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