INDIVIDUAL PROJECT – (MECHATRONICS)

PCB DRILLING MACHINE

By

W. C. Dunstan

This report is submitted in partial fulfillment of the requirements

for the

Degree of Bachelor of Technology

Department of Mechanical Engineering

Faculty of Engineering Technology

The Open University of Sri Lanka

Nawala, Nugegoda, Sri Lanka

November 2010.

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 INDIVIDUAL PROJECT – (MECHATRONICS)

TO MY DEAR PARENTS AND TEACHERS

WHO GIVE THEIR BEST EVERY DAY

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TABLE OF CONTENTS

List of Figures V

List of Tables VI

List of Symbols VII

Abbreviations VIII

Acknowledgments IX

Abstract X

CHAPTER 1…………………………………………………………………. 01

1. Project Background 02
1.1 Aim And Objectives 02
1.2 Introduction 03
1.3 Typical PCB Drill 04
1.3.1 Hand Drill And Power Drill 04
1.3.2 Optical Drilling Machines 04
1.3.3 CNC Drill Machine 05
1.3.4 Laser Drilling Machines 06
1.4 Literature Survey 07
1.4.1 Dual Encoder Configuration (Dual-Loop Control System) 07
1.4.2 Coefficient Of Friction Under Different Conditions 08
1.4.3 Application Of Screw And Material Selection 08

CHAPTER 2…………………………………………………………….......... 09

2. Project Approach 10
2.1 Overall Design 10
2.1.1 Introduction 10
2.2 Mechanical Design 11
2.2.1 Design Parameters And Selection Procedure 11
2.2.2 Mechanical Arrangement And Design Layout 27
2.2.3 Views Of PCB Drill Machine 28
2.2.4 Motor Mounting 29
2.3 Software And Electronic Hardware Design 30
2.3.1 PCB Drilling Algorithm 30
2.3.2 PCB Drill Software 31
2.3.3 Functional Organization Of The Controller 33
2.3.4 Block Diagram Of Motor Controller System 35
2.3.5 Block Diagram Of Distance And Speed Controller 36
2.3.6 Control Unit 38
2.3.7 Microcontroller Control Algorithm 39
2.3.8 Schematic Diagram Of Overall Design 41
2.3.9 Micro Control Board PCB Design Layout 42

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2.3.10 L298 PCB Design Layout 43

2.3.11 Selecting A Power Supply 45

CHAPTER 3………………………………………………………………….. 46

3. Design Analysis 47
3.1 Stress Analysis Of Bearing Coupling 47
3.2 Stress Analysis Of Guide Bar 48
3.3 Conclusion 49

REFERANCES……………………………………………………………….. 50

4. References 51

APPENDIX A ………………………………………………………………….. 52

5. Appendix A (MECHANICAL) 53
5.1 Values Of Service Factor For Bearing 53
5.2 Values Of X0 And Y0 For Bearing 53
5.3 Life Rating Equation 53
5.4 Values Of X And Y For Dynamically Loaded Bearings 54
5.5 Basic Static And Dynamic Capacities Of Various Types Of Radial Ball
Bearings 55
5.6 Bearing Coupling Dimensions 57
5.7 X And Y Axis Dimensions 58
5.8 Y Axis Moving Part Dimensions 59
5.9 Z Axis Moving Part Dimensions 60
5.10 Drill Machine Assembly Drawing 61

APPENDIX B ………………………………………………………………….. 62

6. Appendix B (ELECTRONIC)
63
6.1 Microcontroller Specification 63
6.2 Motor Specification 64
6.3 Encoder Specification 66
6.4 LM 629 Controller Specification 66
6.5 L298 Dual Full Bridge Driver Operation 67

APPENDIX C ………………………………………………………………….. 70

7. Appendix C (COST ANALYSIS) 71

APPENDIX D ………………………………………………………………….. 73

8. Appendix D (SOURCE CORDING OF MICROCONTROLER) 74

APPENDIX E ………………………………………………………………….. 73

9. Appendix E (PHOTO OF PCB DRILL MACHINE) 79

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LIST OF FIGURES…………………………………………………………………………..

