transcript
- Slide 1
- P14311: PCB Isolation Routing System Systems Design Review
- Slide 2
- Agenda ItemTime Allotted Introduction 2 minutes Review Problem
Definition 5 minutes Benchmarking 5 minutes Functional
Decomposition 5 minutes Concept Development 10 minutes Engineering
Analysis10 minutes Test Plans 3 minutes Risk Analysis 5 minutes
Schedule Update 3 minutes Questions?12 minutes
- Slide 3
- Team Introductions NameMajorRole Matthew ClarkMELead Mechanical
Engineer Marley Collier Sears MEME Interface Manager Sarah
DumanIEProject Manager Richard KalbEELead Electrical Engineer
Joseph PostEEEmbedded Controls Zoe RabinowitzMEDocumentation
Manager Kevin RichardEEEE Interface Manager Our Senior Design
Team
- Slide 4
- Problem Statement RIT students need rapid prototyping for
creation of unique circuit boards Requires multiple revisions to
perfect each circuit board Currently each iteration must be created
off campus Long lead times Expensive Limits circuit refinement
Students not involved in process
- Slide 5
- Problem Statement (Continued) Isolation Routing System Rapid
prototyping Inexpensive In-house fabrication Students control
production process Proposed System Create boards to accommodate
through hole components Ex. Improved Radiation Meter (Elektor PN
110538-71) Debris management system
- Slide 6
- Benchmarking- Scott Systems Isolation Router Able to produce
double-sided Board Smallest bits used -.016 Minimum width between
traces - 5mm Stepper control for Z-axis Stepper control for X-Y
movement Alignment pins and double sided tape used to secure board
Sacrificial plastic layer Uses an air gun to blow dust out during
the drilling PVC with shop-vac sucks up debris Data Flow Eagle
design file G-code Flashcut CNC Motors
- Slide 7
- Benchmarking- Scott Systems Isolation Router
- Slide 8
- Pros, Cons, Potential Improvements Pros: Can etch double-sided
boards Easy to switch bits 5mm minimum trace width Cons: System
lacks real time feedback sensors X,Y, and Z, axis alignment is done
manually. Improvements Improve debris management Replace or repair
Z-axis motor Enclose system
- Slide 9
- Benchmarking- RIT Robotics Lab Milling set-up is not used
regularly because its a pain Zeroing the plane is highly mechanical
Smallest tolerance is 10 mil Floor of the mill is warped Difficult
to change drill bits Interface software include expensive Isopro
Manual debris management Utilizes two alignment pins Board is
secured down with tape
- Slide 10
- Pros, Cons, Potential Improvements Pros: Relatively Inexpensive
Cons: Difficult to swap bits Poor board alignment process Z-axis
solenoid Improvements Debris management system Z-axis zeroing
- Slide 11
- Customer Requirements
- Slide 12
- Most Critical Customer Requirements
- Slide 13
- Engineering Requirements
- Slide 14
- Most Critical Engineering Requirements
- Slide 15
- Functional Decomposition
- Slide 16
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Process Flow Chart Turn on Device / Computer Open Design File
Align / Secure Bare Board on Base Run Program Program Prompts For
Drill Bit Change Program Pauses / Swap Drill Bit Program Prompts
for Mill Bit Change Program Pauses / Swap Mill Bit Program Alerts
User it has Finished Flip Board Remove Completed Etched Board Is
There Another Side to Etch? YES No
- Slide 21
- P14311 Morphological Analysis
- Slide 22
- Slide 23
- Pugh Analysis
- Slide 24
- Slide 25
- Slide 26
- Concept #1 X-Y axis Control of Spindle Assembly Spindle
Assembly Vacuum Nest with Alignment Pins Upper and Lower Acrylic
Guards Z axis Control of Base Cyclone Separator Electronic Waste
Collection + Combination nozzle/vacuum with cyclone separator
effectively manages debris + Straight forward design easy to
understand + Vacuum nest and alignment pins ensure accuracy and
repeatability Pressurized Air Nozzle - Minimal guards allow access
to moving parts during operation - Difficult to relocate, much
larger than Ryans and Robs systems - Large weight of gantry limits
maximum accuracy - Redundant systems increase complexity
- Slide 27
