PROJECT REPORT : DIPLOMA : SEM 1 : 2011-12

PROJECT REPORT : DIPLOMA : SEM 2 : 2012-13April 15, 2013

Chapter 1: INRODUCTIONChapter 2: BLOCK SCHEMATICS

2.1 POWER SUPPLY: +12 V

SHAPE \* MERGEFORMAT

Chapter 3: CIRCUIT DIAGRAMS & EXPLANATIONS

3.1 POWER SUPPLY - +12V

1. 3 figure

Main circuit 3.2 figure3.2 MAIN HARDWARE CIRCUIT

Figure 3.3 Main hardware circuit3.3 MAIN CIRCUIT

3.4 POWER SUPPLY SECTION

Figure 3.4 Power supply circuitChapter 4: Electrical Components

S. NoComponentsSpecification/valueQty

1.Resistors

2.Capacitors

4.Transistor

5.Diodes

7.Voltage Regulator

9.

10.TRANSFORMER

11.IC

12.

13.

14.

15.Load

Chapter 5: PCB MAKING

Fig 5.2 CNC machine

Fig 5.3 Position A : Lever in normal position, chuck closed. The motor is connected to the spindle via the coupling ( Fig 1.4). Position B: To open the chuck, press the lever down. This separates the motor with the coupling and opens the chuck over a spring assembly. In this position, the tool can be removed or inserted with the aid of tweezers (only in tool change position!!). Note: The lever always moves back to position A when it is not

pressed down!

5.4 Fig

During the milling of isolation channels on the PCB materials it is of special importance that the milling depth is kept constant. The LPKF ProtoMat S42 achieves this by means of the mechanical scanning using the working depth limiter. Introduction to board master This following chapters provide basic information on the operating principles and a first impression of Board Master to familiarize you with the user surfaceNote: As a beginner, always read the following chapter carefully before starting to work with Board Master in combination with your circuit board plotter. Chapter 8 then presents a practical introduction into the basic methods of operation and chapter 9 describes the basic functions of the ProtoMat.1. HOME position and Reference Hole System

Reference point programmed in the software

It must be located on the reflection axis of the machine for production of double-sided PCB

Reference point for the milling and drilling data

1. Home Position

2. Reference pin groove

3. Additional reference hole, rear position

2. Switching On the Circuit Board Plotter

Danger!!! Never reach into the machine during switching on

Switch on SequenceA. Switch on the computer

B. Then switch on the circuit board plotter Protomat S42

Note: When the machine is switch on, the machining head starts to move immediately to approach the limit switches in X and Y position. Then it stops in the zero position.C. Then start the Board Master.

3. Starting the Board Master

Click once on the entry BOARDMASTER 5.0 in the program group LPKF LASER & ELECTRONICS in the START menu or double click the BOARDMASTER 5.0 icon on your desktop.Note: During start-up the following image appears before the main menu or the wizard (input assistance) is displayed:After starting LPKF Board Master, the following prompt appears if the plotter was not switched on previously:4. Wait Message

As long as BoardMaster is waiting for a reply from the circuit boardplotter (i.e. circuit board plotter is in motion), a box with a corresponding

message is displayed:

The box disappears as soon as the head has arrived at the tool change position!

Always wait this long and do not click the Stop button!!This message is also output when the machine is still busy editing the last command from the command buffer. This is not an error message! It is possible to change to other applications while the box is displayed. As soon as the plotter sends the requested reply to the PC, the box disappears and the program is continued normally.After clicking the Stop button, an (additional) error message appears:

Message: Do you really want to cancel the current process?

Yes

NoNote: If you really want to cancel the current process, it is discontinued only after clicking the YES button a number of times. The communication between computer and circuit board plotter is then interrupted.5. Switching of The Circuit Board Plotter

When switching OFF the circuit board plotter, first quit Board Master before switching OFF the machine. In the opposite sequence, recurring error messages are possible, which can be cancelled only by repeatedly actuating the YES button.(Error message: Do you really want to cancel the current process...)Before Board Master is actually switched OFF, a menu is displayed asking where the machining head is to be displaced to:

Click on Ja to make the machine head go to the reference point ( i.e. zero position).

