Meeting with Jeff Luneville

29 Aug 2013

Purpose: Understanding the Customer Environment

Notes:

The lab where the PCB Isolation Routing System with reside, CEMA, is open to students campus wide. EE, CE, NTID, MicroE, Manufacturing students, etc. design and build prototypes then assemble them in the lab.

· Students generally require 1-5 prototype boards, this often is limited by budget constraints

· Eagle or Express PCB, and Gerber Data are used in the design of the boards

· In order to use the placement machine for components, students need reels which are pricy

· For a low volume of boards, students most often design, come in, and hand place components. Pick and place is only cost effective if many boards are produced

Industries also make use of the lab

· MicroGen, Windsor, Redcam, GM, Johnson & Johnson, etc.

Before utilizing the lab, students design and send Gerber files to bare board manufacturers

· Metrocircuits is a manufacturer of bare boards that take Gerber files

· Students send Gerber data to Metrocircuits who manufacture the board

The mill will make noise and dust

· The lab has a vent system, which is used for fumes

· Noise requirements can be figured out based on prototype

The actual machine will be located where the SEM is currently located in the lab

· The mill will ideally be placed in the front of the lab to create “flow” for work and tour puposes.

· Proposed order: Mill, Stencil printer, placement machine, Oven, Selective soldering or hand soldering

Would like to manufacture “RIT” boards with LED lights to give away at ImagineRIT

· Currently have the “RIT” stencil

· 1 Layer board, stencil with pads, squeegees apply pads, components placed with the placement machine

· Boards are expensive

Placement Machine

· Places components on boards

· Components are very small, an entire reel must be purchased

· Machine identifies parts by size, but can’t tell the difference between components of the same size

· How do we make sure components are on the right reel

Reflow Oven

· “Big pizza oven”

· How fast it runs and the temperature it runs at based on properties of the board, thickness, lead type, etc.

Selective Soldering

· Just solder where you want it

· Solders thru holes

· K.I.S.S. -102

· Magnetic motor screw attachment (magnetic clutch), uses a high powered magnet

· Backwards router

· X-Y-Z axis

Additional Lab Technology

· 5 axis X-Ray system

· Ultrasound

· Adhesive Jet

· Thermal Shock System

· Humidity System

· Highly Accelerated Stress Tester (Pressure cooker)

· Acoustic Scanning Microscope

· Scanning Electron Microscope (SEM)

· Shear Tester

· Cross-sectioning capabilities

Selective Soldering Machine uses G code

· Recommended programming system

· Software is easy to use

· Similar to editing coordinates in notepad

Boards

· Largest board to manufacture would be 8x11” (sample in possession)

· Need 500-600 boards ahead of time for ImagineRIT

· Current manufacturing and assembly time is 5-10 minutes, with no target for milling process time

· Use IPC specs for board tolerances

· Not all boards are rectangular, some are irregular shapes

· 402 size would be doable, dependent on bit size and speed

· Units are not standard in electronics – a conversion system would probably be needed

Servicing Equipment

· Maintenance to the machine would be done by the lab – lubrication, preventative maintenance (1 every 2 weeks)

· Safety Emergency Shut-off

· Guards

MISC

· Off the shelf parts are preferred due to people changeover and cost

· BOM required

· Management of wiring and cabling – look at other manufacturers

· RIT – Safety Training – Lab Safety Training

· Will know space requirements once the electron microscope is gone

· Eagle software is free on the internet

Jeff is available during the day usually beginning around 7. Walk-ins Welcome