Post on 18-Jan-2016
P15311: Circuit Board Router (Rev2) Gate Review
Team Members and Roles
Devon Monaco (ME)◦ Project Manager
Emily Roberts-Sovie (IE)◦ Safety, Statistics, and Documentation Manager
Joseph Lee (ME)◦ Lead Mechanical Engineer, Facilitator
Thomas Bizon (EE)◦ Lead Electrical Engineer
Nathan Faulknor (EE)◦ Systems Integration
Yevgeniy Parfilko (ME)◦ ME Interface Engineer
Kenny Ung (EE)◦ Electrical Design Engineer
Agenda PIZZA
MSD I Project Goals Recap◦ Review problem statement and
deliverables◦ Review stakeholders and use scenarios◦ Finalized List of Needs and Engineering
Requirements◦ Review Functional Decomposition and
System Level Proposal◦ Review Proposed Subsystems
Breakdown
Discussion of Accomplishments and Achievements
Discussion of Unanticipated Problems and Issues
Material Updates
Open Design Items
Budget Update
Updated Risks Assessment
Overall Plan vs Current State of Project
Discussion of Lessons Learned
Team Self Critique
Suggested Improvements for MSD I Experience
Quick Start Plan for Return Next Semester
Preliminary MSD II Schedule
Trip to Lab for System Demos
Inherited State of Router, P14311 (Rev1)
Trial Mach3 software for converting Eagle PCB layouts to milling tool path with router
Vacuum table clamp and vacuum/brush debris collection as single subsystem
Manual homing and datum zeroing with computer jog keys
7”x7” max board size
PC, vacuum, and Bosch router enclosed in single roller unit
Monitor and keyboard on separate table
Problem Statement Printed Circuit Boards (PCBs) are expensive to produce.
MSD team P14311 developed a PCB Isolation Router that functioned but needed performance improvements.
Several features are needed for open use to students:◦ Easy tool setup and automatic homing◦ Safe debris collection system ◦ Improved board security and overall trace routing◦ User-friendly controls and operating procedures◦ Low noise level during operation
Refined router must operate predictably and precisely for corporate clients.
Project Deliverables Analyze the design of the current router and identify all improvement areas.
Modify the design to improve operator controls, setup automation, debris and noise management.
Define and document clear procedures from use scenarios and personal experience.
Compile a quick start guide, user manual, troubleshooting guide, maintenance schedule and replacement parts list.
Stakeholders Primary
◦ RIT Students◦ Inventors/tinkerers◦ Jeff Lonneville◦ CAST Electronics Lab
Secondary◦ Investors◦ MSD Team◦ RIT
Use Scenarios
Novice User
Outside Company
Experienced User
Use Scenarios Flow Chart
Prioritized List of Needs (1-3-9)Customer Rqmt. #
Importance Description Comments/Status
CR1 3 Capable of routing traces for finer pitched SMD's Tolerances currently too large
CR2 9Safe and easy to operate by minimally trained (<0.5 hour) user
Took several days to get machine operating
CR3 9Have quick start, service, and detailed troubleshooting/operation manuals
Improvements needed to documentation
CR4 3 Cost less than commercial systems on the marketFactor in lead time and process
costs
CR5 3Require minimal maintenance and part replacement Frequent drill bit breakage
CR6 9
No mechanical, electrical, environmental, or health related hazards to operators of those in the general lab area
Concerns with noise level and particulate matter
CR7 3 Alignment system capable of auto homingNeed for more precision and
repeatability
CR8 1 Automatic tool change and recognition Convenience feature
CR9 3 Visual feedback system for error detection Difficult to see traces through glass
CR10 9 Improve debris removal system Messy and dangerous for operation
CR111
Contain all components of system in one unit Detached monitor and keyboard
CR12 3 Rout PCB rapidly Long setup time
