Introduction

The study of Electronic Board has encountered us for so many answer regarding the PCB(Printed Circuit Board), on how to use Protheus.7 Software, ISIS and ARES, the steps taken to create a piece of complete PCB that can be used in daily live. The PCB that is used for so many applications in nowadays technology is include in the three classes of applications which is, general electronics products, dedicated service electronics, and high reliability electronics. Consumer electronics include some computer and computer product, as well as general military hardware suitable for applications, and the major requirement of the board is PCB functionality. Consumer electronics Telecommunications Medical Electronics Digital Wrist Watch, CD Player, Alarm Clock, Radios, Cell Phones Heart monitor, MRI imaging equipment

The table shows the example of what a PCB capable of. They remain in the body part of the electronic and work as the main component. There is still massive function of PCB that has been used throughout the world in other electronic design applications. Generally, PCB is used to mechanically support and electrically connect electronic components using conductive pathway. Two board type are subjected to us. There are positive and negative board. One sided and two sided copper laminated to the board. In our lab, we did use positive board. To increase our knowledge in the electronic design world, we did create a new circuit board of a car battery tester. The car battery tester is easy to use, and really easy to be assembly.

Battery car tester. Battery car tester is widely used for testing and gauging the battery of a car. Generally, a battery car tester is around Rm6x something in the market. In order to improve and learning, we created a battery tester that is cheaper than in the market. The requirement that client put on use are : The battery is totally discharged (the voltage between poles is less than 9.5V) The battery is partially discharged(the voltage between poles is between 9.5V and 11V) The battery is normally charged(the voltage between the battery poles is between 11V and 13V) The vehicle is in motion, the alternator provides a sufficient current and the voltage between the battery poles is superior to 13,5V. (It does not exceed 15V)

If the product requirement doesnt achieve the clients expectation, the company will get heavy penalty for the failures.

Objective
Objective of this project is : To use and apply the studying of PCB in working environment To dedicate self to the electronic design work, and to know how the components and design related to electronics. To learn how to use Protheus.7, including the uses of ISIS and ARES. To learnt how a PCB is created step by step including designing, printing, drilling, etching etc. To study about the devices used to complete the design of the board. To observe the result of the LED output happened after the finished of the project.

Aim

To create an easy to understand circuit board kit that can be understand for student especially. The minor target is to sell the product to the market and learnt to fulfil the clients requirement, if it is not burden the company and making los es that the company has to take if the client rejected the product. In order to fulfil all the situated requirement, truth table, early designing should be done to encounter major and minor problem in the future.

Example of a battery car tester

Block diagram

Equipment and components

Equipment and components are the major parts that consist in this project. In this project, we did use our own lab in Unikl MFI, as all the equipment are available and can be used, including designing(Protheus.7), printing, drilling, UV laminating, etching and so on.

Equipment.

Computer that is used to monitored ISIS and ARES. This is important in designing part.

Printer to print out the components part and solder point.

The Semi- automatic PCB CNC drilling machine. This is use to drill the point-to-drill of the PCB board. It is easier to use fully automatic CNC drill, but we used Semi auto in our lab.

Photonex UV laminating.

UV explousere.

Tri-Tank etching/stripping

Components.

The components or devices that been used in this project is OP AMP, resistor, LED, battety, voltmeter, capacitor, oscilloscope.

All the components above are parts in the ISIS.

Project Hypothesis

Level Of Voltage Red X < 9V 9.5V < X < 11V 11V < Z < 13V X > 13V

L.E.D Yellow

Green

This is the truth table of the incoming result. The result should be like this. If the battery voltage is below 9V, all LED will be off, and vice versa to the 13V and above battery voltage.

Methodology
I. II. III. IV. V. VI. VII. VIII. IX. X. First, design the circuit diagram in the ISIS. Convert the circuit into ARES. Print out the component parts. Transfer the folder into CNC drilling computer. Using ISO CAM, drill the set the drill, drill point and so on. Place the board into the CNC drill. Laminate the PCB using blue UV plastic. Soak the PCB using Sodium Hydroxide and Sodium Carbonate, by using Stripper and Developer tank. Laminate again using green UV plastic. Solder all components to the PCB board.

