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Chapter 1: INRODUCTION

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Chapter 2: BLOCK SCHEMATICS

2.1 POWER SUPPLY: +12 V

230
230
AC
AC
mains
mains

Transfor
Transfor
mer
mer

Rectifier

Smoothing

Regulat
or

Figure 2.1 power supply

Main Circuit 2.2

Ujt relaxation
Oscillator

Pulse
Pulse
transformer
transformer

AC
AC voltage
voltage
controller
controller

Lamp
Lamp load
load

Figure 2.2 main circuit

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Regulat
ed
12V+
DC

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Chapter 3: CIRCUIT DIAGRAMS & EXPLANATIONS

3.1 POWER SUPPLY - +12V

figure 3 .1

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3.2 figure

April 15, 2013

Main circuit

3.2 MAIN HARDWARE CIRCUIT

Figure 3.3 Main hardware circuit

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3.3 MAIN CIRCUIT

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3.4 POWER SUPPLY SECTION

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Figure 3.4 Power supply circuit

Chapter 4: Electrical Components

S. No

Components

.1

Resistors

.2

Capacitors

.4

Transistor

.5

Diodes

Specification/value

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Voltage Regulator

.9
.10

TRANSFORMER

.11
.12
.13
.14
.15

IC

Load

Chapter 5: PCB MAKING

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Fig 5.2 CNC machine

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Fig 5.3

Position A : Lever in normal position, chuck closed. The motor is connected

.to the spindle via the coupling ( Fig 1.4)
Position B: To open the chuck, press the lever down. This separates the motor
with the coupling and opens the chuck over a spring assembly. In this position, the
tool can be removed or inserted with the aid of tweezers (only in tool change
.position!!)
Note: The lever always moves back to position A when it is
not
!pressed down

Fig 5.4

During the milling of isolation channels on the PCB materials it is of special

importance that the milling depth is kept constant. The LPKF ProtoMat S42 achieves
.this by means of the mechanical scanning using the working depth limiter
Introduction to board master
This following chapters provide basic information on the operating principles and a
first impression of Board Master to familiarize you with the user surface
Note: As a beginner, always read the following chapter carefully before starting to
work with Board Master in combination with your circuit board plotter. Chapter 8
then presents a practical introduction into the basic methods of operation and chapter
.9 describes the basic functions of the ProtoMat
1. HOME position and Reference Hole System

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Reference point programmed in the software

It must be located on the reflection axis of the machine for production
of double-sided PCB
Reference point for the milling and drilling data
1. Home Position
2. Reference pin groove
3. Additional reference
hole, rear position

2. Switching On the Circuit Board Plotter

Danger!!! Never reach into the machine during switching on
Switch on Sequence
A. Switch on the computer
B. Then switch on the circuit board plotter Protomat S42
Note: When the machine is switch on, the machining head starts to
move immediately to approach the limit switches in X and Y
.position. Then it stops in the zero position
C. Then start the Board Master.
3. Starting the Board Master
Click once on the entry BOARDMASTER 5.0 in the program group LPKF
LASER & ELECTRONICS in the START menu or double click the
.BOARDMASTER 5.0 icon on your desktop
Note: During start-up the following image appears before the main menu or the
:wizard (input assistance) is displayed

After starting LPKF Board Master, the following prompt appears if the plotter was
:not switched on previously

4. Wait Message
As long as BoardMaster is waiting for a reply from the circuit board
plotter (i.e. circuit board plotter is in motion), a box with a corresponding
:message is displayed

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!The box disappears as soon as the head has arrived at the tool change position
!!Always wait this long and do not click the Stop button
This message is also output when the machine is still busy editing the last command
from the command buffer. This is not an error message! It is possible to change to
other applications while the box is displayed. As soon as the plotter sends the
.requested reply to the PC, the box disappears and the program is continued normally
:After clicking the Stop button, an (additional) error message appears
?Message: Do you really want to cancel the current process
No
Yes
Note: If you really want to cancel the current process, it is discontinued only after
clicking the YES button a number of times. The communication between computer
.and circuit board plotter is then interrupted
5. Switching of The Circuit Board Plotter
When switching OFF the circuit board plotter, first quit Board Master before
switching OFF the machine. In the opposite sequence, recurring error messages
.are possible, which can be cancelled only by repeatedly actuating the YES button
(...Error message: Do you really want to cancel the current process)
Before Board Master is actually switched OFF, a menu is displayed asking where
:the machining head is to be displaced to

