Electronic Project Design and Fabrication

by Reis, Ronald A.

• ISBN13: 9780130195654
• ISBN10: 0130195650
• Edition: 5th
• Format: Paperback
• Copyright: 2005-01-01
• Publisher: Pearson College Div

Summary

For courses in Shop Fabrication. Hands-on approach and carefully focused on key topics, this innovative text presents thorough coverage of the fundamentals of electronic design, fabrication, and documentation, PLUS a complete experience in creating electronic prototype devices. Students work their way through Sample, Exercise, and Elective Projects (covering all skill levels) and develop a thorough Project Reportwith written and graphic documentationdelineating procedures, developments, and specifications of a project.

Table of Contents

PART I Project Design and Fabrication	1	(261)
An Overview---Making It in Electronics	3	(26)
Electronics Design and Fabrication in the School Laboratory	3	(3)
The Traditional Electronics Course	4	(1)
The Need for an Electronics Design and Fabrication Experience	5	(1)
The Electronics Design and Febrication Process	6	(4)
From Thought to Finished Prototype: A Five-Stage Process	6	(2)
The Electronics Design and Fabrication Process and This Book	8	(2)
Tools of the Trade: On the Board	10	(4)
The Drafting Table	10	(1)
Drafting Equipment	11	(3)
Tools of the Trade: At the Computer	14	(5)
The What and Why of CAD	14	(1)
Computer Systems/CAD Systems	15	(4)
Tools of the Trade: On the Bench	19	(10)
The Bench: More Than the Kitchen Table	19	(1)
Tools for the Workbench	20	(9)
Safety---It's Your Life	29	(12)
Safety: Who Cares?	29	(3)
Safety as a Part of Your Job Description	30	(1)
Body Parts Susceptible to Damage	30	(2)
Where the Danger Lies	32	(9)
Electricity: The Tingle That Hurts	32	(1)
Exposure to Toxic and Hazardous Chemicals	33	(1)
Safety Hazards Caused by the Misuse of Hand Tools	34	(1)
Safety Hazards Caused by the Misuse of Power Tools	34	(1)
Project Safety	35	(3)
Environmental Concerns	38	(3)
The Design Process---An Idea Is Born	41	(34)
Electronics Design: Problems in Search of Solutions	42	(2)
Design and Designers	42	(1)
The Design Methodology	43	(1)
Electronics Design: The Systems Approach	44	(14)
The Fundamentals of Electronics Design	44	(8)
Total Quality Management (TQM) and the Design Process	52	(1)
The Two-Step Design Process	53	(2)
Sketching Techniques	55	(3)
Electronics Design: Two Practical Projects	58	(9)
Designing the Variable Power Supply	59	(3)
Designing the 3-Channel Color Organ	62	(5)
Before Breadboarding: Computer-Based Circuit Design and Analysis	67	(8)
The Virtual Circuit	67	(1)
Multisim V6.2	68	(7)
Drawings---Show Me a Plan	75	(14)
Drawing: The Language of Engineering	75	(4)
When Worlds Are Not Enough	75	(1)
Electronic Fabrication Drawings	76	(3)
Working Schematic: The Cireuit Scheme	79	(10)
Reading Schematic Drawings	79	(1)
To Read Is Not to Write	80	(2)
Working Schematic: Two Practical Projects	82	(7)
Technical Writing---Telling It Like It Is	89	(10)
Tech Talk, Straight Talk	89	(2)
Just the Facts, Ma'am	90	(1)
A Technical Writing Career?	90	(1)
Proposal Writing	91	(2)
Sell Me On It	91	(1)
Writing Your Proposal	92	(1)
Editing---Cleaning Up Your Act	93	(6)
The Technical Writing Style	93	(1)
Punctuate and Eliminate	94	(5)
Experimenting---Breadboarding to Prove Out the Design	99	(30)
Making It, Step by Step	99	(3)
Trying It Out Before Going All Out	99	(1)
Breadboard Decumentation	100	(2)
Soldering: The Tie That Binds	102	(7)
Solder: A Liquid Bond	102	(1)
Soldering Irons	103	(2)
Soldering	105	(1)
Desoldering	106	(3)
Breadboarding: A Half-Dozen Ways to Go	109	(11)
Cut-Slash-and-Hook (CSH): Tried and True	109	(3)
Solderless Wiring Terminals: Point to Point the Easy Way	112	(1)
Solderless Circuit Boards: Breadboarding Modern Circuits	112	(2)
Wire Wrap: Twisting the Night Away	114	(3)
Universal Printed Circuit Boards	117	(1)
Electronic Network Designer (END)	118	(2)
Project Breadboarding and Troubleshooting	120	(9)
Breadboarding the Projects	120	(2)
Troubleshooting the Projects	122	(7)
Prototyping---Printed Circuit Board Design	129	(34)
The Printed Cireuit Board	129	(6)
Circuits without Wires	129	(1)
Double-Sided and Multilayer Printed Circuit Boards	130	(1)
The PC Board Advantage	131	(1)
Overview of the Design and Fabrication Processes	132	(3)
The Printed Cireuit Board Design Layout	135	(10)
Preliminary Considerations	135	(2)
The Design Layout: Basic Techniques	137	(7)
Doing the Design Layout: Two Steps	144	(1)
The Printed Cireuit Board Artwork	145	(7)
Getting Ready	146	(2)
Tapping-Up: Component-Mounting Configurations and Donuts	148	(1)
Laying Down the Tape	148	(2)
Identification Designations	150	(2)
Project Printed Cireuit Board Design	152	(11)
Printed Cireuit Board Design for the Variable Power Supply	152	(3)