Click on YES, if possible, as the machining head is then located at the reference point during the new start. After clicking on NO the machine must perform a time-consuming new approach of the reference positions during a new start.6. Board Master User Interface

1-Title bar , 2-Menu bar, 3-Function bar, 4-Working area5-Blue cross hairs represent the current position of the mill/drill head

1. Interface

This display provides information on the interface set for transferring the control data. Here NULL means that the data is not sent to an interface. When the mouse is moved over this display field, the values set for the interface are indicated in the status bar.2 Actual position of milling drilling head

This display shows the actual position in all 3 axis.

3. Number of vectorsThe number of vectors which have already been processed is displayed (here vector means section of line, causing movement in X, Y, or Z direction).

4. Estimated Processing TimeFor current production phase the display indicates the estimated time in hours or minutes required for processing the enabled production phases. Individual selections are not taken into consideration here.5. Working with Production Data and Phases

A. Importing Production Data

You can import LMD production data prepared by CircuitCAMB. Assigning Tools

Assigning tools is usually done by Board Master.C. Placing Production Data

The data are automatically placed at the middle of the working area. But it is possible to change the position by clicking this button D. Saving a Job

Before starting the machining process, the milling depth has to be manually adjusted. The milling depth can be adjusted by turning the knurled nut on the working depth limiter. When the wheel is turned clockwise, the milling depth is increased; turning counterclockwise reduces the milling depth.

5.5 figure Turning the knurled nut by one increment changes the milling depth by approximately to 4 m and turning the knurled nut one complete rotation changes the milling depth by approx. 0.5 mm.

Note

Milling depth can be set in steps of 2mMilling width of the Universal Cutter can be set in steps of 4 m and the width of the Micro Cutter in steps of 2.3 m6. Steps for Single Sided PCB Fabrication

A. Marking Drills

B. Drilling Plated

C. Milling Button

D. Cutting Outside7. Selecting first production Phase

Each production phase, like milling the solder side (Milling Bottom) must be selected individually and prepared for processing (inserting the correct tool and so on). Now start with the first production phase: First check whether in the function bar in the list field PRODUCTION STEP the production phase MARKING DRILLS is selected.

Select for marking all data

Click on the button in the function bar to send the marked data of

the current production phase to the circuit board plotter.

Before the production phase is processed, a demand is displayed to insert the corresponding tool. Insert the corresponding tool After the marking drills you will see this message. Just click OK to end. Then proceed to the next phase. Doing the same step.

After doing all the phases, Click the button to moved the drill head in pause position to remove the PCB. Chapter 6: Mechanical workThe steps of working in mechanical workshop:1. Choose the suitable sheet for our project box (steel sheet because its strong and easy to bend and file) and cut it by using sharing machine. We cut two pieces of steel (414) mm X (340) mm and (410) mm X (180) mm.We cut this size of piece to be able to handle the circuit

Fig 6.1 Fig 6.22. By using the Venire height gauge and ruler with scriber the lines has been marked in the sheet and we follow the lines to cut. Marking out the dimensions on the sheet.3. After that, the holes were making in the sheet for each of fuse, power supply and 1M preset, Using hammer with center punch to mark or to point the place of the holes and using drilling machine. Fig 6.3 4. We Use flat file to make the sides of the sheet smoother and also we use it for the holes. 5. We take the dimension for the front sid and for the BACK side. After that we use drilling machine to make .Then we use hammer with flat chisel to remove unwanted pieces.6. We use bending machine in bend the base sheet which include back and front view and we bend the cover which include the side of the box. 7. Paint the Box and finalizing the mechanical fabrication.Chapter 7: SYSTEM ANALYSIS AND DESIGNIn general THE PROJECT LIFE CYCLE involves 4 phases:

1. STUDY PHASE

2. DESIGN PHASE

3. DEVELOPMENT PHASE

4. OPERATION PHASE

IN OUR PROJECT: the project life cycle was executed as follows

1. STUDY PHASE

(i) Initial Investigation:

An electrical power circuit controlled by electronic circuit based project containing hardware was necessary to be initiated; since it was a curriculum requirement for us being Diploma students at Colleges of Technology.

(ii) Feasibility analysis:

We selected a project named Timer enhanced on/off single phase load that also included discrete components and Integrated circuits. Since we have studied about active and passive components and about integrated circuit in our previous courses. 2. DESIGN PHASE:

The circuit details were surfed from the internet; and the circuit design was discussed with our supervisor. The availability of the components were checked and on confirmation; the project development was initiated.