CR133 Ability to flip and zero reverse side of board
accuratelyNo flipping method or ability to re-
zero flipped board
Engineering Requirements
ER Importance Source Engr. Requirement (metric)
Unit of Measure
Marginal Value Ideal Value P14311
1 9 CR6 Noise Generation dBA <100 <65 Marginal pass
2 9 CR1 Minimum Width Between Traces Supported inches 0.020 0.016 marginal
pass
3 3 CR4 Manufacturing Cost $ 2800 2000 Fail
4 9 CR5 Unit Reliability (mean time between failures) TBD TBD TBD
5 9 CR5 Mean to time between maintenance hours 50 100
6 9 CR3, 7 Minimum Tolerance to locating positions on board inches 0.002 0.0005 Marginal
pass
7 3 CR5, 8 Bit Replacement Time minutes 2 <1
8 3 TBD Feed Rate in/minute 10 20 Marginal pass
9 3 CR2, 3 Time for initial machine set-up minutes 20 10
10 3 TBD Maximum Compatible Board Size inch x inch 5 x 5 8 x 8
11 3 TBD Minimum Compatible Board Size inch x inch 2 x 2 1 x 1
12 9 CR2, 11 Up to date PC & software for system control Binary No Yes Pass
13 9 CR2, 3, 5 Minimize Operator Training hours 1.5 .5 hours
14 9 CR1 Router Speed rpm 15000 30000 Marginal pass
15 9 C10 Debris Removal (Copper and Substrate) mg ratio 0.90 0.99
16 9 CR1 Total Indicated Runout inches <.0006 <0.0004 Marginal pass
17 9 CR7, 10 Vacuum Table Force lbs force 30 40 Marginal pass
18 9 CR6 Max Power Consumption for entire system watts 1920 1800
19 3 CR6 Aesthetic wiring and schematics Binary No Yes
Functional Decomposition
System Level Proposal New vacuum debris collection system
◦ Redesign vacuum inlet assembly◦ Include improved vacuum with more powerful motor and higher flow rate◦ Separate vacuum table and debris collection unit
Redesign vacuum table assembly◦ Include vacuum pump with high sealing pressure◦ Separate vacuum table and debris collection to eliminate interface losses◦ Make single standard size vacuum table top
Implement automatic homing◦ Eliminate need for user jogging to home position◦ Set permanent global zero in mach3 code◦ Include proximity sensors for home location verification◦ Improve limit switches for hard stop backup
System Level Proposal Maximize tool life and trace width capabilities
◦ Provide predetermined ideal drill bits and sizes◦ Enable spindle speed and feed rate selection for tool optimization
Improved user experience◦ Quick start guides◦ Troubleshooting documentation◦ Visual feedback◦ Intuitive user interface◦ System contained in single unit◦ Dampen noise generated by system
Subsystems Breakdown
Subsystems Breakdown
Subsystems Breakdown
Accomplishments and Achievements
Conceptualize◦ Develop problem statement◦ Perform customer and student
interviews◦ Compile use scenarios◦ Perform benchmarking◦ Produce customer requirements◦ Develop engineering requirements◦ Produce functional decomposition chart◦ Create morphological chart◦ Compile Pugh analyses (debris collection,
securing board, auto homing)◦ Create subsystems breakdown chart◦ Produce user process flow diagram
Manage◦ Create project schedule◦ Update weekly tasks◦ Create 1 page project summary◦ Compose project priorities vs time
poster◦ Perform locker inventory◦ Produce running budget sheet◦ Compose and update risks
assessment for project, team, and subsystems
◦ Compile purchased parts drawings◦ Create and populate Bill of Materials◦ Track meeting minutes
Accomplishments and Achievements
Analyze and Validate◦ Download new Mach3 and make
machine operational◦ Create bit use and failure spreadsheet◦ Create machine issues and
troubleshooting spreadsheet◦ Meet with RIT safety◦ Edit Mach3 background code◦ Perform vacuum table calculations◦ Perform debris system flow loss
calculations◦ Perform drill bit tool life calculations◦ Hold discussion with Professor Wellin on
vacuum table monitoring
