Week 4 and 5
This commit is contained in:
Aidan Sharpe
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@online{MorePCB,
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title = {A Comprehensive Guide to Prototype Board},
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author = {MorePCB},
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||||
year = 2023,
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||||
url = {https://morepcb.com/a-comprehensive-guide-to-prototype-board/},
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urldate = {2025-02-03}
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}
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@online{All3DP,
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title = {3D Printing Tolerances: How to Test & Improve Them},
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||||
author = {Ofir Galiki and Hironori Kondo and Zachary Wilson},
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||||
year = 2023,
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||||
url = {https://all3dp.com/2/3d-printing-tolerances-test-fdm/},
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||||
urldate = {2025-02-18}
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||||
}
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||||
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||||
---
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||||
title: Project 1C - Traffic Light Enclosure
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subtitle: Rapid Prototyping & Fabrication
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author:
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||||
- Aidan Sharpe (916373346)
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- Michelle Frolio
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- Karl Dyer
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date: February 3rd, 2025
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||||
geometry: margin=1in
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bibliography: citations.bib
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output:
|
||||
pdf_document:
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||||
md_extension: native_numbering
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||||
---
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||||
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||||
\newpage
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||||
## Introduction
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The purpose of this project was to construct an enclosure for the previously protoboarded circuit. The circuit board has three LEDs aranged in a line, resembling a traffic light. Additionally, the protoboard has a 1x6 right angle pin header with 100 mil pitch at the base. These pins are to be connected to a breadboard. The purpose of the enclosure is to protect the electronics from the outside environment and give it a more "finished" look.
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||||
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||||
## Requirements
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||||
1. Enclosure must have two pieces
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2. Enclosure must achieve an IP20 rating
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3. LEDs and header pins must extend through case walls
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4. All screws must fasten to heat set inserts
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5. Two halves must mate mechanically
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## Procedure
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||||
First, we created a low-resolution mockup of the protoboard, with its most prominent features present. This was done in ECAD with standard component libaries to ensure proper sizing. The board edges were also measured, and the final PCB was exported as a STEP file for use in MCAD. This model is seen in the figure below:
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Next, the enclosure front was built up around the model with 25 mil gaps on all sides of the board except the edge with pins to add some wiggle room for the PCB. This shape was extruded vertically, both above and below the board to create the walls of the enclosure. Then the top face was added, using the protoboard model as a guide to cut holes for the LEDs to poke through. Finally, another body, the back panel, was added. This panel adds both a back to the enclosure, further protecting the electronics, and internal support for the PCB to restrict its motion inside the enclosure. Grooves and tabs were added to the front and back pieces respectively to allow them to slide together. The final model is seen in the figure below:
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Once the model was done, we exported the two bodies as STL files, and sliced them using Orca Slicer. The sliced gemetries are seen below:
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The two parts, fresh off the 3D printer are seen below:
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We assembeled the two halves in a final test fit. First, we tested the board fit, as seen below:
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We had used a 20mil (~0.5mm) tolerance for the sliding fit [@All3DP]. The final fit was loose, but still acceptable. The fully assembled case with board inside is seen below:
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Plugging it in, we can confim that the circuitry still works, and the pins are able to plug fully into the breadboard still, as seen below:
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## Reflection
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Initially, we planned for the top of the enclosure to slide with dovetail-like joints into the bottom half. That way, when the board slid in with the top, it would fall into a pocket, securing the enclosure together. Unfortunately, this design made the pins less accessable, since the board had to be surrounded on all four edges. Fortunately, this was easily remidied, since the design could be easily modified. Speaking of ease of modification, using realtive measurements proved to be highly valuable. Going back and making changes was very simple this way. Additionally, we learned that doing small test prints was very helpful for testing fit, to see if dimensions had to be made smaller or larger. Finally, we learned that using ECAD and MCAD tools together, to combine their strenths, is super useful. Using ECAD to make the PCB model with standard library parts was way faster than measuring all the dimensions of the parts on the board.
