeat the same operations also on the setting of the external part of our PCB in order to have both files ready for cutting.

EXTERNAT PART OF OUR PCB INTERNAL PART OF OUR PCB

 

 

 

 

When we go to cut, the procedures to do are as follows:

 

 

I put my files on the PC dedicated to the machine and save them on the Desktop so that they are easy to find.

PC OF PCB MACHINE

MACHINE

 

 

I take the sheet that I will then have to use and I stabilize it with double-sided tape so that there is no movement during processing.

DOUBLE-SIDED TAPE ON THE BACK OF MY PCB

PCB ATTACHED TO THE WORKTOP

 

 

Once this is done, I enter the program of the machine called V-Panel and set the origin of X-Y-Z with these simple operations:

ROLAND VPANEL OF PCB MACHINE

OBJECT MADE TO DETECT THE X-AXIS

 

 

Slowly, with the program, we make sure that the tip descends at a reduced speed so as to be as accurate as possible and when the tip will have touched the slab, the green LED will light up and in this way we will understand that we have arrived at bat.

OBJECT IN OPERATION DESIGNED TO DETECT THE Z-AXIS

 

 

Once all the parameters are set, I can start importing my files into the program, first the "TRACES" (internal) and then the "CUT" (external contour). For each of the two files (traces-cut) we will use a different tip.

EXTERNAL AND INTERNAL FILE

 

PCB OUTDOOR TIP

TIP FOR PCB INTERIOR

The tip for making the outer, OUTLINE part is round and notched because it clearly has to cut the PCB.
The tip for the inside, the TRACES, is a 1/2 "V" shaped tip which allows it to mill even the most attached parts, but in any case there is obviously a cutting margin beyond which the tip cannot reach.

IMPORTANT !

It is very important to check that the TRACES bit is always sharp and not broken, otherwise it will not cut properly. .

To get these types of tips there is no single link, there are many, for example:


(DIGIKEY)      (ALIBABA)      (PCB FACILE)     

 

THE MACHINE IS WORKING

 

 

 

Once the machine has finished both cuts, I use the special "knife" to lift the plate and then have my PCB ready.

KNIFE TO REMOVE THE PCB AFTER THE CUT

 

 

During the processing I made a mistake and in the program (fab-module) I set 1/32 also for the "traces" file: doing so the tip dug too deep, making my PCB unusable, even if I must admit that aesthetically it is very artistic (hahahah).
I reset my "traces" file so that it is 1/64: this time the result is correct and you can see the clear difference between the wrong and the right one.

PCB WRONG

 

RIGHT PCB

 

 

Referring to the site where I downloaded the previous files, (FabTinyISP) I identify which electronic components I will need:

ELECTRONIC COMPONENTS

RESULT AFTER WELDING

 

 

 

 

I TESTED MY CARD TO SEE IF EVERYTHING WORKS AND IT LOADED SUCCESSFULLY

 

 

FILE


- OUTLINE
- TRACES

 

 

 

 

 

 

 

 

SOMETHING ABOUT THE MACHINE

this is the link where you can find all the information about the machine and the supplier (LINK)

 

The MDX-40A and the CAM SRP Player

The MDX-40A milling machine can handle both data input and output thanks to the fact that it can not only model but also scan the object to be reproduced. In addition to the prototyping part, the MDX-40A is equipped with a contact scanning probe that can be installed on the machine spindle. The ZSC-1 probe allows the surfaces on the work table to be scanned with centesimal resolution. The file is then managed by the software supplied with the probe. The MDX-40A comes complete with a software suite for managing both milling and scanning.

KNIFE TO REMOVE THE PCB AFTER THE CUT

 

 

4th rotary axis (optional)

With its dedicated rotary axis, the MDX-40A performs automatic two-sided and four-sided machining. Once one side is completed, the part is automatically rotated until all four faces are finished. This feature reduces errors associated with manual handling and provides significant time savings in addition to all-round machining. With the fourth axis ZCL-40A, the working area increases significantly and allows four times the overall volume of the previous series, with a maximum weight on the axis of 1kg. This makes it possible to work on material with a diameter of 120 mm and a length of 270 mm, such as, for example, the prototype of a 500 ml plastic bottle. 

KNIFE TO REMOVE THE PCB AFTER THE CUT

 

 

SRP technique for modelling with MDX-40A

The SRP technique, a feature of all Roland modelling machines, has several advantages over additive synthesis. SRP technology is much more competitively priced and allows the use of different types of modelling material, with high precision on axis movement and better quality of finish and detail.

KNIFE TO REMOVE THE PCB AFTER THE CUT

 

 

Versatility

The Roland MDX-40A can machine a wide range of materials such as ABS, waxes, resins, chemical wood, acrylics, PVC, POM, wood, etc. This allows designers to create functional prototypes for application and working tests with significant time and cost savings. In fact, the prototypes can be tested and tried out before the final product is manufactured to assess their quality and functionality. The working area is 305 x 305 x 105 mm (without 4th axis installed). 

 

 

Precision and accuracy

The MDX-40A is equipped with a high-precision spindle with a clear reduction of vibrations and a consequently high quality of part manufacturing. The mechanical working resolution is 0.002 mm/step, allowing accurate part production. The spindle mounts standard ISO15448 collets and the resulting finishes require no further machining. The spindle motor has a power of 100 W and a variable speed of 4500 to 15000 rpm.

 

 

MDX-40A: Surface scanning

Thanks to the ZSC-1 scanning probe, it is possible to transform the MDX-40A into a three-dimensional contact scanner with centesimal resolution. All this is driven directly by the software supplied with the probe, Dr.Picza3 and 3D Editor, which allow you to act on the scanned surface. The manageable scanning area is 305 x 305 x 60 mm and the scanning resolution is 10 microns.
 The scanning quality is really good, with smooth and very detailed surfaces. The scanning phases proceed automatically and therefore operations take place without the need for an operator. Installation of the scanning probe is quick and easy. The workpiece can be stopped using the wax provided. Surface detection is carried out on all three axes X, Y and Z. The resulting files can be commonly exported to the most common formats for 3D CAD and computer graphics software.

KNIFE TO REMOVE THE PCB AFTER THE CUT

 

 

For every working environment

Thanks to its compact design, the MDX-40A can be easily placed in a wide range of environments, from design studios to technical offices as well as production workshops. The MDX-40A is equipped with an emergency stop switch and a safety cover that makes the worktable inaccessible during milling and prevents machining waste from escaping from the machine.

 

 

Software Included

Roland shapers come with a software suite that allows the operator to start working immediately without any additional software.

 

 

 

 

 

 

 

 

Group Assignment

We mainly use our loyal Roland MDX-40 in order to mill circuit boards. We also generally use FabModules to generate CAMs.

Our design rules are generally the following:

 

 

Task list