- Concept #2 + Collet for holding tooling + Suction debris
removal + Alignment Template system - DC motors with encoders for
X,Y,Z - Horizontal Vice for mounting
- Slide 28
- Concept #3
- Slide 29
- Concept #4
- Slide 30
- Concept #5
- Slide 31
- Concept #6 + X- and Y-axis control using steppers and lead
screws, which offers great resolution + Fully enclosed unit
provides a much safer operating environment + Interlock would
safely disconnect power in case of emergency/unit malfunction +
Unit is overall very easy to use (assuming board is aligned) -
Incineration not a feasible method of debris management - Rack and
pinion Z-axis movement control would cause unnecessary backlash -
Board alignment not very easily performed with electromagnets
- Slide 32
- Concept #7
- Slide 33
- Hybrid Design
- Slide 34
- Pugh Total Scores Scott Systems Robotics Lab Concept 1 Concept
2 Concept 3 Concept 4 Concept 5 Concept 6 Concept 7 Hybrid Design
Total +0234443434 Total S0332014225 Total -0544653451 Total
Score0-30-200-23 Total Rank21062862281
- Slide 35
- Hybrid Solution- Selected Concept Stepper Motor with Lead Screw
for Y Axis Control Stepper Motor with Lead Screw for X Axis Control
Stepper Motor with Lead Screw for Z Axis Control Vacuum Clamping w/
Replaceable Sacrificial Layer Guide Rails Vacuum Attachment
Pressurized Air Nozzle Spindle Motor and Collet Assembly Vacuum
Clamp Sourced From Main Vacuum X and Z Axis Wire Management Debris
Management Vacuum Assembly
- Slide 36
- Emergency Kill Switch Door Interlock Acrylic Door Assembly To
Spindle VFD and X, Y, and Z Axis Stepper Motor Control To Vacuum
Assembly with HEPA Filter To Pressurized Air Source Metal Casing
Door Handle Hybrid Solution- Selected Concept
- Slide 37
- System Block Diagram Motor X Motor Controller Computer Design
file G-code Motor Z Motor Y USB, serial, Ethernet, etc GUI Power
Source Main Logic Board USB, serial, Ethernet, etc Debris
Management System Interlock Power conditioning Motor Theta
- Slide 38
- A system that creates negative pressure to hold down work
pieces during machining Will allow for easy set up by user Work
pieces will be held down after being cut Collect debris being cut
from board. Engineering Analysis Vacuum Table
- Slide 39
- Slide 40
- Engineering Analysis Spindle vs Router Commercial Routers High
Speed (~25,000+ RPM) but with manual control Large run out, not
published as they are typically hobbyist and woodworking Run
directly from 120 VAC line power Heat problem, not designed to be
run continuously Low average cost (Free - $200) Brand specific
collets Loud
- Slide 41
- Low to Medium Speeds (usually 400 to 24,000 RPM) Extremely low
run out (typically less than 0.005mm/0.0002) Need an inverter
(capable of producing 0-400Hz @240VAC) Air or Water cooled options
available Higher average cost ($100 - $700) Standardized collet
sizes (ER11, ER20, R8, 3MT, etc.) Quiet Spindle Motors Engineering
Analysis Spindle vs Router
- Slide 42
- Higher cost of spindle motor justified by advantages Inverter
vs. speed control, ~ equal complexity (VFD) More professional look
and results from spindle Justifies laser centering upgrade in the
future Engineering Analysis Spindle vs Router
- Slide 43
- Engineering Analysis- Direct Material Cost Estimate
- Slide 44
- Slide 45
- Future Engineering Analysis Weight analysis Can the Z motor
handle the weight of spindle? Vacuum Analysis- Can one shop vacuum
both collect debris and secure board? Does the vacuum have enough
suction to keep the board secure while milling the outline?
- Slide 46
- Potential Test Plans PCB Trace Accuracy Analysis Attach pen to
Gantry to draw board on paper Test movement of carriage Check
condition power
- Slide 47
- Risk Analysis
- Slide 48
- Slide 49
- Slide 50
- Project Schedule Update
- Slide 51
- Problem Definition Systems Design Subsystems Design Detailed
Design MSD I Gate Review
- Slide 52
- Project Schedule Update Problem Definition Systems Design
Subsystems Design Detailed Design MSD I Gate Review
- Slide 53
- Subsystems Schedule
- Slide 54
- Questions?