Figure 1.1 Hand Drill and Power Drill 04

Figure 1.2 Optical Drilling Machine 04
Figure 1.3 CNC Drill Machine 05
Figure 1.4 CNC Machine 06
Figure 1.5 Laser Drilling Machine 06
Figure 1.6 Standard Dual-Loop Control System 07
Figure 2.1 System Overview of Drilling Machine 10
Figure 2.2 Side View of X Axis 12
Figure 2.3 Plan Of X Axis 15
Figure 2.4 Free Body Diagram of X Axis Screw 15
Figure 2.5 Free Body Diagram of Guide Bar 19
Figure 2.6 Diagram of Bending Movement 19
Figure 2.7 Side Views of Z Axis 21
Figure 2.8 Free Body Diagram of Z Axis Screw 24
Figure 2.9 Dimension of X Axis 27
Figure 2.10 Dimension of Y Axis 27
Figure 2.11 Views of PCB Drill Machine 28
Figure 2.12 Direction of Motor Mounting 29
Figure 2.13 Mounting Type 29
Figure 2.14 PCB Drilling Algorithm 30
Figure 2.15 Data Protocol 31
Figure 2.16 PCB Drilling Machine Software Interface 32
Figure 2.17 Software Interface Message Box 32
Figure 2.18 Functional Organization of the Controller 33
Figure 2.19 Duty Cycle Diagram 34
Figure 2.20 Encoder Sensor Diagram 35
Figure 2.21 Motor Controller Block Diagram 35
Figure 2.22 Block Diagram of Controller System 36
Figure 2.23 Block Diagram of the PCB Drilling Controller System 38
Figure 2.24 Microcontroller Control Algorithm 39
Figure 2.25 Schematic Diagram of Overall Design 41
Figure 2.26 Top View of Main Microcontroller Board 42
Figure 2.27 Copper Side View of Microcontroller Board 43
Figure 2.28 Top View of L298 PCB Design Layout 43
Figure 2.29 Copper Side View L298 PCB Design Layout 44
Figure 2.30 View of L298 with dsPic PCB design layout 45
Figure 3.1 Bearing Coupling -Cosmosxpressstudy-Stress-Plot 47
Figure 3.2 Guide Bar-Cosmosxpressstudy-Stress-Plot 48
Figure 5.1 Bearing Coupling Dimensions 57
Figure 5.2 X and Y Axis Dimensions 58
Figure 5.3 Y Axis Moving Part Dimensions 59
Figure 5.4: Z Axis Moving Part Dimensions 60
Figure 5.5 Drill Machine Assembly Drawing 61
Figure 6.1 Pin Diagram of Microcontroller 63
Figure 6.2 Typical Motor 64
Figure 6.3 Typical Motor Performance 65
Figure 6.4 Encoder Resolution Selection Data 66

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Figure 6.5 LM 629 Typical Block Diagram 67

Figure 6.6 L298 Pin Configuration 68
Figure 9.1 PCB Drill Machine 79
Figure 9.2 PCB Drill Machine Control Circuit 80

LIST OF TABLES…………………………………………………………………………….

Table 1.1 Coefficient of Friction under Different Conditions 08

Table 1.2 Application of Screw and Material 08
Table 2.1 L298 Function Table 34
Table 2.2 Rule-Base 37
Table 5.1 Values of Service Factor 53
Table 5.2 Values of X0 and Y0 for Bearing 53
Table 5.3 Values of X and Y for Dynamically Loaded Bearings 54
Table 5.4 Basic Static and Dynamic Capacities of Various Types of Radial Ball
Bearings 55
Table 7.1 Bill of Components for PCB Drill 70

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LIST OF SYMBOLS…………………………………………………………………………...
Quantity Symbol SI Unit

Angle θ, α rad (radian)

Length L, d m (Meter)

Area A m2

Volume V m3

Time t s (Second)

Angular Velocity ω rads-2

Velocity v ms-1

Weight W N (Newton)

Mass m kg (Kilogram)

Force F, FA, P N

Moment M Nm

Power - W (watt)

Coefficient of friction μ -

Gravitational acceleration g ms-2

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ABBREVIATIONS………………………………………………………………………..

Shortened form Phrase

LED Light Emitting Diode

PC Personal Computer

PCB Printed Circuit Board

CNC Computer Numerical Control

NC Numerical Control

PID Proportional–Integral–Derivative

PD Proportional–Derivative

PA Port A

PB Port B

PC Port C

PD Port D

PE Port E

PWM Pulse-width modulation

AISI American Iron and Steel Institute

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ACKNOWLEDGEMENT

I would like to acknowledge and extend my heartfelt gratitude to the project supervisor, Mr.
H.D.N.S. Priyankara for being with me in each and every steps which taken my project into
success giving vital encouragement and support.

Also I would like to express my sincere thanks to the Project coordinator, Head of the
Department and all other staff members of the Department of Mechanical Engineering in
Open University of Sri Lanka for their assistance.

I am grateful to my parents for encouraging me towards this task.

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ABSTRACT

The main interest drew me to create this design because the PCB drilling devices available in
market are of high cost and low availability in markets.
So I planned to modify and create a low cost and simple design.
According to my plan I divided my design specifically for mechanical and electronic part.

In the mechanical design first, for a normal use the 150×150 mm plate is enough, so that I
planned to modify my design according to that dimension and allocated the length of the
guide bars. Using Solid Works software calculated the Strength of the materials and
considering the safety factor optimized the components dimensions. The maximum speed
required in X, Y axis is 1600 rpm, to satisfy that the torque calculations were made. From the
torque calculations, selected the motors. The acceptable resolution for a linear motion is 0.1
mm, considering that selected an encoder inbuilt with the motor. Other mechanical parts such
as screws were selected for standard size and the bearings were selected by doing the bearing
calculations.

In the electronic section I’ve used 16F877A & DSPIC 30F3010 microcontroller as the
controlling device. Using the ORCAD software the PCB design were drawn and it
automatically generates a drill file contains X, Y coordinates and the drill bit size. Created
Software reads the drill file data and send it to the controller. Controller aligns the position of
the plate and places near the drill bit. The Z axis contains the drill set was allowed to place
down for specified length and drawn up to make the holes. The size of the drill bit should be
manually replaced according to the bit size data given by the software.

The product will be placed in the Mechatronics Laboratory, from that I hope the students will
get more beneficial and knowledge about PCB.

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