Printed Cireuit Board Design for the 3-Channel Color Organ	155	(8)
Prototyping---Printed Circuit Board Fabrication	163	(22)
The Photographic Negative and Printed Circuit Board Fabrication Drawing	163	(9)
Creating the Photographic Negative: An Overview	163	(4)
Producing the Negative: Setup and Procedure	167	(2)
The ``Negativeless'' Negative Approach	169	(1)
The PC Board Fabrication Drawing	170	(2)
The PC Board Fabrication Process	172	(13)
Creating the Photoresist Pattern	172	(4)
Etching and Drilling the PC Board	176	(3)
Repairing the Printed Cireuit Board	179	(1)
Printed Cireuit Board Manufacturing in Industry	180	(1)
Printed Circuit Board Fabrication of the Sample and Exercise Projects	181	(4)
Protoyping---Final Assembly and Project Packaging	185	(36)
Printed Cireuit Assembly	185	(4)
Printed Cireuit Assembly Drawing	185	(2)
PC Assembly Techniques	187	(2)
Cabinets: The Design Phase	189	(6)
Elements of Design	189	(2)
Sheet Metal Design Layouts	191	(4)
Cabinets: The Fabrication Process	195	(7)
Working in the Flat: Cutting the Blank and Making Holes	195	(4)
Forming the Sheet Metal Cabinet	199	(3)
Cabinets: The Finishing Process	202	(5)
Covering It Up	202	(2)
Surface Labeling	204	(3)
Wiring Up and Finishing Up	207	(6)
Wiring Methods	207	(1)
Wiring Plans	208	(1)
Final Packaging	209	(4)
Assembling and Packaging the Sample and Exercise Projects	213	(8)
The Variable Power Supply	213	(2)
The 3-Channel Color Organ	215	(6)
Testing, Troubleshooting, and Final Documentation---The Moment of Truth	221	(18)
Prototype Testing and Troubleshooting	221	(5)
Testing and Troubleshooting Procedures	221	(1)
Testing---One, Two, Three	222	(1)
Troubleshooting the Prototype Project	223	(2)
Performance Testing	225	(1)
Final Documentation	226	(7)
Test Results Document	226	(2)
Summary and Recommendations Document	228	(5)
Testing, Troubleshooting, and Final Documentation for the Variable Power Supply and 3-Channel Color Organ	233	(6)
Sample Project: The Variable Power Supply	233	(2)
The Exercise Project: The 3-Channel Color Organ	235	(4)
Computer-Aided Design (CAD) and the Project Design Process	239	(22)
Making CAD Drawings	239	(5)
Creating CAD Schematic Drawings	239	(3)
Creating CAD PC Board Design Layouts and Artwork Patterns	242	(2)
Logic Creator	244	(17)
Schematic Capture Using Logic Creator	244	(3)
Creating PC Board Artwork Using Logic Creator	247	(14)
PART II Project Design and Fabrication Using Surface Mount Technology	261	(60)
Introduction to Surface Mount Technology	263	(24)
Surface Mount Technology---A Packaging Revolution	264	(4)
Surface Mount Technology Defined	264	(1)
Development of Packaging Technologies	265	(1)
Advantages and Limitations of Surface Mount Technology	265	(3)
Surface Mount Components	268	(6)
Discrete Passive Components	268	(2)
Disrete Active Components	270	(1)
Surface Mount Integrated Circuits	271	(1)
Other Surface Mount Components	272	(2)
Industrial SMT Assembly Processes	274	(13)
Automatic SMT Assembly Using Reflow Soldering	274	(6)
Automatic SMT Assembly Using Flow (Wave) Soldering	280	(3)
The SMT Technologist: An Emerging Carrer Path	283	(4)
Project Design and Fabrication Using Surface Mount Technology	287	(22)
SMT Project Design	288	(10)
SMT Design Factors	288	(1)
SMT Breadboarding	289	(2)
SMT PC Board Design Layout	291	(4)
SMT PC Artwork	295	(3)
SMT Project Fabrication	298	(11)
Making the Printed Circuit Board	298	(1)
Attaching SMCs to the PC Board Prior to Hand Soldering	299	(2)
Surface Mount Assembly Using Solder Wire	301	(3)
Surface Mount Assembly Using Solder Paste	304	(1)
The Completed Sample Project	305	(4)
SMT Rework---Removal and Replacement of Surface Mount Devices	309	(12)
SMD Removal: Taking It Off	309	(7)
Tools for Disengagement: Methods of SMD Removal	310	(3)
Effecting the Pullout: Dislodging SMDs	313	(3)
SMD Replacement: Putting Them in Their Place	316	(5)
SMD Replacement with Direct heat Attachment	316	(1)
SMD Replacement with Handheld Air Devices	316	(1)
Solder Joint Integrity	317	(4)
Part III Student Construction Projects	321	(210)
Sample Project Report/Variable Power Supply	323	(20)
Exercise Project Report/3-Channel Color Organ	343	(22)
Concepts and Requirements Documents and Three-Drawing Set/Elective Projects	365	(166)
Appendices
A Electronics Safety Test	504	(6)
B Sheet Metal Layouts	510	(2)
C Adding a Voltmeter to the Variable Power Supply Project	512	(2)
D Active Component Outline Drawings	514	(8)
E Surface Mount Technology Projects	522	(1)
F Surface Mount Technology Sources	523	(2)
G Books and Magazines	525	(1)
H Five-Band Resistor Color Codes	526	(1)
I Schematic Capture and Drawing Program Sources	527	(1)
J Electronic Kit Sources	528	(1)
K Electronic Project Design and Fabrication Web Sites to Visit	529	(2)
Answers to Chapter Questions and Safety Test	531	(4)
Glossary	535	(10)
Index	545