PCB Design & Engineering

• Illustrative 3D model drawn in code to explain how the build works. Not a photograph.

  Control card redesign

  Three-channel firing board, through-hole to SMD

  A control card for an electroplating machine: a 136 × 183 mm plug-in card with a 22-way, 3.96 mm edge connector. We designed it as a through-hole board, then redesigned it as an SMD assembly that keeps the same edge-connector pinout, so the new card fits the same slot.

  • On-board regulators for the ±12 V rails
  • Phase reference inputs, three timing channels and three output drivers
  • Firing point set against an adjustable control level, trimmed on the board
  • SMD revision keeps every original terminal connection
  • Odd component values built from stocked parts, for example 22 kΩ as 10 kΩ + 10 kΩ + 2 kΩ

  

• Illustrative 3D model drawn in code to explain how the build works. Not a photograph.

  Interface board

  40-pin pass-through adapter

  Two 2 × 20 headers wired pin for pin, so two 40-way ribbon cables join straight through.

  • Every pin on one header goes to the same pin on the other
  • Odd pins routed on the top layer, even pins on the bottom layer
  • Pin 1 marked with a square pad on both headers
  • Two mounting holes

  

• Illustrative 3D model drawn in code to explain how the build works. Not a photograph.

  LED board

  LED lighting board

  64 LEDs in 16 strings: each string is four LEDs in series with its own 47 Ω resistor, and the strings are wired in parallel in two banks of eight.

  • One current-limiting resistor per string
  • If one LED fails, only its own string goes out
  • Two-way supply terminal in the middle of the board
• Illustrative 3D model drawn in code to explain how the build works. Not a photograph.

  Interface board

  DB9 breakout board

  Breaks a 9-way D-sub plug out to rows of solder pads for wiring into a machine.

  • Right-angle D-sub on the board edge, with jack screws
  • Pins 6 to 9 and the shell ground on one row
  • Pins 1 to 5 on two linked rows, so each signal can be picked up twice
  • Wide ground track from the connector shell

  

• Illustrative 3D model drawn in code to explain how the build works. Not a photograph.

  Interface board

  5 + 4 to 9-way connector adapter

  Combines a 5-way and a 4-way wire-to-board connector into one 9-way connector, so two cables can plug into equipment that takes one.

  • 5-way input to pins 9 to 5, 4-way input to pins 4 to 1
  • Short, straight tracks between the connectors
  • Mounting hole in each corner for standoffs

  

1. STEP 01

   Understand

   Review the project requirements and intended application.

2. STEP 02

   Assess

   Clarify interfaces, constraints and information available.

3. STEP 03

   Agree

   Confirm deliverables, technical scope and quotation.

4. STEP 04

   Design

   Develop the board design and layout.

5. STEP 05

   Hand over

   Deliver the agreed design outputs.

Verification depends on the equipment and available test conditions. Workshop checks are distinguished from testing that requires your machine, program or production setup.