REPORT OF THE PROJECT WORK

In partial to the fulfilment of Student Development Programming

on
PCB DESIGN AND FABRICATION
Under Naan Mudhalvan Scheme (2025-26)

PROJECT TITLE:

“PCB FOR A CIRCUIT THAT MEASURES AND

DISPLAY BATTERY VOLTAGE LEVEL”
SUBMITTED BY:

REGISTER No. NAME OF THE STUDENT

24491805 SANJAY V
24491803 POOVARASAN S
24491807 VISHVA A
24491801 NAVEEN KUMAR A
24405053 SACHIDHANANDHAN K

DEPARTMENT OF ELECTRONICS AND COMMUNICATION ENGINEERING

786, MARUTAM NELLI POLYTECHNIC COLLEGE, DHARMAPURI
 786, MARUTAM NELLI POLYTECHNIC COLLEGE

DEPARTMENT OF ELECTRONICS AND COMMUNICATION ENGINEERING

CERTIFICATE

This is to certify that the project report entitled

PCB FOR A CIRCUIT THAT MEASURES AND DISPLAY BATTERY VOLTAGE LEVEL
Is a bonafide record of work done by

Mr. /Ms. Reg. No.

During the year 2025-2026

In partial fulfilment of requirements for the successful completion of PCB DESIGN

AND FABRICATION course under Naan Mudhalvan Scheme of the State Board of

Technical Education, Chennai - 25

STAFF IN CHARGE HEAD OF THE DEPARTMENT

Mrs. PUSHPA [Link] Mr. KARTHICK [Link]

Submitted for the Board Practical Examination held on

Internal Examiner External Examiner

 CHAPTER1

INTRODUCTION TO PCB

1.1 PRINTED CIRCUIT BOARD

PCB (Printed Circuit Board) is a board that provides mechanical support and electrical
connections for electronic components. PCBs are typically made of a non-conductive material with
conductive pathways (traces) etched or printed on them, allowing current to flow between different
components.

1.2 TYPES OF PCBs:

PCB s ae classified by their structure, flexibility, and number of layers. They are as follows,

Single-Sided PCBs:

These are the most basic type, featuring a single layer of conductive material (usually
copper) on one side of the substrate. The components are mounted on the opposite side. It is
suitable for simple circuits with low component density.

Double-Sided PCBs:

This has conductive layers on both sides of the substrate. It allows for more complex circuit
designs and higher component density compared to single-sided PCBs. Both Through-hole
connections or Surface mount components can be used.
Multi-Layer PCBs:

It features three or more conductive layers separated by insulating layers. It is ideal for
complex electronic devices with high component density and demanding performance
requirements. It provides increased design flexibility and improved signal integrity.
Rigid PCBs:

It is made from solid, inflexible materials (like FR-4) that provide structural support. It is
commonly used in a wide range of electronic devices where rigidity is needed. It can be single-
sided, double-sided, or multi-layered.
Flexible PCBs:

It is made from flexible materials (like polyimide) that allow the board to bend and conform
to different shapes. It is suitable for applications where space is limited or where the board needs to
be flexible. It can be single-sided, double-sided, or multi-layered.
Rigid-Flex PCBs:
It combines rigid and flexible circuit board sections in a single assembly. It offers the
benefits of both rigid and flexible PCBs, allowing for complex designs and space optimization. It
provides a hybrid solution for applications requiring both structural support and flexibility.
Each type has distinct characteristics and applications, offering solutions for diverse
electronic device designs.

1.3 PCB LAYERS:

PCBs (Printed Circuit Boards) have four main types of layers: substrate (or base material),
copper, solder mask, and silkscreen. These layers work together to create the foundation for
electronic components and their connections. The function of each layeris as follows,

Substrate Layer:
This is the foundation of the PCB, providing structural support and insulation. Common
materials include fiberglass (like FR4) or other dielectric materials.

Copper Layer:
This layer is where the conductive pathways (traces) are etched to connect components. It's
usually a thin layer of copper applied to both sides of the substrate.

Solder Mask Layer:

A non-conductive layer that covers the copper traces, protecting them from damage and
preventing short circuits.

Silkscreen Layer:
A layer of ink applied on top of the solder mask, often used to label components and provide
other visual information on the board.
1.4 PCB TOOLS:

The different PCB design tools are as follows,

Several popular PCB (Printed Circuit Board) design tools are available, including both free and
commercial options.

