Practical manufacturing of prototypes of electronic circuits

Higher education teachers: Vidmar Matjaž
Credits: 4



Subject description

Prerequisits:

  • Passed all exams of the first year of any study programme in the field of science and/or engineering that includes mathematics.
  • Alternatively students currently in the first year can be admitted provided that they already passed the exam mathematics 1 with a minimum grade of 9 or 10.

A rough breakdown of content:

  • Overview of elements, marking, properties,
  • Review of processes for manufacturing printed circuit boards,
  • A method of manufacturing a printed circuit board with toner transfer,
  • Review of procedures for soldering printed circuit board elements,
  • Soldering the PCB with a manual soldering iron,
  • Electromagnetic interference
  • Shielding and housing
  • Practical work: Creating the IR remote control (transfer of theory into practice).
  • Individual work : Creating a working device of their choice in the form of a seminar.

A detailed breakdown of content:

Theoretical part:

1. Basic components of a circuit, manufacturing technology overview, implementing features, marking, traps when ordering items.

2. Programs for printed circuit board design,
3. Procedures in designing printed circuit boards.
4. Drawing the scheme, designing the circuit.
5. Drawing a printed circuit board, the choice of eyelets for hand/machine soldering and drilling.
6. File formats and preparing the mask for various manufacturing processes.
7. Photo etching process with positive photo-illumination and development.
8. Direct toner transfer, temperature and other parameters.
9. Chemical etching of printed circuits: Fe2O3, HCl + H2O2, (NH4) 2S2O8 and Na2S2O8.
10. Practical toner transfer to the one-sided printed circuit board.
11. Retouching errors in photo etching process or toner transfer method by hand drawing.
12. Practical etching with HCl + H2O2 and Na2S2O8.
13. Control of the etched circuit board with a microscope, the effect of underetching.
14. Removing photo compound/toner, trimming and drilling of printed circuit boards.
15. Alloy of the solder, tin and lead, eutectic, accessories.
16. Various fluxes for soldering: stearn, rosin.
17. Muriatic acid, cinol paste, water-soluble fluxes.
18. A method of soldering, melting and wetting working elements.
19. Types of soldering stations, types of points and temperature control.
20. Tinning of a printed circuit board.
21. Practical tinning of printed circuit board (IR remote control).
22. Assembling the device by soldering, suitable SMD soldering technics.
23. Removing excess solder with solder wick and pump.
24. Gain and frequency boundaries of modern components, unwanted sections.
25. Shielding the low-frequency electric field, electrostatics.
26. Shielding the low-frequency magnetic fields, an example of the cathode ray tube in an oscilloscope.
27. Shielding the radiated electromagnetic field, penetration depth.
28. High-frequency shielded coils, intermediate frequency transformers.
29. Soldered brass housing for internal shielding.
30. Usage of ferrite beads to suppress unwanted resonances.
31. The usage of ferrite rings to damp phase interference.
32. Capacitors bushings for soldering and screwing, types of ceramics.
33. Housing resonance of microwave circuits, absorber and surface waves.
34. Electromagnetic compatibility with other devices.
35. The external aluminum housing, the choice of metal and drawing on a sheet.


Practical part:

  1. Practical soldering of IR remote control.
  2. Testing the IR remote control, seting the frequency of the transmitter.
  3. Correction of errors in soldering.
  4. Replacing the damaged or incorrectly installed components.
  5. Practical aluminum sheet cutting for IR remote control transmitter.
  6. Transfering the housing drawing of the IR remote control device to the sheet using laminator.
  7. Practical drilling of different holes and openings in housing of the IR remote control transmitter.
  8. Cutting the metal for the casing of the remote control.
  9. Practical aluminum sheet bending for casing the remote control.
  10. Assembling the housing and installing the IR remote control transmitter.
  11. Experimental work with a hot air soldering station.

Seminar:

  1. Selection of topics.
  2. Product design.
  3. Creating a printed circuit board.
  4. Assembling (SMD) circuit board.
  5. Installation in housing.
  6. Presentation for the other participants.

Objectives:

  • The ability to create prototype electronic circuits with SMD components on the PCB, learning to use appropriate tools for the work (soldering iron, laminator, flux). Learning the proper handling of (own) tools for the job. Testing of the finished product, detecting and correcting errors.

Competences (occupation specific):

  • Knowing different ways of manufacturing prototype printed circuit boards
  • Knowledge of effective ways for hand soldering SMD components
  • Rapid prototype production of electronic circuits such as planning step

Knowledge and understanding:

  • Manufacturing of prototype printed circuit boards
  • Reliable hand soldering
  • Assembling SMD circuits
  • Troubleshooting errors on printed circuit boards
  • Installation in housing and shielding

Learning and teaching methods:

Lectures, laboratory courses and practical construction of prototype devices in the laboratory. Participants can also carry out part of the practical work independently, outside of the laboratory exercises and then bring the final product to the review and assessment on the last laboratory exercise. After the pedagogical work, participants independently design, construct and test their own product.





Study materials

Priročnik za vaje v digitalni obliki, prosto dostopno udeležencem 2

Literatura je udeležencem dostopna prek spletne učilnice ali prek spletne strani.

http://antena.fe.uni-lj.si/literatura/VajeOK/Spajkanje/Spajkanje.pdf

http://antena.fe.uni-lj.si/literatura/VajeOK/IRRTX/prirocnik/IRdaljinec.pdf



Study in which the course is carried out

  • 0 year - cycle - Extracurricular activities