SA POLYTECHNIC COLLEGE

INTERNSHIP REPORT

Title: PCB FABRICATION FOR SERIAL LIGHT CONTROLLER AND IOT

VENUE: EXHIBIT ELECTRONIX

DATE:

SUBMITTED BY:

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2.

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 CONTENT

CHAPTER TITLE PAGE NO.

ACKNOWLEDGEMENT

1 ACTIVITIES IN THE INTERNSHIP

2 SERIAL LIGHT CONTROLLER AN INTRODUCTION

3 BLOCK DIAGRAM WITH DESCRIPTION

4 CIRCUIT DESCRIPTION

5 PCB FABRICATION USING ORCAD

6 CIRCUIT DESIGN USING CAPTURE CIS

7 LAYOUT DESIGN USING ORCAD LAYOUT PLUS

8 PCB MAKING PROCEDURE

9 PCB ASSEMBLY

10 INTERNET OF THINGS
IOT BUILDING BLOCKS

11 CONCLUSION

CURRENT PROJECT AND FUTUTRE EXPANSION

ACKNOWLEDGEMENT
 ACTIVITIES IN THE INTERNSHIP

We at Exhibit Electronix believe the technology can be learned only by doing.since we

were indulged in PCB domain, we made students to start from scratch till PCB development and

assembly. The step by step procedure includes,

 Introduction on PCB materials, PCB design software and PCB fabrication

 Testing the electronic circuits using breadboard

 Designing the circuits in OrCAD software

 Generating PCB layout using OrCAD software.

 Observation of components and various sensors

 PCB making using etching process

 Preparing etching solution, transferring layout from pc over copper clad boards

 PCB drilling process

 PCB assembly

 Output verification and PCB repair if required.

 BLOCK DIAGRAM WITH DESCRIPTION

BUZZER
SIGNAL
PIR SENSOR CONDITIONER DRIVER

LED ARRAY

 Input DC voltage of 9V is given as power supply voltage

 555 timer is used as square wave generator

 The output of 555 is given as clock pulse source to CD4017 Decade counter

 An LED array is used as serial light and connected as strings of led at corresponding

output pins of cd4017 counter.

 CIRCUIT DIAGRAM OF PIR INTRUDER ALARM
R1
+9V

J3 100
2
1

BU ZZER D1 D4 D7
LED LED LED

J2
2 +9V D2 D5 D8
1 LED LED LED

CON2 +9V

D3 D6 D9
LED LED LED
R2
1k

J1
3
2 Q1
1 BC 547

CON3

PIR BASED INTRUDER ALARM

LAYOUT OF PIR INTRUDER ALARM-TOP SIDE

LAYOUT OF PIR INTRUDER ALARM-BOTTOM SIDE

 PCB FABRICATION USING ORCAD

Steps Involved in the Printed Circuit Board Prototyping

1. Circuit Identification

2. Designing the Circuit

3. Designing the Libraries

4. Components Placement in the PCB

5. Designing the layout

6. PCB fabrication

7. PCB Assembly

Circuit Identification:

This step includes the identification of electrical interconnection between all the

components. This step requires more attention towards the circuit mapping. if the circuit

mapping goes wrong the entire steps following the circuit identification will be merely waste.

Designing the Circuit:

Once the circuit identification is over, the next step is Circuit designing. Circuit designing

is the base of the PCB Design. Many no. of Professional and Commercial CAD software’s are

available. ORCAD were the pioneer in the field of PCB Design.

Designing the Libraries:

This step is about designing the new components that are not available in the software.

Most of the designs would not have the components symbols that are required for designing.
Designing the libraries meets all the information about the components like component symbol,

pin numbers, pin names, etc...

Once the circuit is designed with all the components, the next thing to focus is about the

PCB design. After designing the circuit netlist file is need to be created. The netlist file gives the

relation between the electrical inter connection between the components. Only with the help of

netlist file the PCB design could be completed efficiently.

Components Placement in the PCB:

Once the circuit design, netlist generation is over. PCB design could be started. PCB Design is

not straight forward the basic steps associated with PCB design are linking existing footprints to

the components, creating new footprints to the components, preparing board outline, placing the

components, designing the layouts,Gerber file generation and finally the PCB fabrication.

Components placement in the PCB is more important for the customization in the PCB’s. The

PCB design could be done more efficiently with the proper placement of components. The

proper placement of the components will helpful for neat, error free designs and could be helpful

for fault diagnostics.

Designing the layout:

Designing the layout should be strictly adhered towards the Design rules. The design

rules include distance between the components, distance between the tracks, width of the tracks,

etc…One should aware of different layers in the PCB.

PCB fabrication and assembly:

Once the layout is ready, the PCB file is needed to be submitted for the PCB fabrication

Industry. The end PCB comes with needed data’s like name of the components, pad drills, layer,

etc…

Once the PCB is fabricated final step is the assembly and testing.
 CIRCUIT DESIGN USING CAPTURE CIS

OrCAD Version 9 is used to design the schematic and pcb.

Follow the steps given below for circuit entry

 Open orcad capture CIS

 Goto file NewDesign

 Save the file.dsn

 Add the default libraries from CProgram filesOrCADCapture CIS library

 To place the part in schematic window click on place part. Search for the part and place it

in the schematic window.the shortcut for placing the part is P.