OPEN-SOURCE PCB TOOLS

Following are the available Free and Open-Source Options,

KiCad:

A popular open-source EDA (Electronic Design Automation) suite with schematic capture, PCB
layout, and 3D visualization.

Easy EDA:

A free, web-based PCB design tool that supports schematic capture, PCB layout, and
collaboration.

Fritzing:

An open-source project aimed at designers, artists, and hobbyists, offering a user-friendly interface
for PCB design.

DesignSpark PCB:

A free PCB design software known for its user-friendliness and ease of learning.

CircuitMaker:
A free PCB design tool powered by Altium, offering a collaborative environment and a
streamlined interface.

FreePCB:
A free, open-source PCB layout editor.
Commercial Options:

Altium Designer:

A comprehensive PCB design software known for its advanced features and capabilities, often
used for complex designs.

OrCAD:

A popular software for designing complex PCB layouts and schematics, particularly favored for
high-speed designs.

Eagle:

A widely used PCB design software with both free and paid versions, known for its user-
friendliness and active community.

DipTrace:

An advanced PCB design tool with a user-friendly interface and comprehensive features for
schematic capture, layout, and 3D modeling.

Allegro PCB Designer:

A high-speed PCB design software from Cadence, known for its performance and scalability.

PADS Professional:
A PCB design software from Siemens, designed for high-speed designs and complex
requirements.
Other Notable Tools:

Upverter: A web-based PCB design tool for creating, sharing, and reviewing designs.

ExpressPCB Plus: A fully featured PCB design software with an integrated approach from
schematic to layout.

Proteus: A popular software for schematic capture, PCB layout, and simulation.

Some well-regarded choices include KiCad, Altium Designer, Eagle, EasyEDA, OrCAD,
and DipTrace. These tools offer varying features, price points, and levels of complexity, catering to
a range of users from hobbyists to professionals.

1.5 About OrCAD

 OrCAD is a suite of electronic design automation (EDA) software tools used for
professional PCB (Printed Circuit Board) design, layout, simulation, and routing. It includes a
schematic editor called Capture, a circuit simulator named PSpice, and a PCB layout solution called
PCB Designer Professional. Newer versions like OrCAD X also offer cloud-based collaboration
and enhanced features for high-speed and complex designs.

CHAPTER2

PROJECT DEVELOPMENT USING OrCAD

This chapter provides every step to design a complete electronic project using OrCAD
Capture, CIS and OrCAD PCB Designer (Allegro). It covers everything from schematic creation
to 3D visualization, including libraries, DRC, ERC, Gerber generation, and professional
documentation.

2.1 Introduction to OrCAD

OrCAD is a suite of electronic design automation (EDA) tools used for circuit design simulation

and PCB layout. The main tools are:

- OrCAD Capture CIS: for schematic design and logical connections.

- PSpice: for circuit simulation and analysis.

- OrCAD PCB Designer (Allegro): for PCB layout, routing, and 3D design.

A complete project involves three key phases:schematiccapture,PCBlayout,andmanufacturing

preparation.

2.2 Creating a New Project

1. Open OrCAD Capture CIS Click File New Project.

2. Choose 'Project Type' as Schematic.

3. Enter the project name and select a folder location.

4. Click OK, then select 'Create Empty Project'. This will generate a `.opj` project file. Save the

work immediately using Ctrl + S.

2.3 Understanding the OrCAD Project Structure

After project creation, the Project Manager window shows:

- Design Resources: Contains schematic sheets and libraries.

- Layout: Stores schematic diagram and details.

Outputs: Stores reports and generated files (BOM, netlist, etc.).

- Simulation Profiles: For PSpice simulation settings.

We can right-click the schematic name to add new pages or folders.

2.4 Setting Up the Schematic Sheet

Go to FilePage Setup and choose the sheet size depending on our circuit size. We can edit the
title block by double-clicking it to add designer name, date, and project title.

Set grid spacing for easy alignment: Options Preferences Grid Display.

2.5 Adding Components

1. Choose Place Part or click the part icon.

2. In the 'Place Part' dialog, click Add Library to include libraries such as `[Link]`,
`[Link]`, or custom `. OLB` files.

3. Search for components like resistors, capacitors, ICs, or connectors.

4. Left-click to place components and press ESC to stop placement.

To rotate components, press R before placing or after selecting.