.Click on Ja to make the machine head go to the reference point ( i.e. zero position)
Click on YES, if possible, as the machining head is then located at the reference point
during the new start. After clicking on NO the machine must perform a time.consuming new approach of the reference positions during a new start

6. Board Master User Interface

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Title bar , 2-Menu bar, 3-Function bar, 4-Working area-1

Blue cross hairs represent the current position of the mill/drill head -5

Interface .1
This display provides information on the interface set for
transferring the control data. Here NULL means that the data is not
sent to an interface. When the mouse is moved over this display
.field, the values set for the interface are indicated in the status bar
Actual position of milling drilling head 2
.This display shows the actual position in all 3 axis
Number of vectors .3
The number of vectors which have already been processed is displayed (here vector
.means section of line, causing movement in X, Y, or Z direction)

Estimated Processing Time .4

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For current production phase the display indicates the estimated time in hours or
minutes required for processing the enabled production phases. Individual selections
.are not taken into consideration here
5. Working with Production Data and Phases
A. Importing Production Data
You can import LMD production data prepared by CircuitCAM
B. Assigning Tools
.Assigning tools is usually done by Board Master
C. Placing Production Data
The data are automatically placed at the middle of the working area.
But it is possible to change the position by clicking this button
D. Saving a Job
Before starting the machining process, the milling depth has to be manually
adjusted. The milling depth can be adjusted by turning the knurled nut on the
working depth limiter. When the wheel is turned clockwise, the milling depth
.is increased; turning counterclockwise reduces the milling depth

figure 5.5

Turning the knurled nut by one increment changes the milling depth by approximately
to 4 m and turning the knurled nut one complete rotation changes the milling depth
.by approx. 0.5 mm
Note
Milling depth can be set in steps of 2m
Milling width of the Universal Cutter can be set in steps of 4 m and the width
of the Micro Cutter in steps of 2.3 m
6. Steps for Single Sided PCB Fabrication
A.
B.
C.
D.

Marking Drills
Drilling Plated
Milling Button
Cutting Outside

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7. Selecting first production Phase

Each production phase, like milling the solder side (Milling Bottom) must be
selected individually and prepared for processing (inserting the correct tool and
:so on). Now start with the first production phase
First check whether in the function bar in the list field PRODUCTION
STEP the production phase MARKING DRILLS is selected.

Select

Click on the
data of

for marking all data

button in the function bar to send the marked

.the current production phase to the circuit board plotter

Before the production phase is processed, a demand is displayed to insert the
.corresponding tool

Insert the corresponding tool

After the marking drills you will see this message. Just click OK to
end. Then proceed to the next phase. Doing the same step.

After doing all the phases, Click the

.position to remove the PCB

button to moved the drill head in pause

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Chapter 6: Mechanical work

:The steps of working in mechanical workshop
1. Choose the suitable sheet for our project box (steel sheet because its strong
and easy to bend and file) and cut it by using sharing machine. We cut two
pieces of steel (414) mm X (340) mm and (410) mm X (180) mm.
We cut this size of piece to be able to handle the circuit

Fig 6.1

Fig 6.2

By using the Venire height gauge and ruler with scriber the lines has been marked .2
.in the sheet and we follow the lines to cut. Marking out the dimensions on the sheet
After that, the holes were making in the sheet for each of fuse, .3
power supply and 1M preset, Using hammer with center punch to
.mark or to point the place of the holes and using drilling machine
Fig 6.3
We Use flat file to make the sides of the sheet smoother and also we use it for the .4
.holes
We take the dimension for the front sid and for the BACK side. After that we use .5
drilling machine to make .Then we use hammer with flat chisel to remove unwanted
.pieces
We use bending machine in bend the base sheet which include back and front view .6
.and we bend the cover which include the side of the box
.Paint the Box and finalizing the mechanical fabrication .7

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Chapter 7: SYSTEM ANALYSIS AND DESIGN

In general THE PROJECT LIFE CYCLE involves 4 phases:
1. STUDY PHASE
2. DESIGN PHASE
3. DEVELOPMENT PHASE
4. OPERATION PHASE
IN OUR PROJECT: the project life cycle was executed as follows
1. STUDY PHASE
(i) Initial Investigation:
An electrical power circuit controlled by electronic circuit based
project containing hardware was necessary to be initiated; since it was a
curriculum requirement for us being Diploma students at Colleges of Technology.
(ii) Feasibility analysis:
We selected a project named Timer enhanced on/off single phase load that
also included discrete components and Integrated circuits. Since we have studied
about active and passive components and about integrated circuit in our previous
courses.
2. DESIGN PHASE:
The circuit details were surfed from the internet; and the circuit design
was discussed with our supervisor. The availability of the components were
checked and on confirmation; the project development was initiated.
3. DEVELOPMENT PHASE:
The power supply sections were built on the bread board to supply 9v
for our main circuit. Next the MAIN POWER CIRCUIT was built on the bread
board and tested by using lamp as load.
4. OPERATION PHASE:

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The system is put to operational and tested after the components are
soldered in the PCB and then suitable container is used to enclose our project
to make good view

Chapter 8: CONCLUSION

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REFERENCES

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PHOTOS FROM WORKING

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APPENDICES

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Tools Used
Soldering of Iron(1

2) Reel of solder:
The best size for electronics is 22swg (swg = standard wire
gauge).

3) Side cutters:
For trimming component leads close to the circuit board.

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4) Small flat-blade screwdriver

For scraping away excess flux and dirt between tracks, as well as
driving screws!

Steel rule
.It is used to measure the dimensions

Scribers

Scribers are hand tools used in the metal trades to mark lines on work pieces,
prior to machining. This is used instead of pencils as the marks from pencils
cannot be seen clearly as Scriber marks. They consist simply of a rod of highcarbon steel, in its hardened state, that has been sharpened to a point at one or
both ends. They are used by drawing the point over the surface of the work piece
.to leave a shallow scratch on its surface scribers

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Center punches
A center punch is typically used as an aid to drilling operations; a drill, when brought
into contact with a flat surface, will have a tendency to wander on the surface until it
gains sufficient purchase to start cutting a hole. A center punch forms a small dimple
in which the tip of the drill (if it is small enough) will fit. When drilling

the drill is wider than the

larger holes and the web of

indentation produced by a center punch, the drilling of a pilot hole is usually needed.
A center punch usually has a tip, that when viewed on a profile, has sides at a 90
degree angle to one another. Used with a hammer to produce a small angled
indentation on the work surface. This indentation can be used as appoint location for
.dividers or trammels
Files
A file (or hand-file) is a hand tool used to shape material by abrasion. A file typically
takes the form of a hardened steel bar, mostly covered with a series of sharp, parallel
ridges or teeth. Most files have a narrow, pointed tang at one end to which a handle
can be fitted. The rasp is a related tool which is generally larger and has raised,
pointed teeth on its surface rather than straight ridges. There are many types of files. It
is specification by length, type, cut and grade. The cut of files refer to the direction in
which the teeth are formed. The way in which a file used to remove metal depends on
.the operating being carried out
Vernier measuring instruments

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Vernier measuring instruments are designed for making accurate measurements to

two hundreds of millimeter (0.02mm). In practice, however, you would find this
accuracy extremely difficult to obtain as it requires considerable skill, good eyesight
and a sensitive touch or feel. Under normal working conditions, an racy of between
.two hundredths of a millimeter above or below the dimension is more realistic

Flat chisels
It used to cut flat face where there is too much material to file, and too little to
.hacksaw. Another application is cutting sheet metal

Hacksaws
These tools are used to remove length of waste metal where it is impractical to
remove the amount by a file or chisel. Hacksaw blades can vary in their length,
tooth pitch, and the material from which they manufactured the applications for
different blade material and pitch. To prevent a hacksaw blade from binding in a
.slot being cut, asset is applied to the teeth. Blades are having a coarse pitch

Drill bits
Drill bits are cutting tools used to create cylindrical holes. Bits are held in a tool
called a drill, which rotates them and provides axial force to create
the hole. This article describes the types of drill bits in terms of the
design of the cutter. The other end of the drill bit, the shank, is
described in the drill bit shank article. Drill bits come in standard
.sizes, described in the drill bit sizes article

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Machines

Electrical Shearing Machine

It used to cut sheet metal working like aluminum sheet. The maximum of thick is
.2mm.It is working by three phase electrical power

Drilling machine
Sensitive drilling machines are so called because they are of fairly light and simple
constriction, which enables the operator to feel the pre-sure on the drill as it cuts
through the work. This type of drilling machine is capable of very high spindle
.speeds,

and generally is capable of drilling holes up to 12 mm diameter

Bending or

folding

machine

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These are generally used for bending sheet metal at right angles although other angles
can be obtained. Many bend using a cylindrical mallet. A simple folding machine is
shown in figure. Basically, it consists of a number of steel clamps which hold the
.sheet metal firmly in a horizontal position

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