Module III
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PCB Designing and Prototyping
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PCB Designing and Prototyping
Introduction: PCB, pads, track, SMD, trough hole, via and its Design
rules. Design any
two simple circuit using Easy EDA/Eagle/Flat CAM, Routing and
Generating GERBER
file.
PCB Chemical etching Vs Milling techniques, PCB Chemical
Etching/Milling
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Introduction to PCB
Definition: Printed Circuit Board (PCB) is a base for connecting
electronic components.
Purpose: Provides mechanical support and electrically connects
components.
Applications: Computers, smartphones, automobiles, and medical
devices.
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Key Terms in PCB Design
Pads: Surface areas for soldering components.
Tracks: Copper traces that connect components.
SMD (Surface-Mount Devices): Components mounted directly onto the
PCB surface.
Through-Hole Components: Components with leads inserted into holes
and soldered.
Via: A small hole connecting layers of a PCB.
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Key Terms in PCB Design
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PCB Layers
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PCB Layers
1. Substrate Layer:
• Base material of the PCB providing mechanical support.
• Common materials: FR-4 (fiberglass), polyimide (for flex PCBs), or aluminum (for
thermal management).
• Determines the board's rigidity, flexibility, and heat resistance.
2. Copper Layer:
• Conductive layer made of copper foil.
• Can be single-sided, double-sided, or multilayered depending on the PCB type.
• Thickness typically measured in ounces per square foot (e.g., 1 oz = 35 µm thick).
• Forms the electrical pathways (traces) to connect components.
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PCB Layers
3. Solder Mask Layer:
• Protective layer applied over the copper traces.
• Prevents oxidation and short circuits by insulating the traces.
• Provides a non-conductive surface for handling and assembly.
Common colors: green (standard), but also red, blue, black, and others for aesthetic or
functional purposes.
4. Silkscreen Layer:
• Topmost layer used for labeling and markings.
• Contains component designators, logos, pin numbers, and assembly instructions.
• Printed using ink, typically white, but other colors can be used.
• Helps in identifying components during assembly and troubleshooting.
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Design Rules
Trace Width: Minimum width for tracks to handle current.
Clearance: Minimum space between adjacent tracks or pads.
Pad Sizes: Should match component pins for effective soldering.
Via Diameter: Sufficient to accommodate current and manufacturing
limits.
Layer Stackup: Defines the arrangement of PCB layers.
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PCB Design Tools
EasyEDA: Cloud-based PCB design tool.
Eagle: Industry-standard PCB design software.
FlatCAM: Used for PCB milling processes.
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Simple Circuit Design Example 1
Example: LED Flasher Circuit
Components: Resistor, LED, and timer IC.
Steps:
Create schematic.
Place components.
Route tracks.
Generate GERBER files.
Tool Used: EasyEDA
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Simple Circuit Design Example 2
Example: Temperature Sensor Circuit
Components: Temperature sensor, op-amp, and display.
Steps:
Design schematic.
Place and connect components.
Validate design.
Generate GERBER files.
Tool Used: Eagle
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GERBER Files
Definition: Standard format for PCB manufacturing.
Content: Copper layers, solder mask, silkscreen, drill data.
Importance: Ensures compatibility with manufacturing processes.
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PCB Manufacturing Techniques
Chemical Etching: [Link]
Uses chemicals (ferric chloride) to remove unwanted copper.
Advantages: Precision, suited for complex designs. Disadvantages: Hazardous waste, longer
process.
PCB Milling: [Link]
Uses a CNC machine to remove copper mechanically.
Advantages: Eco-friendly, faster prototyping.
Disadvantages: Limited precision for dense designs.
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CNC PCB milling machine
CNC (Computer Numerical Control) PCB milling machines are advanced
tools used in the production of printed circuit boards (PCBs). There are
several types of CNC PCB milling machines available in the market, each
offering unique features and capabilities.
These machines are specifically designed to mill printed circuit boards
(PCBs) with precision and accuracy.
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CNC PCB milling machine
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Comparison: Etching vs. Milling
Criteria Chemical Etching PCB Milling
Waste Management Hazardous chemicals Minimal waste
Precision High Moderate
Speed Slow Fast
Cost Moderate High
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SMOKE DETECTOR WITH ALARM
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Working Explanation
The working of this circuit is explained here simply. When the light of
the LED will be continuously falling onto the LDR from a small distance
of a few inches, so if any type of smoke crosses between the LED and
the LDR the resistance of LDR will increase due to which transistor Q1
will switch off while Q2 will switch on. Q2 will trigger the 555 timer IC
and its output goes high for a preset time period which activates the
UM3561 alarm IC. As a result, a loud alarm will be produced. the alarm
will stop after the preset time period is over. To adjust the sensitivity of
this circuit we have used two variable resistors, the 100K variable
resistor will control the brightness of the LED and the 1K variable
resistor is used to adjust the sensitivity of the LDR.
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