2.6 Creating Custom Symbols

If a required part is not in the library, create it manually:

1. Go to File New Library.

2. Right-click and select New Part.

3. Define the symbol shape, add pins with correct names and numbers.

Save as `. OLB` library and add it to our project libraries list.

2.7 Wiring the Schematic

1. Select Place Wire and draw connections between pins.

2. To label connections, use Place Net Alias.

3. Use Place Bus for multiple-bit connections like data buses.

4. Keep wires neat and avoid crossovers. Use 90° turns where possible. Name nets logically (e.g.,
VCC_5V, GND, MOTOR_OUT).

2.8 Adding Power and Ground

UsePlace Powertoinsertpredefinedpowersymbolslike+5V, GND,orVCC. Ensure all ICs receive

the correct power rails.

Add 'PWR_FLAG' if ERC warns about unconnected power sources.

2.9 Annotating Components

Before creating a PCB, all components must have unique reference designators:

Go to Tools Annotate Annotate Schematics and click OK to automatically assign numbers

(R1, C1, U1, etc.).

2.10 Running Electrical Rule Check (ERC)

Go to Tools Electrical Rules Check to find errors such as:

- Unconnected pins or floating nets.

- Power pins not driven by voltage sources.

- Short circuits or naming conflicts.

Fix all critical errors before exporting the net list.

2.11 Assigning Footprints

Each schematic symbol must have a PCB footprint (package):

1. Double-click a component Edit Properties Add column PCB Footprint.

2. Assign the correct footprint.

3. Check pin numbers match the datasheet footprint.

For missing footprints, create one in PCB Editor’s Library Manager.

2.12 Generating Net list

Go to Tools Create Net list.

Select the OrCAD PCB Editor format (Allegro).

Enable 'Create PCB Editor Net list' and specify output directory. Click OK to generate the netlist
and `.mnl` files.

2.13 Creating the PCB Layout

1. Open OrCAD PCB Editor (Allegro).

2. Create a new board: File New Board.

3. Define board outline using Shape Rectangular Board Outline or draw a custom shape.

4. Import the netlist: File Import Logic (Netlist) and select the generated `.mnl` file.

5. [Link]
Place Components Manually.

2.14 Component Placement Guidelines

Arrange components logically:

- Group by function (e.g., power section, control section).

- Keep decoupling capacitors close to IC power pins.

- Maintain symmetry for differential pairs.

- Place connectors and mechanical parts first.

- Ensure test points and jumpers are accessible.

2.15 Defining Design Rules

Setupdesignconstraints:Setup ConstraintsManager.

- Trace width and spacing.

- Via size and drill hole diameter.

- Solder mask expansion.

Import manufacturer-provided DRC files if available.

2.16 Routing the PCB

Start manual routing: Route Connect.

Forautorouting,gotoRoute Autoroute AllConnections. Keep traces short, avoid sharp 90° turns,
and minimize vias.

Use Add Via for layer transitions.

Ensure ground planes are properly connected with thermal reliefs.

2.17 Running Design Rule Check (DRC)

RunTools DesignRuleCheck todetectclearanceandoverlaperrors. Inspect reports carefully and fix all

warnings.

Ensure there are no unconnected nets ('ratsnest' lines).

2.18 3D Visualization

Open the 3D Viewer: View 3D Canvas.

Assign3DSTEPmodelstofootprintsinthefootprinteditor. Adjust lighting and board thickness in the 3D

viewer.

Export the board as a STEP or IGES file for mechanical integration.

2.19 Generating Gerber and Drill Files

1. Go to File Manufacture Artwork.

2. Select layers (Top, Bottom, Solder Mask, Silkscreen).

3. Click Create Artwork to generate Gerber files.

4. Generate NC Drill files for holes and vias.

5. Verify outputs using a Gerber viewer.

2.20 Creating BOM and Documentation

Use Tools Bill of Materials (BOM) in Capture or PCB Editor.

Includefields: PartName,Value,Footprint,Quantity,Manufacturer.

Create assembly and fabrication drawings with dimensions and hole tables.

2.21 Final Packaging and Handoff

Before manufacturing, include:

- Gerber files.

- Drill files.

- Pick and Place data.