Design◦ Wiring and power schematics◦ Keyboard mounting system◦ Physical LED switch layout◦ Vacuum table top◦ Vacuum table sacrificial material◦ Debris inlet tube◦ Debris inlet tube mounting blocks◦ Flow reducer◦ Photomicrosensors and limit switches
layouts
Accomplishments and Achievements
Build◦ Implement new PC and 2nd monitor◦ Attach monitors and keyboard tray◦ Attach fan grate◦ Assemble vacuum table system◦ Assemble debris collection system◦ Construct auto homing circuit
Test◦ Compile test tracking sheet◦ Produce test plan document◦ Noise testing with decibel meter◦ Flow meter testing for debris system◦ Vacuum table holding force testing◦ Sensor repeatability testing◦ Auto homing code implementation
with sensors◦ Spindle runout testing◦ Spindle RPM testing
Unanticipated Problems Budget Negotiation
◦ Initial uncertainty in budget based on vague project readiness package◦ Conversed with MSD office and negotiated $2000 budget, which will likely be more than adequate
USB Issue◦ Error reported in communication between UC300 and Mach3 program◦ Numerous troubleshooting methods implemented, and more to try for MSD II
Vacuum Pump◦ Ordered vacuum pump early on based on price, specs, and want for testing◦ Ended up providing inadequate flow◦ Recovered thanks to early testing and further research into ordering another pump (arrives today)
Solidworks Versions◦ ME team had struggles with working between Solidworks 2014 and 2015 versions◦ Saving parts as .STEP files and making multiple copies for use by all
Stability of keyboard tray and monitor mounts stress◦ Keyboard tray was noticed to be flimsy◦ Additional steel support bracket added to tray and backing for stability
IO limitations on UC300◦ Mach3 doesn’t allow for free inputs/outputs (must be tied to functions)
Materials Progress Materials Ordered
◦ Photomicrosensors◦ Sensor connectors◦ Limit switches◦ Switch relays◦ Vacuum hose◦ Vacuum pressure switch◦ Vacuum pumps◦ Vacuum table material◦ Vacuum table gasket◦ Sacrificial material◦ Hose barbs (male, female, tee)◦ Plumber’s tape◦ Sealing washers
Overall Materials Ordered Progress: 74%
◦ Silicone rubber◦ Vacuum table tubing◦ Vacuum pressure gage◦ Borescope camera◦ LED pushbuttons (1 of 5)◦ Sound damping foam◦ Velcro◦ Monitor mounts◦ Spindle motor◦ Mach3 full license◦ New PC◦ Second monitor◦ Standard PCB boards◦ Drill bits
Materials Progress Materials Produced
◦ Vacuum table basin◦ Vacuum table top◦ Debris inlet tube◦ Keyboard tray◦ 3D printed vacuum flow reducer◦ Temporary spindle mount plate◦ 1st iteration photomicrosensor flag◦ Monitor bracket stabilizer◦ Fan grating◦ Sound damping material cut to size
Overall Materials Produced Progress: 47%
Open Design Items IO Board Redesign
◦ Difficulty: medium◦ Priority: high◦ Status: 25%
Photomicrosensor mounts◦ Difficulty: medium◦ Priority: medium◦ Status: In Progress (location dependent)
Photomicrosensor flags◦ Difficulty: low◦ Priority: medium◦ Status: 50%
Limit switch mounts◦ Difficulty: low◦ Priority: medium◦ Status: In progress
Physical Switch Box◦ Difficulty: low◦ Priority: medium◦ Status: 75% complete
Vacuum Pump Controls◦ Difficulty: low◦ Priority: medium◦ Status: 25% complete
Camera mount◦ Difficulty: low◦ Priority: low◦ Status: 75% complete
Final spindle mount plate◦ Difficulty: very low◦ Priority: low◦ Status: 75% complete
Budget Analysis
Proposed Purchases/BudgetItem Use/Description Supplier Worst Case Most Likely Case Actual (Team Spending) Spending Track
Alignment System Auto Homing with Precision Digi-Key, mouser $300.00 $200.00 $145.00 $145.00Wire Rewire to color code, and relocation Unknown $300.00 $250.00 $250.00
Mach 3 License Improve bugs with program, z-axis precision ArtSoft $200.00 $175.00 $175.00 $175.00
Drill Bits For testing, bit analysis, and selection Think & Tinker $200.00 $200.00 $100.00 $100.00
Misc Parts, Hardware, 3D Printing, Camera, Etc.