 Wire the components using wire symbol.

 To create library, goto file newlibrary.select library.olb and right click on olb file,

click on new part. draw the symbol of the part and assign pn numbers and save the

library.

 Draw the schematic and create mnl file that is required to design the layout.

LAYOUT DESIGN USING ORCAD LAYOUT PLUS

Follow the steps given below for layout design

  Goto fileNewopen default.tch from the location C/program files/OrCAD/layout

plus/data/default.tch

 Open the mnl file that is created in capture CIS.

 Assign the footprint for the components that is given below.

Sr. No. Component footprint

1. Voltage Source JP100
2. Voltmeter JP100
3. Resistor R_AX300_W100
4. Capacitor CP_CYL100_D230_L470
5. Capacitor_NP C_RAD100_L150_W100
6. Inductor L_CYL200_D350
7. Diode DO41-10
8. 78XX regulator TO220 (LM7805C)
9. Transistor-BC547 TO92
10. Transistor-BC107 TO18
11. LED LED_100_D200_Red
12. Transformer EE20_1P_1S (TR)
13. Transformer with center tapped EE20_1P_1S
14. 8 pin DIP IC (uA741,NE555) DIP8
15. 14 pin DIP IC (Logic gates) DIP14
16. 16 pin DIP IC (XR2206) DIP16
 Draw the board outline

 Place the components using the component tool

 Draw the layout in bottom layer. While drawing the layout assign the proper track width.

 Print the design in photo paper for PCB fabrication.

PCB MAKING PROCEDURE

Courtesy: Electronics Hub

Warning: Before proceeding with the process, I suggest you to take necessary safety

precaution like using goggles, gloves, mask etc.

Printing the PCB Layout on a Paper

After completing drawing the PCB layout of the circuit, we need to print the layout on a

paper. To print the layout, first click on the Print Option. You will get a new window

with options for setting up the print layout.

How to Select the Paper for PCB?

 a single sided Glossy Paper for Laser Printers with thickness of 130 GSM.

NOTE: Do not use Inkjet Glossy Paper with Laser printer as it might damage the drum in

the laser printer.

Getting the Board Ready for Toner Transfer

 First, print the layout on the paper using laser Printer. Here, we have made

multiple copies of the layout just to demonstrate that we can make multiple boards

with a single paper (Save Paper!!!).

NOTE: While printing, set the paper size to A4, orientation to Portrait and check the

Actual Size option (IMPORTANT).

 STAGE 1
8051 TARGET BOARD SCHEMATIC

 Now, cut the piece of paper with layout printed on it. Select the size of the paper a

little bit larger than the final size of the board so that you can wrap the paper

around the board.

 Take a Copper Clad PCB Board and mark the size of the board on one corner. In

our case, it was a rectangle of size 4cm x 3cm.

  Cut the small board using a saw. Before cutting the board with saw, use a sharp

tool like a box cutter and make fine groves on the surface. This will allow you to

easily cut the board using the saw.

 Now, the surface of the board (the one we just cut) is not clean with deposits of

fingerprints and dirt. So, in order to clean the surface, use a mild emery paper and

rub it on the Copper side of the board.

Transferring the Toner from Paper to PCB

 The next step is to transfer the toner from the paper on to the Copper side of the

board. For this, I’ll be using an Iron Box.

 Place the copper side of the board on the top and place the iron box on the board

and slow start ironing the board. Apply slight pressure on the board for about 10

minutes and take of the iron box. You can see a change in color of the paper

before and after ironing.

 This instant cooling will bind the toner more strongly on to the Copper board. Let

the board cool down in water for a minute or two.

 Use the water from the bowl and rub off the paper from the board. Do not apply

too much pressure while removing the paper.

 When the paper is completely removed, you can see a clean transfer of the toner

on the Copper Clad Board.

  In case you feel that a part of the trace or pad did not transfer perfectly, use a

permanent marker and draw on the broken or unclear toner.

Etching the Copper from Board

 The next step is to remove all the unnecessary copper from the PCB Board. This

process is called Etching. For this, I’ll be using Ferric Chloride (FeCl3). Ferric

Chloride is a very harmful and toxic chemical. Be extremely careful when using it

for making PCB.

 Take a spoon or two of Ferric Chloride Powder and put it in a thick plastic or steel

container. Pour some hot water in the container.

Warning: You can see fumes coming out of the container as soon as you add the

water.

 Drop the PCB in the container and stir the water for 10 to 15 minutes (or until the

Copper is completely etched).

 Ferric Chloride will not react with Carbon (which is the main component in the

toner) but only with the Copper. Hence, the Copper on the board, except that

beneath the toner (which acts as a protective layer) will be completely removed.

 Dispose of the water carefully and add fresh water in the container. Now, place the

PCB in the water to clean of the surface from chemical deposits.

 Take another piece of mild emery paper and slowly clean the toner from the PCB

using acetone.
Drilling Holes on the PCB

 Next step is to drill holes on the PCB to mount the components. We used a small

hand drill (motorized drill) to make the holes.

 Once all the holes are drilled, PCB is ready for assembly.

PCB Assembly

Collect all the components required for assembling on the PCB. Place all the components

in their respective positions and check if all the holes, tracks and pads are as expected or

not. Start soldering the components on the PCB.