P15311: Isolation Printed Circuit Board

Router (Rev2)

Team Members and Roles

Devon Monaco (ME)◦ Project Manager

Joseph Lee (ME)◦ Lead Mechanical Engineer, Facilitator

Thomas Bizon (EE)◦ Lead Electrical Engineer

Emily Roberts-Sovie (IE)◦ Safety, Statistics, and Documentation Manager

Nathan Faulknor (EE)◦ Systems Integration

Yevgeniy Parfilko (ME)◦ ME Interface Engineer

Kenny Ung (EE)◦ Electrical Design Engineer

Agenda Project Background

Problem Statement & Project Deliverables

Stakeholders

Use Scenarios

Prioritized List of Needs

Engineering Requirements

Benchmarking

Risk Analysis

Draft Project Schedule

WBS

Current State of Router, P14311 (Rev1)

Trial Mach3 software for converting Eagle PCB layouts for milling with router

Vacuum table clamp

Vacuum/brush debris collection

Manual homing and zero datum

7”x7” max board size

PC, vacuum, and 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:◦ Automated tool setup and homing◦ Safe debris collection system ◦ 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

Prioritized List of Needs (1-3-9)Customer Rqmt. #

Importance Description Comments/Status

CR1 3Capable 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 3Cost less than commercial systems on the market Factor 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

Engineering Requirements

ER Importance Source Engr. Requirement (metric)

Unit of Measure

Marginal Value Ideal Value P14311

1 9 CR6 Noise Generation dBA <100 <75 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 0.005 0.001 Marginal

pass

7 3 CR5, 8 Tool Replacement Time minutes 2 <= 1

8 3 TBD Feed Rate in/minute 10 100 Marginal pass

9 3 CR2, 3 Time for initial machine set-up minutes 60 30

10 3 TBD Maximum Compatible Board Size inch x inch 5 x 5 8.5 to 11

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 TBD TBD

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 11.7 1.7 Marginal

pass

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 % 25% 100%

Current Methods of PCB Routing

Criteria Chemical Etching

Commercial MITS Auto Lab

LaserJet PCB Printing

P14311 PCB Router

Max. Workable Area (in)

Most Sizes 9 x 11.8 8 x 10 7 x 7

Minimum Trace Spacing (mm)

x ≥ 0.1 x ≥ 0.1 x ≥ 0.17 0.51 < x < 0.41

Material Depth Removal

(precision)

Varies on process

0.2 mm; 1.18” maximum

thickness of board

Varies on process

3.175 mm

Cycle time/Feed Rate

Weeks 55 Drill Cycles/min

25 to 60 min (total)

10 in/min

Space Requirements

Room-size 46.7 ft3 32 ft3 40 ft3

Maximum Noise Output (dB)

minimal low minimal 100 < x < 75

Cost Varied $15,200 ~$500 $4000

Potential RisksID Risk Item Effect Cause

Likelihood

Severity

Importance Action to Minimize Risk Owner

1

Breaking Bits Circuit board ruined, extra costs, time spent on maintenance

Improper feed rate, uneven surface, wrong material

9 3 27 Documentation of bit use, statistical study, (bit selection option?)

Team

2 Dusting Issues

Respiratory issues, OSHA compliance issues, can get into small parts and cause mechanical failure

Vacuum not powerful enough or close enough to routing, user not using PPE if needed 6 6 36

Get a stronger vacuum, find a way to get the vacuum as close to the dust as possible, find the particle size of the dust, do not have the operator clean it off by hand

Mechanical Team/Safety

3 Controls FailureCircuit ruined, extra time

Unable to control z axis, programming issues 9 6 54

Update Mach 3, investigate z-axis motor, analyze drill bit fit and slip

Electrical Team

4 Operator Error

Injury, machine breakage, RIT shuts machine down, circuit board ruined

Improper training, unclear instructions, unlabeled parts, poor user interface 6 6 36

Standard Work, Instructions posted on machine, training before use, poka-yokes, improve user interface Safety

5 Electrical Failure

Shortage, loss of power, blow fuse, cannot use machine

Movements, overheating, improper wiring 3 9 27

Standard Inspection/Replacement of wires, reorganize wires, rewire any improperly done wires

Electrical Team

6 Computer/Software Failure Cannot use machineOlder hardware, outdated software 3 6 18

Inspections of hardware, regular software updates Team

7 Router FailureRuins board, cannot use machine Over use, overheating 3 9 27 Buy extra router

Mechanical Team

Draft Project Schedule

Second phase consists mainly of hands-on time with the machine◦ See WBS

Work Breakdown Structure

Team Member Week 4 Week 5 Week 6

ME

Devon -Familiarize with previous machine and run test program (Route a PCB)

-Further familiarize and troubleshoot previous machine

-Compile and discuss experiences with previous machine

Joe -Familiarize with previous machine and run test program

-Further familiarize and troubleshoot previous machine

-Compile and discuss experiences with previous machine

Yev -Familiarize with previous machine and run test program-Order extra test drill bits

-Further familiarize and troubleshoot previous machine

-Compile and discuss experiences with previous machine

IE

Emily -Familiarize with previous machine and run test program-Talk to RIT Safety/Research on copper particles-Update Edge

-Create Spreadsheet for Bit Use Data Collection-Create Document for issues and troubleshooting-Further familiarize and troubleshoot previous machine

-Compile and discuss experiences with previous machine-Go through 5S, and label the machine

EE

Kenny -Troubleshoot previous machine-Familiarize with previous machine and run test program-Order extra PCB material

-Further familiarize and troubleshoot previous machine -Create Template for base PCB boards

-Compile and discuss experiences with previous machine

Nate -Troubleshoot previous machine-Familiarize with previous machine and run test program

-Further familiarize and troubleshoot previous machine -Draw more detailed pinout and circuit diagrams-Create Template for base PCB boards

-Compile and discuss experiences with previous machine

Tom -Troubleshoot previous machine-Familiarize with previous machine and run test program -

-Further familiarize and troubleshoot previous machine-Draw more detailed pinout and circuit diagrams-Create Template for base PCB boards

-Compile and discuss experiences with previous machine

Questions?