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. # 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

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

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 2 nd 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 ◦1 st 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/Budget ItemUse/DescriptionSupplierWorst CaseMost Likely CaseActual (Team Spending)Spending Track Alignment SystemAuto Homing with PrecisionDigi-Key, mouser$300.00$200.00$ WireRewire to color code, and relocationUnknown$300.00$ Mach 3 License Improve bugs with program, z-axis precision ArtSoft$200.00$ Drill BitsFor testing, bit analysis, and selectionThink & Tinker$ $ Misc Parts, Hardware, 3D Printing, Camera, Etc. Unnaccounted for extra expenses, sacrificial material, hoses, etc. (to date) McMaster, Digi-Key, Mouser, Amazon $ $175.00$ Vacuum SwitchTo monitor vacuum table pressureDwyer$150.00$75.00$35.00 Replacement Router/Spindle Bausch router has been discontinuedUnknown$200.00$100.00$80.00 PCB BoardsFor testing and machine familiarityDigiKey$ $95.00 Misc LaborMachining, etc.RIT/Other$100.00$50.00 Computer Monitor Dual Mount Make the machine one unitTaoTronics$100.00$50.00$55.00 Wire Duct, Heat Shrink, Etc. Wire managementUnknown$50.00$35.00 Vacuum PumpHold PCB board onto tableParker, Medo (ebay)$75.00$40.00$ Sound Absorbing Material Reduce noise and impove working environment Unknown$75.00$35.00$ New Computer/Monitor Upgrade computer and provide for camera view RIT$0.00 Total:$2,050.00$1,510.00$1, $1, 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