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
Budget Update
MSD I Project Goals Recap
Updated Risks Assessment
◦ 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
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:
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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
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RIT Students
Inventors/tinkerers
Jeff Lonneville
CAST Electronics Lab
Secondary
◦ Investors
◦ MSD Team
◦ RIT
Use Scenarios
Novice User
Experienced User
Outside Company
Use Scenarios Flow Chart
Prioritized List of Needs (1-3-9)
Customer
Rqmt. #
Importance
CR1
3
CR2
9
CR3
9
CR4
3
CR5
3
Description
Capable of routing traces for finer pitched SMD's
Safe and easy to operate by minimally trained
(<0.5 hour) user
Have quick start, service, and detailed
troubleshooting/operation manuals
Comments/Status
Tolerances currently too large
Took several days to get machine
operating
Improvements needed to
documentation
Factor in lead time and process
costs
CR6
9
Cost less than commercial systems on the market
Require minimal maintenance and part
replacement
No mechanical, electrical, environmental, or
health related hazards to operators of those in the
general lab area
CR7
3
Alignment system capable of auto homing
CR8
1
Automatic tool change and recognition
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
CR11
CR12
CR13
1
3
3
Contain all components of system in one unit
Rout PCB rapidly
Ability to flip and zero reverse side of board
accurately
Frequent drill bit breakage
Concerns with noise level and
particulate matter
Need for more precision and
repeatability
Convenience feature
Detached monitor and keyboard
Long setup time
No flipping method or ability to rezero flipped board
Engineering
Requirements
ER
Importance
Source
Engr. Requirement
(metric)
Unit of
Measure
Marginal
Value
Ideal Value
1
9
CR6
Noise Generation
dBA
<100
<65
2
9
CR1
Minimum Width Between
Traces Supported
inches
0.020
0.016
3
3
CR4
Manufacturing Cost
$
2800
2000
4
9
CR5
TBD
TBD
TBD
5
9
CR5
hours
50
100
6
9
CR3, 7
Minimum Tolerance to
locating positions on board
inches
0.002
0.0005
7
3
CR5, 8
Bit Replacement Time
minutes
2
<1
8
3
TBD
Feed Rate
in/minute
10
20
9
3
CR2, 3
minutes
20
10
10
3
TBD
inch x inch
5x5
8x8
11
3
TBD
inch x inch
2x2
1x1
12
9
CR2, 11
Binary
No
Yes
13
9
CR2, 3, 5
hours
1.5
.5 hours
14
9
CR1
Router Speed
rpm
15000
30000
15
9
C10
Debris Removal (Copper
and Substrate)
mg ratio
0.90
0.99
16
9
CR1
Total Indicated Runout
inches
<.0006
<0.0004
17
9
CR7, 10
Vacuum Table Force
lbs force
30
40
18
9
CR6
watts
1920
1800
19
3
CR6
Binary
No
Yes
Unit Reliability (mean time
between failures)
Mean to time between
maintenance
Time for initial machine
set-up
Maximum Compatible
Board Size
Minimum Compatible
Board Size
Up to date PC & software
for system control
Minimize Operator
Training
Max Power Consumption
for entire system
Aesthetic wiring and
schematics
P14311
Marginal
pass
marginal
pass
Fail
Marginal
pass
Marginal
pass
Pass
Marginal
pass
Marginal
pass
Marginal
pass
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
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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
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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
Manage
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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
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
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
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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
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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
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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
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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:
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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
74%
Materials Progress
Materials Produced
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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
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
Item
Alignment System
Wire
Proposed Purchases/Budget
Supplier
Worst Case Most Likely Case Actual (Team Spending) Spending Track
Digi-Key, mouser
$300.00
$200.00
$145.00
$145.00
Unknown
$300.00
$250.00
$250.00
Drill Bits
Use/Description
Auto Homing with Precision
Rewire to color code, and relocation
Improve bugs with program, z-axis
precision
For testing, bit analysis, and selection
Misc Parts, Hardware, 3D
Printing, Camera, Etc.
Unnaccounted for extra expenses,
McMaster, Digi-Key,
sacrificial material, hoses, etc. (to date)
Mouser, Amazon
$200.00
$200.00
$175.00
$200.00
Vacuum Switch
Replacement
Router/Spindle
PCB Boards
Misc Labor
Computer Monitor Dual
Mount
To monitor vacuum table pressure
Dwyer
$150.00
$75.00
$35.00
$35.00
Bausch router has been discontinued
Unknown
$200.00
$100.00
$80.00
$80.00
For testing and machine familiarity
Machining, etc.
DigiKey
RIT/Other
$100.00
$100.00
$100.00
$50.00
$95.00
$95.00
$50.00
Make the machine one unit
TaoTronics
$100.00
$50.00
$55.00
$55.00
Wire management
Unknown
$50.00
$35.00
Parker, Medo (ebay)
$75.00
$40.00
$130.00
$130.00
Unknown
$75.00
$35.00
$100.00
$100.00
RIT
$0.00
$0.00
$0.00
$0.00
$1,510.00
$1,090.00
$1,450.00
Mach 3 License
Wire Duct, Heat Shrink,
Etc.
Vacuum Pump
Hold PCB board onto table
Reduce noise and impove working
Sound Absorbing Material
environment
New Computer/Monitor
Upgrade computer and provide for
camera view
ArtSoft
$200.00
$175.00
$175.00
$175.00
Think & Tinker
$200.00
$200.00
$100.00
$100.00
Total: $2,050.00
$35.00
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
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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 risklow 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
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Vacuum Table
Debris Collection
Auto Homing
Limit Switches
Spindle Motor