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## References
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||||
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BIN
8th-Semester-Spring-2025/rapid-prototyping/protoboarding/lit.jpg
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8th-Semester-Spring-2025/rapid-prototyping/protoboarding/lit.jpg
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---
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||||
title: Project 1B - Traffic Light Protoboard
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subtitle: Rapid Prototyping & Fabrication
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||||
author: Aidan Sharpe (916373346)
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||||
author:
|
||||
- Aidan Sharpe (916373346)
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||||
- Michelle Frolio
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||||
- Karl Dyer
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||||
date: February 3rd, 2025
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||||
geometry: margin=1in
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||||
bibliography: citations.bib
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||||
output:
|
||||
pdf_document:
|
||||
md_extension: native_numbering
|
||||
---
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||||
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||||
\newpage
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||||
## Introduction
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This exercise transitions the breadboarded circuit from the last exercise to a protoboard. We were provided with a kit of parts, which included three 220$\Omega$ axial resistors, a through-hole six-position 100-mil-pitch 90$^\circ$ pin header, and three through-hole LEDs (red, yellow, and green). Finally, we were provided with the following schematic:
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{ width=50% }
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The goal of the completed board is to have a common ground pin and individual power pins for each LEDs. This allows for independent control of the LEDs. The components are all to be permanently affixed to the protoboard with solder. In doing so, our prototype will be more durable than a simple breadboard layout.
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## Requirements
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1. Traffic light LEDs
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1. Traffic light shall have three (3) LEDs
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2. The top LED (furthest from pin header) shall be red
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3. The middle LED shall be yellow
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4. The bottom LED (closest to pin header) shall be green
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5. All LEDs shall have a 220$\Omega$ resistor connected in series to the power connection
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2. Traffic light header
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1. Header shall be 1 row, 6 positions, male (pins), 90-degree, through-hole mount, 100 mil pitch
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2. Header shall be extend from the short side of the board
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3. Pin 0 shall be a common ground pin
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4. Pin 1 shall supply +5V to the red LED
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5. Pin 2 shall supply +5V to the yellow LED
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6. Pin 3 shall supply +5V to the green LED
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## Procedure
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First, we had to modify the protoboard and the pin header for them to mate properly. Since we are using stripboard as opposed to perfboard [@MorePCB], some of the pins would be shorted together through the pre-existing traces. We also had to remove two pins from the pin header, because the pins do not have a corresponding hole on the board.
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Next, we attached the LEDs, with red on top, followed by yellow, and green at the bottom, closest to the pin header. This order matches traffic lights. Finally, we added the resistors and additional connections to match the circuit described by the schematic provided. The final board is seen below:
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{ width=50% #fig:top}
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{ width=50% }
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The board also worked as desired, with each LED lighting up when power is applied to its respective pin. The fully lit board is seen below:
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{ width=50% }
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## Reflection
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My first key takeaway from this exercise was that planning is key to laying out a protoboard. Espeially, since we used stripboard, it is easy to forget that two adjacent pins are connected or that there are no rails. Instead, we have to make the rails.
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Another takeaway I had was that holding the wire being soldered down with the helping hands can melt and leave and remove the insulation. Luckily, this did not cause a short on the board we made.
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We also learned that stripboard is not ideal for mounting pin headers on the short end. To connect a pin header in this way, both the board and the header had to be modified. Cutting traces with a utility knife works, but is far from perfect. It leaves an opening in the solder mask that could easily short and cause a board failure.
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Finally, we learned how to best create solder points along a wire. Our ground wire (shown in black above) is a single wire with slits cut into it. First a segment of wire was cut, and one end was stripped and soldered into the board. Then, we marked the point along the wire where we wanted the first slit to start. We used wire strippers to cut the insulation, and then slid the insulation down the un-soldered end to create the opening. Using small lengths of uninsulated wire, we were able to make a connection from the slit to a pad on the board.
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## References
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||||
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{
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"zones": 0.6
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"text": true,
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Load Diff
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{
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{
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||||
@@ -0,0 +1,791 @@
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||||
(kicad_sch
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||||
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||||
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||||
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||||
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||||
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||||
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||||
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||||
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||||
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||||
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||||
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||||
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||||
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Reference in New Issue
Block a user