Building a Typical Electronic

Project in Senior Design

Peter Wihl
(former Guest Lecturer)

Scope
The purpose of this presentation is to
introduce you to the process of
implementing a circuit design into an actual
working design solution.

Process Overview

Requirements*
System Architecture*
Component Selection
Mechanical/Packaging Design
Detailed Board Design
Layout
Fabrication
Board Assembly
Testing and Debugging
Design Changes/Workarounds
*Must be completed prior to this process.

Lecture Example
Building a distance measuring sensor device

Requirements
Must be completed prior to board design
and implementation
A detailed list of what the system must do
Not how it does it.
Should be well thought out and clear

Requirements Example
Must be wireless
Must measure in the range from 0.30 to 2.5
meters
Must have a resolution of at least +/- 10 cm
Must interface with a microprocessor on
both transmitter and receiver side using
5.0V CMOS Logic

System Architecture
A detailed block diagram
Includes all significant signal paths
Include signal direction, width, and type

System Architecture Example

Component Selection
Identify the best component solution for
each design block in the system architecture
Identify all necessary support components
for each major design block component
Explore different package options if
available
Take any mechanical requirements into
account

Component Selection Example

Reynolds 433 MHz Tx/Rx Module (COTS)

US Transducers Tx/Rx
40 kHz Crystal
74Inverter
74NAND
LMV722 OpAmp from National
LMC567 Tone Decoder from National
Headers
SM Resistors and Caps

Mechanical/Packaging Design
Identify the mechanical or packaging
requirements of your design
May possibly have to select components
based on these requirements
Identify possible layout restrictions
Think about non-circuit requirements, i.e.
mounting and packaging

Mechanical Design Example

Mechanical Design Example

Mechanical Design Example

Mechanical Design Example

Mechanical Design Example

Detailed Board Design

Build your schematics in a schematic
capture program e.g. OrCAD
Once your schematic is complete run a
design rule check (DRC)
When schematic is done convert to netlist
for layout

Detailed Design Example

Detailed Design Example

Layout
The process of designing the PCB
Requires a schematic netlist, the Bill of
Materials or BOM and all package
mechanical information

Layout Example

Fabrication
This is the process of placing the
components on the PCB
Can be done by hand or machine

Fabrication Example
See sample

Board Assembly
The process of populating the PCB with all
components
This includes ICs, Resistors, Caps
Connectors and LEDs, etc.

Board Assembly Example

Testing and Debugging

You need to develop a thorough and
complete test plan for your board.
Should include a check list of steps in a test
procedure
Each step should include status of all board
voltages
Use continuity, clock signals and/or
signature analyzer to verify net connections

Design Changes/Workarounds
White wire part of the board
Must create detailed step by step
instructions on white wire corrections
Sometimes minor design changes are
needed when an error is found in the board
design
May have to be done in software

Conclusion
This process consists of different types of
engineers working together.
Depending on system complexity and level
of design reuse this process can take from 1
to 18 mouths.
Any questions?