P15311: Circuit Board Router (Rev2) Systems Level Design 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 MSD I Project Background ◦Review problem statement and deliverables ◦Review stakeholders and use scenarios Updated List of Needs and Engineering Requirements Additional Benchmarking Functional Decomposition Concept Development ◦Morphological Chart ◦Pugh Analysis System Level Proposal Feasibility Analysis Potential Test Plan Refined Risk Analysis Chart Up to Date Project Schedule Time for Questions

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: ◦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

Use Scenarios Flow Chart

Prioritized List of Needs (1-3-9) Customer Rqmt. # ImportanceDescriptionComments/Status CR13Capable 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 CR43Cost less than commercial systems on the market Factor 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 CR12 3 Rout PCB rapidlyLong setup time CR13 3 Ability to flip and zero reverse side of board accurately No flipping method or ability to re- zero flipped board

Engineering Requiremen ts ERImportanceSource Engr. Requirement (metric) Unit of Measure Marginal Value Ideal Value P CR6Noise GenerationdBA<100<65 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, 8Bit Replacement Timeminutes2<1 83TBDFeed Ratein/minute1020 Marginal pass 93CR2, 3 Time for initial machine set-up minutes2010 3TBD Maximum Compatible Board Size inch x inch5 x 58 x 8 113TBD Minimum Compatible Board Size inch x inch2 x 21 x 1 129CR2, 11 Up to date PC & software for system control BinaryNoYesPass 139CR2, 3, 5 Minimize Operator Training hours1.5.5 hours 149CR1Router Speedrpm Marginal pass 159C10 Debris Removal (Copper and Substrate) mg ratio CR1Total 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 BinaryNoYes

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

Additional Benchmarking- RIT’s ME Lab PCB Router T-Tech PCB router system- limited specs on site Mobile X-Y axis bed Z axis solenoid control with hard stop pad Separate vacuum unit with individual debris vacuum and vacuum table pump EXPENSIVE ◦For all of the features we wish to have on our router, this unit costs upwards of $20,000

Functional Decomposition

Morphological Chart for Concept Development

Pugh Analysis for Concept Selection: Securing Board

Pugh Analysis for Concept Selection: Auto Homing

Pugh Analysis for Concept Selection: Debris Collection

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

System Architecture (Block Diagram) Revised from P14311 documentation

Board Architecture (Block Diagram) Revised from P14311 documentation

Power Distribution Revised from P14311 documentation

Feasibility Analysis Test Observe Analyze Demonstrate Current Working Router

Completed Work, Tests, and Updates Locker inventory Running old PC and software Purchasing full software license and installing Updating to new PC Including 2 nd monitor and allowing for video feed Investigating drill bits and deciding on best styles for purchasing and testing Sourcing and purchasing PCB material Sourcing and purchasing monitor brackets Hands on time with machine running test profiles and routing boards Investigating background code in mach3 and implementing custom macros Performing and compiling student interviews for refined requirements

Vacuum Table Calculations When analyzing the ShopVac system calculations from the last group: ◦The team failed to account for the maximum holding pressure of ShopVac ◦The team incorrectly assumed that there would be ~1CFM of flow ShopVac Specs Vacuum Pump Specs

Vacuum Debris Collection Calculations Reasons For Loss Support structures left in 3D printed parts 3D printed joints do not create a good seal Air is leaking out of the sides of the vacuum table

Drill Bit Tool Life Calculations 10,000 linear inches of cut expected at 20 in/min feed rate Roughly 100 boards per tool life Breakage caused by high feed rate + deep plunge Four tools needed to cut board: 1: Drill for through-holes 2: Fine-tip trace isolation tool 3: Wide-tip rubout tool 4: Deep-plunge cutout tool

Budget Estimate ItemUse/DescriptionSupplierWorst CaseMost Likely Case Actual (Team Spending) Alignment SystemAuto Homing with PrecisionUnknown$500.00$200.00TBD WireRewire to color code, and relocationUnknown$300.00$250.00TBD Mach 3 License Improve bugs with program, z-axis precision ArtSoft$ $ Drill BitsFor testing, bit analysis, and selectionThink & Tinker$ $ Misc Parts, Hardware, 3D Printing, Etc. Unnaccounted for extra expenses, sacrificial material, etc. (to date) Unknown$ $0.00 New Vacuum More powerful to improve debris removal, quiet ShopVac$200.00$150.00TBD Replacement RouterBausch router has been discontinuedUnknown$150.00$100.00TBD PCB BoardsFor testing and machine familiarityDigiKey/Mouser$ TBD Misc LaborMachining, etc.RIT/Other$100.00$50.00TBD Computer Monitor Dual Mount Make the machine one unitTaoTronics$100.00$50.00$55.00 Wire Duct, Heat Shrink, Etc.Wire managementUnknown$50.00$35.00TBD Vacuum PumpHold PCB board onto tableunknown$75.00$40.00TBD Sound Absorbing Material Reduce noise and impove working environment Unknown$75.00$35.00TBD New Computer/Monitor Upgrade computer and provide for camera view RIT$0.00 Total:$2,250.00$1,610.00$331.06

Budget Estimate

Refined Overall System Risks Assessment IDRisk ItemEffectCause Likelihood Severity Importance Action to Minimize RiskOwner 1Controls FailureCircuit ruined, extra time Unable to control z axis, programming issues 9654 Update Mach 3, analyze z axis motor, analyze drill bit fit and slip Electrical Team 2Dusting Issues Respiratory issues, OSHA compliance issues, can get into small parts and cause mechanical failure Underpowered vacuum, bad joints 6636 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 3Operator Error Injury, machine breakage, RIT shuts machine down, circuit board ruined Improper training, unclear instructions, unlabeled parts, poor user interface 6636 Standard Work, Instructions posted on machine, training before use, poka-yokes, improve user interface Safety 4Safety Issues Injury, Machine locked out, Damage to machine Improper PPE, Improper Machine structure, Improper or lack of saftey devices/designs, Poor training/manuals 6636 Involve RIT saftey, incorporate saftey in all new designs, improve any unsafe structures, update manual Safety 5Electrical Failure Shortage, loss of power, blow fuse, cannot use machine, broken wall plug Movements, overheating, improper wiring 3927 Standard Inspection/Replacement of wires, reorganize wires, rewire any improperly done wires Electrical Team 6Router Failure Ruins board, cannot use machine Over use, overheating3927Buy extra routerMechanical Team 7 Computer/Software Failure Cannot use machine Older hardware, outdated software 3618 Inspections of hardware, regular software updates Team 8Team Issues Extra workload, unable to complete tasks/designs, Reapeating work Loss of a team member, poor time management, poor documentation 3618 Update and continuously check tasks and meeting minutes, inform team of outside issues Team

Detailed Risks Assessment Updated risk assessment includes detailed considerations and importance evaluations of our highest importance items: ◦Controls Failure ◦Debris System Risks ◦Operator Error ◦Safety Issues See edge site for full risks assessment

Potential Test Plans Produce machine troubleshooting/errors data sheet and analyze ◦Determine machine reliability ◦Compile troubleshooting requirements Produce drill bit data sheet and analyze tool life, tool wear, breakage ◦Optimize tools and maintenance requirements Use load cell to confirm breaking force of vacuum table hold in x,y,z ◦Ensure board security and trace spacing Use flow meter to analyze vacuum debris inlet flow rate ◦With and without HEPA filter Experiment with mach3 customized macros ◦Improved functions ◦Extended tool life Measure change in board weight vs debris collected by vacuum ◦Minimize interference of debris with routing ◦Mitigate airborne particulates Measure sound produced with decibel meter

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