3. DEVELOPMENT PHASE:

The power supply sections were built on the bread board to supply 9v for our main circuit. Next the MAIN POWER CIRCUIT was built on the bread board and tested by using lamp as load.4. OPERATION PHASE:

The system is put to operational and tested after the components are soldered in the PCB and then suitable container is used to enclose our project to make good view

Chapter 8: CONCLUSIONREFERENCES

PHOTOS FROM WORKING APPENDICESTools Used

Soldering of Iron(1

2) Reel of solder:

The best size for electronics is 22swg (swg = standard wire gauge).

3) Side cutters:

For trimming component leads close to the circuit board.

4) Small flat-blade screwdriver

For scraping away excess flux and dirt between tracks, as well as driving screws!

Steel rule

It is used to measure the dimensions.

ScribersScribers are hand tools used in the metal trades to mark lines on work pieces, prior to machining. This is used instead of pencils as the marks from pencils cannot be seen clearly as Scriber marks. They consist simply of a rod of high-carbon steel, in its hardened state, that has been sharpened to a point at one or both ends. They are used by drawing the point over the surface of the work piece to leave a shallow scratch on its surface scribers. Center punchesA center punch is typically used as an aid to drilling operations; a drill, when brought into contact with a flat surface, will have a tendency to wander on the surface until it gains sufficient purchase to start cutting a hole. A center punch forms a small dimple in which the tip of the drill (if it is small enough) will fit. When drilling

larger holes and the web of the drill is wider than the indentation produced by a center punch, the drilling of a pilot hole is usually needed. A center punch usually has a tip, that when viewed on a profile, has sides at a 90 degree angle to one another. Used with a hammer to produce a small angled indentation on the work surface. This indentation can be used as appoint location for dividers or trammels. FilesA file (or hand-file) is a hand tool used to shape material by abrasion. A file typically takes the form of a hardened steel bar, mostly covered with a series of sharp, parallel ridges or teeth. Most files have a narrow, pointed tang at one end to which a handle can be fitted. The rasp is a related tool which is generally larger and has raised, pointed teeth on its surface rather than straight ridges. There are many types of files. It is specification by length, type, cut and grade. The cut of files refer to the direction in which the teeth are formed. The way in which a file used to remove metal depends on the operating being carried out. Vernier measuring instruments

Vernier measuring instruments are designed for making accurate measurements to two hundreds of millimeter (0.02mm). In practice, however, you would find this accuracy extremely difficult to obtain as it requires considerable skill, good eyesight and a sensitive touch or feel. Under normal working conditions, an racy of between two hundredths of a millimeter above or below the dimension is more realistic. Flat chisels It used to cut flat face where there is too much material to file, and too little to hacksaw. Another application is cutting sheet metal.

Hacksaws

These tools are used to remove length of waste metal where it is impractical to remove the amount by a file or chisel. Hacksaw blades can vary in their length, tooth pitch, and the material from which they manufactured the applications for different blade material and pitch. To prevent a hacksaw blade from binding in a slot being cut, asset is applied to the teeth. Blades are having a coarse pitch. Drill bitsDrill bits are cutting tools used to create cylindrical holes. Bits are held in a tool called a drill, which rotates them and provides axial force to create the hole. This article describes the types of drill bits in terms of the design of the cutter. The other end of the drill bit, the shank, is described in the drill bit shank article. Drill bits come in standard sizes, described in the drill bit sizes article. Machines

Electrical Shearing MachineIt used to cut sheet metal working like aluminum sheet. The maximum of thick is 2mm.It is working by three phase electrical power.

Drilling machine

Sensitive drilling machines are so called because they are of fairly light and simple constriction, which enables the operator to feel the pre-sure on the drill as it cuts

through the work. This type of drilling machine is capable of very high spindle

speeds, and generally is capable of drilling holes up to 12 mm diameter. Bending or folding machine These are generally used for bending sheet metal at right angles although other angles can be obtained. Many bend using a cylindrical mallet. A simple folding machine is shown in figure. Basically, it consists of a number of steel clamps which hold the

sheet metal firmly in a horizontal position.

Ujt relaxation Oscillator

Transformer

Rectifier

Smoothing

Regulator

Regulated

+12V DC

Lamp load

AC voltage controller

Pulse transformer

2.2 Main Circuit

230

AC

mains

Figure 2.2 main circuit

Figure 2.1 power supply

ENGINEERING DEPARTMENT:NIZWA COLLEGE OF TECHNOLOGY1