WEEK 4 - ELECTRONICS PRODUCTION

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In the Apollo Moon missions, the Saturn V rocket was guided by an advanced onboard computer system built by IBM. This system was built from hybrid modules, similar to integrated circuits but containing individual components
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A circuit board from the Saturn V LVDA. MORE DETAILS HERE

aSSIgnment

group assignment: clcik here

  • CHARACTERISE the design rules for your in-house PCB production process
  • send a PCB out to a board house
    individual assignment:
  • make and test a microcontroller development board

Group assignment

You can find our group page here and this week group ASSIGNMENT here.we tested our milling machine with a 1/64 in and 1/100 in flat end mill with good results.

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GLIMPSE OF OUR GROUP WORK

about pcb milling

HERE WE USE ROLAND ROLAND MODELLA MDX-20 WHICH IS A 3D Milling Machine FOR MULTI PURPOSES.

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PARTS AND INTERFACE OF ROLAND MODELLA MDX-20 (FROM USER MANUAL)

Before initiating the milling process, it's essential to FAMILIARISE ourselves with bed leveling and cutting bits. The machine primarily employs two types of drill bits: a 0.4 mm (1/64") trace cutting bit and a 0.8 mm (1/32") PCB cutting bit.

basically there are 2 types cutting types climb and CONVENTIONAL. we use climb bits in our fab lab

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from wayken website

there are different types of fiber epoxy like fr1, fr2, fr3 ,fr4 etc which are composed of:-

FR1 – Basic phenolic resin with paper substrate
FR2 – Cotton paper phenolic
FR3 – Synthetic fiber epoxy
FR4 – Woven glass epoxy
FR5 – High Tg woven glass epoxy

you can find more details here.

MAKING THE Quentorres

QUENTORRES IS A combination of a programmer to rule them all and a hello board to learn to program, created by Quentin Bolsée and redesigned by Adrián Torres.

i downloaded the design of traces which is in png format .
quentorres_interior.jpg, quentorres_drills.jpg, and quentorres_traces.jpg

added some customisation to the traces using gimp

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preparing

we stick the pcb board on bed using double sided tape. TRANSFER the tape on boar and paste it on the work plate of the machine

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now we have to allign the carriage towards THE orgin and install bit

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loose the screw on one side using allen key. and drop the carriage.when i arrive at optimal depth, set the bit touch the board

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now we have to use FABMODS.pcb cut program to set the desired origin. and start uploading your design file PREFERABLY png for pcb milling.

put pcb defaults into 1/64 mill trace mode and pressed calculate .i reviewed the path of traces and finds everything good
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MILLING SPECIFICATIONS

SPEED :-4 MM/S

it started milling the traces .it came good initially but the traces where not milling properly on right upper edges.

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saheen helpED me to sort this situation without redoing it from start by reverse milling and DROPPING the bit more.

yes it worked out and traces came good

SUBSEQUENTLY i uploaded designs of drills and outer cut and proceeded(🚫 do not forget to change the bit to 1/32 for drilling and cutting operations)

setting for each step

  • milling ->mill traces (1/64)
  • drill ->mill outline (1/32)
  • interior->mill outline (1/32)

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while operating this ROLAND MODELLA MDX-20 if something bad happens we need to press "view" button home the carriage and after we need to press both up and down button to clear the job queue
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how to clear queue

soldering

then i sourced the COMPONENTS from our inventory and headed to soldering station

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i had experience of SOLDERING through hole COMPONENTS before but smd COMPONENTS are first time.

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SOLDERING WORKBENCH

i first soldered the xiao rp 2040 ON TO THE PCB.WHAT WE NEED TO TAKE CARE ATMOST IS BOTH SURFACES ARE ADEQUATELY HEATED BEFORE APPLYING SOLDERING WIRE.

*learn soldering basics*

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i used both conventional adn reflow to solder remaining components. tinning the pins properly is something we have to take care in this stage.

.

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board is ready

soldering settings

temperature:- 350°C

installing ide & blinking the leds

arduino ide is already installed in computer. i setup the board and rp 2040 library by following
QUENTORRES documentation.assigned proper port for our baord.

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now its time see our board alive!!!
for that we have to understand each gpio of rp 2040.
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i prompted this code in chat gpt to get the code

Write code to blink LEDs connected to GPIO pins 26, 0, and 1 in Arduino.

// Define the pins for the LEDs

const int ledPins[] = {26, 0, 1}; // GPIO pins 26, 0, and 1

  

// the setup function runs once when you press reset or power the board

void setup() {

// initialize digital pins as outputs

for (int i = 0; i < sizeof(ledPins) / sizeof(ledPins[0]); i++) {

pinMode(ledPins[i], OUTPUT);

}

}

  

// the loop function runs over and over again forever

void loop() {

// Turn on each LED one after another

for (int i = 0; i < sizeof(ledPins) / sizeof(ledPins[0]); i++) {

digitalWrite(ledPins[i], HIGH); // turn the LED on

delay(100); // wait for a second

digitalWrite(ledPins[i], LOW); // turn the LED off

delay(100); // wait for a second

}

}

code to blink all 3 leds -from chat gpt 3.5

upload the code pressing compile and upload button in arduino ide

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the result

ALTERNATIVE PROCESS

I AM PLANNING TO MAKE HELLO D11 by engraving in laser.all the files are present int he repo of the baord.

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minimise wastage

UNFORTUNATELY OUR LABS LASERS CUTTING IS NOT WORKING PROPERLY. I NEED TO DO the edge cut in milling machine.

(tell about trotec speed 400 here...)

i made the files ready by inverting the traces adn putting the edge cut around it in other color. i put red.so that i can allign the baord when using laser.

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i headed to the laser machine for engraving. i took a CARDBOARD adn cut the red part in it adn placed the pcb on it.

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then i started engraving

settings

power:- 100
speed:-30
passes:-5

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settings for the cut

you can assign different setting for each COLOUR.

i did 3 try for engraving

1st try

due to focus issue some right edge part didit came well

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we sorted the issue by LEVELLING the CARDBOARD reference base adn ADJUSTING the focus again

2nd try

in this try some traces we gone and and some traces came like pixelated.?!!
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3rd try

this time i changed the setting a bit and put a another fresh pcb peice.

settings

power:- 90
speed:-30
passes:-8

after 3rd try the traces did not isolated wll which made the board useless. jogin ADVISED giving some more passes in vertical direction may solve the issue.