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. # ImportanceDescriptionComments/Status CR13 Capable of routing traces for finer pitched SMD'sTolerances currently too large CR29 Safe and easy to operate by minimally trained (<0.5 hour) user Took several days to get machine operating CR39 Have quick start, service, and detailed troubleshooting/operation manuals Improvements needed to documentation CR43 Cost less than commercial systems on the marketFactor in lead time and process costs CR53 Require minimal maintenance and part replacementFrequent drill bit breakage CR69 No mechanical, electrical, environmental, or health related hazards to operators of those in the general lab area Concerns with noise level and particulate matter CR73Alignment system capable of auto homing Need for more precision and repeatability CR81Automatic tool change and recognitionConvenience feature CR93Visual feedback system for error detectionDifficult to see traces through glass CR109Improve debris removal systemMessy and dangerous for operation CR11 1 Contain all components of system in one unitDetached monitor and keyboard

Engineering Requiremen ts ERImportanceSource Engr. Requirement (metric) Unit of Measure Marginal Value Ideal Value P CR6Noise GenerationdBA<100<75 Marginal pass 29CR1 Minimum Width Between Traces Supported inches marginal pass 33CR4Manufacturing Cost$ Fail 49CR5 Unit Reliability (mean time between failures) TBD 59CR5 Mean to time between maintenance hours CR3, 7 Minimum Tolerance to locating positions on board inches Marginal pass 73CR5, 8Tool Replacement Timeminutes2<= 1 83TBDFeed Ratein/minute10100 Marginal pass 93CR2, 3 Time for initial machine set-up minutes TBD Maximum Compatible Board Size inch x inch5 x 58.5 to TBD Minimum Compatible Board Size inch x inch2 x 21 x 1 129CR2, 11 Up to date PC & software for system control BinaryTBD 139CR2, 3, 5 Minimize Operator Training hours1.5.5 hours 149CR1Router Speedrpm Marginal pass 159C10 Debris Removal (Copper and Substrate) mg Marginal pass 169CR1Total Indicated Runoutinches<.0006< Marginal pass 179CR7, 10Vacuum Table Forcelbs force3040 Marginal pass 189CR6 Max Power Consumption for entire system watts CR6 Aesthetic wiring and schematics %25%100%

Current Methods of PCB Routing CriteriaChemical Etching Commercial MITS Auto Lab LaserJet PCB Printing P14311 PCB Router Max. Workable Area (in) Most Sizes9 x x 107 x 7 Minimum Trace Spacing (mm) x ≥ 0.1 x ≥ < x < 0.41 Material Depth Removal (precision) Varies on process 0.2 mm; 1.18” maximum thickness of board Varies on process mm Cycle time/Feed Rate Weeks55 Drill Cycles/min 25 to 60 min (total) 10 in/min Space Requirements Room-size46.7 ft 3 32 ft 3 40 ft 3 Maximum Noise Output (dB) minimallowminimal100 < x < 75 CostVaried$15,200~$500$4000

Potential Risks IDRisk ItemEffectCause Likelihood Severity Importance Action to Minimize RiskOwner 1 Breaking Bits Circuit board ruined, extra costs, time spent on maintenance Improper feed rate, uneven surface, wrong material 9327 Documentation of bit use, statistical study, (bit selection option?) Team 2Dusting 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 needed6636 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 3Controls Failure Circuit ruined, extra time Unable to control z axis, programming issues9654 Update Mach 3, investigate z-axis motor, analyze drill bit fit and slip Electrical Team 4Operator Error Injury, machine breakage, RIT shuts machine down, circuit board ruined Improper training, unclear instructions, unlabeled parts, poor user interface6636 Standard Work, Instructions posted on machine, training before use, poka-yokes, improve user interfaceSafety 5Electrical Failure Shortage, loss of power, blow fuse, cannot use machine Movements, overheating, improper wiring3927 Standard Inspection/Replacement of wires, reorganize wires, rewire any improperly done wires Electrical Team 6Computer/Software FailureCannot use machine Older hardware, outdated software3618 Inspections of hardware, regular software updatesTeam 7Router Failure Ruins board, cannot use machine Over use, overheating3927Buy extra router Mechanical Team

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

Work Breakdown Structure Team MemberWeek 4Week 5Week 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?