- BOM and assembly drawing

Compress into a single ZIP folder for PCB fabrication

 CHAPTER3

PROJECT WORK

3.1 PROJECT WORK DETAILS

We have chosen the topic of the syllabus “ PCB

FOR A CIRCUIT THAT
MEASURES AND DISPLAY BATTERY VOLTAGE LEVEL ”
which was designed using a single-layer PCB.

3.2 AIM
The aim of the PCB for a battery voltage measurement and circuit is to efficiently
measure the battery's voltage, level on a suitable screen, and alert the user when the battery
is low. It should be compact, energy-efficient, and include protection features like over-
voltage and reverse polarity protection.

3.3 OBJECTIVE
The objective of the PCB for a battery voltage measurement and circuit is to provide
accurate voltage readings, the battery status clearly, and ensure low power consumption. It
should also include protection features, such as over-voltage and reverse polarity protection,
while maintaining a compact and reliable design for portable use.

3.4 SOFTWARE REQUIREMENTS

 EAGLE TOOL
3.5 CIRCUIT DIAGRAM
3.6 CONSTRUCTION & WORKING
To design a Printed Circuit Board (PCB) for a circuit that measures and battery
voltage levels, the process involves multiple steps. First, select a voltage sensing component
such as a voltage divider circuit or an analog-to-digital converter (ADC) to accurately
measure the battery voltage. The ADC should be connected to a microcontroller that
processes the voltage data and converts it into a readable format. The microcontroller will
then communicate with a 0 module, such as an LED , to show the voltage value. The PCB
design should include power management components like capacitors and resistors to ensure
stable operation and noise filtering. A proper grounding and layout design is essential to
minimize signal interference. For power efficiency, consider adding a low-power regulator to
maintain consistent voltage levels. The PCB should also have provisions for connectors or
pins to interface with the battery, and other external components. Careful attention to trace
width and component placement is crucial to ensure proper functionality and heat dissipation.
Finally, the design should be tested for both accuracy in voltage measurement and clarity to
ensure reliability in real-world applications.
3.7 PROCEDURE
 Schematic Sheet

Schematic making in EAGLE is the process of creating a schematic for a project,

which is the first step in PCB design. A schematic defines the parts and connections between
them in a project.

 Schematic to Board Layout

The process of taking a circuit design created in the schematic view (which defines
component connections without physical placement) and translating it into a physical layout
on a PCB board, where you position components and route traces according to the
connections specified in the schematic, essentially creating the final design for a printed
circuit board.
 Components Arrangements

The process of placing and organizing electronic components on a schematic

diagram, defining their connections and layout, which is done by selecting components from
libraries and positioning them on the design canvas, essentially creating the circuit blueprint
before moving on to the PCB layout stage.

 Layout Design
The process of creating a physical board from a schematic using the EAGLE PCB
design software. This involves placing components on the board and routing electrical paths
between them.
 BOM

BOM stands for Bill of Materials. It is a list of all the parts, materials, and
specifications required to create a product.

 Gerber File

Gerber files are created using electronic design automation (EDA) software like
EAGLE.
 3D Image
3.8 APPLICATION
A PCB for a circuit that measures and battery voltage level typically includes
components like voltage dividers (resistors to scale down the voltage), a microcontroller or a
dedicated battery monitoring IC (such as the LM3914 or LM3915), and a display (like LEDs
or an OLED screen). This circuit finds application in various battery-powered devices,
providing users with a visual indication of the remaining charge, thus preventing unexpected
power loss and aiding in timely recharging.

3.9 ADVANTAGES
A PCB (Printed Circuit Board) for a circuit that measures and battery voltage offers
several advantages. Firstly, it provides a compact and organized platform for all the necessary
electronic components, leading to a cleaner and more reliable circuit compared to breadboard
or point-to-point wiring. Secondly, a PCB allows for consistent and repeatable performance
due to precisely etched conductive tracks, minimizing errors and ensuring accurate voltage
readings. Thirdly, it facilitates easier integration into a larger system or enclosure, making the
final product more robust and professional-looking. Finally, for mass production, PCBs offer
a cost-effective and scalable manufacturing solution.
3.10CONCLUSION
A PCB designed to measure and battery voltage level integrates components for
voltage sensing, signal conditioning, processing (often a microcontroller), and a driver.
Careful layout is crucial for accuracy and noise reduction, especially in the analog sensing
section. The conclusion is that a well-designed PCB enables reliable and user-friendly
monitoring of battery status, essential for various applications.