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.

EasyEDA:

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: schematic capture, PCB layout, and manufacturing
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 File Page 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

Use Place Powertoinsertpredefinedpowersymbolslike+5V, GND, or VCC. 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. All components will appear off-board. Move them onto the layout area using
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

Setup design constraints: Setup Constraints Manager.

- 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.

For auto routing, go to Route Autoroute All Connections. 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)

Run Tools Design Rule Check to detect clearance and overlap errors. Inspect reports carefully and
fix all warnings.

Ensure there are no unconnected nets ('rats nest' 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.

Include fields: Part Name, 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 “INFRARED REMOTE CONTROL

TRANSMITTER CIRCUIT” which was designed using a single-layer PCB.

3.2 INFRARED REMOTE CONTROL TRANSMITTER CIRCUIT:

 An Infrared (IR) Remote Control Transmitter Circuit is an electronic circuit that sends
control signals wirelessly using infrared light waves. It is the transmitting part of a
remote-control system — commonly found in TV remotes, music systems, robot
controls, and home automation devices.
 The IR transmitter emits pulses of infrared light (invisible to the human eye) that can
be detected by an IR receiver. The receiver decodes these pulses to perform specific
actions (like turning ON/OFF a device).
 The IR LED transmits bursts of 38 kHz IR pulses — which can be received by a
matching IR receiver circuit.

3.3 CIRCUIT DIAGRAM

 The complete Infrared remote control transmitter Circuit was designed and simulated
using OrCAD.
1. Pin 1 (GND) → Ground
2. Pin 8 (VCC) → +5 V
3. Pin 4 (RESET) → Connected to +5 V (to avoid accidental reset)
4. Pin 5 (CV) → Connected to ground via 0.01 µF capacitor
5. Pin 2 (TRIG) & Pin 6 (THR) → Connected together
6. R1 (1 kΩ) between VCC → Pin 7
7. R2 (22 kΩ) between Pin 7 → Pins 2/6
8. C2 (10 µF) between Pins 2/6 → GND

 In the single-layer PCB design, all components and copper traces are located on one
side of the board. The other side is used for mounting components and may include a
copper fill region for grounding purposes. Proper routing techniques were followed to
avoid crossover and jumper wires were used where necessary to complete
connections.

Working Principle:

The transmitter generates a modulated IR signal, typically at 38 kHz. This

modulation helps the receiver distinguish the signal from ambient light.

1. The 555 Timer IC is used in astable mode to generate a continuous square wave at 38 kHz.

2. The IR LED converts the electrical signal into light pulses.

3. A push button allows the transmission only when pressed — saving power.

4. The receiver (like a TSOP1738 or similar) detects this modulated IR signal and sends it to
a microcontroller or another control circuit.
3.4 REQUIRED COMPONENTS

1. Resistors & Capacitors

Used to set the output frequency of the IC555 timer.

2. Timer IC (555)

Used to generate 38khz modulated signal for transmission.

3. IR LED

It emits infrared light proportional to the output of the timer.

4. Push button (SW1)

Used to trigger the transmission manually.

[Link] supply(5V)

Powers the circuit (can use battery or USB).

3.5 PCB DESIGN AND LAYOUT

The PCB for the Infrared Remote Control Transmitter Circuit was designed as a single-
layer PCB to simplify fabrication and cost.

 All copper traces and component padsare located on a single side of the board.
 The component side faces upward, while the solder sidecarries all the electrical
connections.
 Short and direct routing was maintained for high-frequency paths in the IR section to
minimize signal loss.
 Grounding was implemented through a wide ground trace
 Jumper wires were added in places where trace crossover was unavoidable due to
single-layer restrictions.

The layout was checked using Design Rule Check (DRC)and Electrical Rule Check
(ERC) in OrCAD to ensure all connections were valid and there were no clearance or short-
circuit issues prior to fabrication.
FILE CREATION
SCHEMATIC DIAGRAM
TRACK CREATION
3D VIEW (1)
 3D VIEW(2)

CONCLUSION

4.1CONCLUSION

After the PCB was fabricated, the circuit was assembled and tested.

The layout minimizes wiring complexity and enhances signal stability for reliable
transmission.

The final project successfully demonstrated the complete design, implementation, and testing
of an Infrared Remote Control Transmitter circuit on a single-layer PCB, achieving all design
and performance objectives.