Calculation

Flowchart

START

Design circuit using ISIS software

Convert the circuit to ARES

Laminate the PCB using UV laminating strip.

Drill the point on PCB board using CNC machine.

Print out the component part and solder resist

Soak PCB into the tri tank to remove all the unwanted film

Solder all the component into PCB

END

Procedure

Below are the picture of an example ISIS design :-

Using Protheus7.0, enter ISIS and insert the device and components needed. The device that should inserted into the plane are : -

Battery (amplitude 9.5V and varies). Using DC voltage source. CONN-SIL2 ( Connector strip ) Red LED Green LED Yellow LED LM741 ( Operational Amplifier ) MINRES10K ( Resistor : the value can change by double click the description of the resistor in the plane )

Create 3 circuit for each LED and the Power Supply Regulator circuit as shown below : The 9.5V LED circuit :

The 11V LED Circuit :

The 13V LED Circuit :

0V LED circuit :

After done create all the circuit in the plane, transfer the circuit to the ARES PCB LAYOUT by include all the components by click the ARES icon.

The circuit figure after transfer to the ARES PCB LAYOUT and connect all the components : -

Print out three mask that will be used in the laminating process after this :-

Below is the product after print the circuit layout by use the above setting for track mask : -

The track mask Setting for label mask: -

Below is the output after print the circuit layout by use the above setting for label mask : -

The label mask

Setting for dot mask: -

Below is the product after print the circuit layout by use the above setting for dot mask : -

The dot mask

After done print all the mask layout, the next task is to create the components hole onto the single layer board by using the PCB CNC machine that connect with the ISOCAM software in the computer in the lab.

PCB CNC machine. Below are the instruction for create the components hole onto the single layer board and how to using the ISOCAM sofware : 1) 2) Open ARES Select PCB, mirror-X Select output Set output origin Click origin to set Select output CADCAM output, metric mm Open ISOCAM Load file CADCAM drill Number format: 2 4 Load file CADCAM bottom copper Number format: 2 4 L0 Save Format: 2 3 Option :

Include drill tool in drill file

Drill filename : ( create new file name no need .nc ) OK

3) Open RouterPRO - Drill file

>>

File type > all>new file name Offset : ( set the machine position) Save the current position OK Update data Open READ-ME file : (to refer drill size) Tools : (insert drill size mm) Start drilling Start spindle

After done create the hole, cut the board to smaller size that are required. Then scratch the copper surface to make sure that the UV film is stick perfectly onto the board. By using the blue UV film, laminated the copper surface then match the track mask with components hole. After that, UV the track mask with the board by using UV machine for 30 seconds.

The laminate machine

The UV machine

The UV Blue film After the UV process, soak the PCB into the developer tank to remove the UV blue film and the track will show up. Then, the PCB soak into the etching tank to remove the copper that is not use as track. After the copper is remove, the PCB then soak into the strippers tank to remove the UV blue film that is stick onto the track.

The developer tank

The stripper tank

The etching tank

After the etching process, laminate the PCB board by using UV green film for both surface. before laminated, remove the transparent layer under the UV green film to stick the UV film to the PCB board. After laminated, match the dot mask with the copper surface and the label mask to other surface. After that, UV the PCB board for 3 minute. Remove the above transparent layer then soak the PCB board into the developers tank, then the label and copper dot will show up.

Conclusion

The conclusion from this project that we can learn is how we study the electronic design of a battery car tester. The design is fairly simple and can be used in workshop or so whatever. The main objective of this project is to make us study how the digital electronic of a PCB work. We did realise that the PCB is really reliable and can be used in many other electronic design, except that it may varies in their shape and size. The size, the material, and the shape of the PCB is part of the designer to do and to arrange the component in his or her own form. And what we can conclude else is, if we been given a task or job, do it quickly without procrastinate. This can be shown if a client give us some requirement or job, we need to do it in his specify or the company should pay for what wrong we did. In learning progress, we did learnt on how device, equipment work to regulate some process. We learnt on how device work, components characteristic. For an example the UV strip that cannot be put under sunlight, though it do make it unusedable. Our flow of work did show us on how to manage simple task by doing work step by step. We should prepare our work, do some calculation first, and do some research before conduct the project. This is to prevent some loses or miscalculation that may lead the unworthy cost to be involve.