Unnaccounted for extra expenses, sacrificial material, hoses, etc. (to date)
McMaster, Digi-Key, Mouser, Amazon $200.00 $200.00 $175.00 $200.00
Vacuum Switch To monitor vacuum table pressure Dwyer $150.00 $75.00 $35.00 $35.00
Replacement Router/Spindle Bausch router has been discontinued Unknown $200.00 $100.00 $80.00 $80.00
PCB Boards For testing and machine familiarity DigiKey $100.00 $100.00 $95.00 $95.00Misc Labor Machining, etc. RIT/Other $100.00 $50.00 $50.00
Computer Monitor Dual Mount Make the machine one unit TaoTronics $100.00 $50.00 $55.00 $55.00
Wire Duct, Heat Shrink, Etc. Wire management Unknown $50.00 $35.00 $35.00
Vacuum Pump Hold PCB board onto table Parker, Medo (ebay) $75.00 $40.00 $130.00 $130.00
Sound Absorbing Material Reduce noise and impove working environment Unknown $75.00 $35.00 $100.00 $100.00
New Computer/Monitor Upgrade computer and provide for camera view RIT $0.00 $0.00 $0.00 $0.00
Total: $2,050.00 $1,510.00 $1,090.00 $1,450.00
Based on the budget projections below, the team is slated to not only be under budget, but to even be under the “most likely case” prediction
Updated Risks Assessment
The team’s risk assessment has been updated faithfully for the duration of the project and is very comprehensive
Current assessment breaks down into categories◦ Overall system◦ Controls◦ Vacuum systems◦ Operator error◦ Safety◦ Electrical◦ Team issues
Thus far, no major risks have been encountered◦ Mitigation techniques have been implemented◦ It is expected that there will be a higher chance of encountering risk items
during the build and test phases of MSD II
Overall Plan vs Current State
Phases 1-3 were finished with all work completed Phase 4 includes some lingering long term and running tasks to be
completed as the team progresses, as well as some low risk-low design tasks to finish
Phase 5 included a shift in team mentality from perfecting designs, drawings, and documentation to preliminary build and test initiatives
◦ Few low risk-low priority design tasks still open◦ Portions of added machining, assembly, and tests still in progress
Lessons Learned Testing is important for learning and understanding (test early and often)
Understanding the cost/benefit of implementing already existing fixes vs custom tailoring everything perfectly to your needs
Not paying special attention to the small details (interfaces, wiring, connectors, mounting locations, etc.) are usually what end up causing the problems, not necessarily the big or obvious things
Benchmarking to see what’s done in industry and already works/doesn’t work well is a valuable technique
“Paralysis by analysis”
Conductive paint is as unreliable as it sounds…….
Team Self Critique Strong test planning, risk assessment, feasibility analysis
Strong skillset, and good distribution of tasks based on expertise
Good assessment of important benchmarks, key analyses
Jumped ahead with testing and manufacturing of components
Some improvement needed in interface of mechanical and electrical systems
Persistent technical issues with USB data connection
Detailed communication, some difficulty in scheduling - Solved with functional teams
Limited communication with stakeholders - Solved by relying on student surveys
Difficulties maintaining integrated updated detailed design
Inheritance of CAD documents (some have version incompatibility)
Suggestions for MSD I Improvement
Post all lectures as PowerPoint slides as opposed to videos of someone talking through them
Splitting teams up at the beginning of the class is very inconvenient. If necessary, make the workshops for the second half of class and give teams discussion time first
Start workshops earlier in semester so there is more time to implement the learnings from them
Possibly make some kind of pre requisite course with information contained in workshops (specifically EE)
Give teams more encouragement in buying/testing critical components early to avoid overanalyzing in the beginning and finding issues in testing too late (“paralysis by analysis” advice from Vince Burolla)
Quick Start Plan for Return
Before we go◦ Ensure test plans are detailed◦ Look over BOM and check for parts already ordered and that need to be ordered
still◦ Check open design items and Overall Plan vs MSD I Progress documents for
individual and team responsibilities upon returning◦ Post preliminary MSD II schedule in project management folder◦ Create weekly tasks tab for week of return◦ Plan for rewiring (connectors, wires, IO board)
When we return◦ Re-run some high level testing (run mach3, re-test subsystems) for familiarity and
sanity checks◦ Electrical/mechanical teams meet to get on same page regarding priority of work
to be done◦ Check Open Design Items and Overall Plan vs MSD I Progress documents for
individual and team responsibilities
Preliminary MSD II Schedule
General Discussion and Trip to Lab
Demonstrations◦ Vacuum Table◦ Debris Collection◦ Auto Homing◦ Limit Switches◦ Spindle Motor