Introduction To Hardware Design
Introduction To Hardware Design
Embedded Hardware
Design
Design Thought
Conceptual Know
Process (Choosing
How (Design
the Design
Aspects of
Components and
Electronic Systems)
Creating Schematic)
Design Concepts – Linear PS, Low Drop Out PS, Switched Mode PS
Power supply design for multibot charging
5-6 Standard Circuit Configurations – AC-DC, DC-DC
Li Ion Battery charger circuit
Battery – Chemistries, Charging methodologies, Battery Protection
Sensors – Temperature, Relative Humidity, Accelerometer, Ultrasonic, IR…
Micro-controller circuit with i/p block –
7-8 Human Input Devices – Switches and Push Buttons, Touch,
Temperature, Accelerometer, Ultrasonic
Signal Conditioning – Filters, Amplifiers, Isolation & Protection circuits
Actuators – Motors (DC, Stepper Motor), H-Bridge circuits Micro-controller circuit with o/p block – H-
9
Display Devices - LEDs, LCD Displays, 7 Segment Displays bridge circuits, Motors, Displays
Manufacturing Files
Before we Begin
• Units of Operation
• 1 inch = 1 pitch = 25.4 mm = 1000 mil = 1000 thou
• Working Grid
• Schematic Editor - 0.1 inch = 100 mil = 2.54 mm
• Layout Editor - Set as a function of component pitch, else connections may fail
• Drill Information - Set in mm grid since all drill equipment are designed this
way
• Board Layout - Set in mm grid
PCB Development Terminology
Track Pad Via Polygon
Copper filled line that Point where the component Connection between layers of Area in which copper can
connects components rests on the PCB the PCB be filled commonly for GND
planes and power planes
Manufacturing Terminology - CAM Process
Comp & Sol Solder/Stop Silk Screen Excellon
Screens on which the Mask Component Outline, Name Drill Information like diameter
components are soldered. and Value and position information
Area around the solder
It concerns tracks, pads and mask which is etched out
vias and their details
Eagle PCB Tool
Schematic Editor
Menu Bar
Action Toolbar
Parameter Toolbar
Coordinate Display Command Line
Command
Toolbar
Working Area
Layout Editor
Design Rules to be followed
• Tracks
• Track width depends on
• Electrical requirements – current flowing through it,
• Maximum temperature rise on the track,
• Routing space and
Track width reference table for 10oC temp rise
• Clearance space
Current (A) Track Width
• The thicker the better.
1 10
• Lower DC Resistance
2 30
• Lower Inductance
3 50
• Are easier to manufacture and check for breakages
• Net Classes can be defined for variable track widths- Power Requirements
Design Rules to be followed
• Pads
• Size, shape and dimensions depend on the component and manufacturing process
• Pad to Hole Ratio: Pad should be atleast 1.8 times the diameter of the hole
• Leaded Components like Resistors, Capacitors and Diodes should have a round pad
with diameter of atleast 70 mil
• DIL components should have oval pads with height 60 mil and length 90-100 mil
• Pin 1 pad of the IC should be different – preferable rectangular, as same dimension
as other pads
• Most SMD components use rectangular pads. SO package ICs use oval pads
• Vias
• Connect the tracks from one side of the PCB to the other through an electroplated
holes. These are called Plated Through Holes (PTH)
• Diameter of Vias are smaller than Pads
• Different kinds of Vias: Through Hole, Buried and Blinded
Design Rules to be followed
Design Rules to be followed
• A connection between 2 or more pads is called a net. Keep the nets as
short as possible. The longer the net, the greater is its resistance,
inductance and capacitance
• Ensure that the tracks have 45 Deg angles and not 90 Deg or more
• Electrical Rule Check (ERC) during schematic design
• Design Rule Check (DRC) during layout design
Generating Manufacturing Files
• Load the CAM processor by
• Either selecting from Control Panel
• Clicking on CAM processor icon in the Layout Editor
• Generating Gerber Files for Manufacturing
• Select ‘gerb274x.cam’ from ‘File/Open/Job’ dialog
• Click button ‘Process Job’
• The following files should be generated
• demo3.cmp - Component side
• demo3.sol - Solder side
• demo3.plc - Silkscreen for component side
• demo3.plc - Silkscreen for solder side
• demo3.stc - Soldering mask for the component side
• demo3.sts - Soldering mask for the solder side
• demo3.gpi - Information file, not relevant here
• Generating Drill Files for Manufacturing
• Select ‘excellon’ from ‘File/Open/Job’ dialog
• Click button ‘Process Job’
• The following files should be generated
• File name.dri – Drill Station Information
• File name.drd – Dril Table Information
1. Assumes clarity of design
2. Requires component library
3. Evaluate power
Manufacturing
1. Initiate CAM Process for
Drill and Gerber generation
2. Check Gerber in gerbv
Example Design
• Design a Regulated 5V AC-DC Converter Power Supply
• Input: Step Down AC Voltage
• Output: 5V Regulated DC Power Supply
• Component Type: All Through hole
• Input Connector, Output Connector
• Transformer is Off board
• Board may be Single Sided or Double Sided
Regulated 5V AC-DC Converter Power Supply
230V AC to 12V
Bridge Filter Regulator
AC Step Down
Rectifier Capacitor Circuit
Transformer
• OLED Display
• Beep/Buzzer
Output
Block • Vibration
• Bluetooth (BLE)
Communi • SPI/I2C/Digital etc
cation
• 3-Axis Accelerometers
• 3-Axis Gyroscope
Input
Block • Camera (Optional)
• Brushless DC Motors
Output • Electronic Speed Controls
Block
• WIFI
Communi • USB for charging and Program download
cation
• WIFI
Communi
cation
Docking
Wheel turn
Alignment
Displays using
Ambient
LEDs, 7
Environment
Segment and
– T,RH,Light
LCD
Input
Switches and
Buttons
Battery Level
Design Details
Design Plan
Power
Supply GPIO
Design View
Setting the Foundations….
Resistors
• Passive Electronic Component used to limit current flow
• Ohms Law - V = I*R, Symbol
• Power = I2R or V2/R
• Units: Ohms (Ω)
• Properties
• Power Rating
• Stability
• Temperature Coefficient
• Resistor Noise
• Parasitic Influences
Resistor Types
Through Hole Resistor Variable Resistance
• Carbon Film Resistors • Potentiometers
• Carbon Composition Resistors • Rheostat
• Metal Film Resistors
• Metal Oxide Film Resistors
• Wire Wound Resistors
Externally Influenced VR
Surface Mount Device Resistor • Thermistor
• 0402 • Photoresistor
• 0603
• Varistor
• 0805
• 1206 • Magneto resistor
Resistors - Carbon Composition
• Fixed form
• Fine carbon particles are baked with clay and
• Pros
• Ability to withstand high energy pulses
• Cons
• Low stability of value
• Low temperature stability
• Applications
• Protection of circuits (surge or discharge)
• Current Limiting, High Voltage Supplies, High Power
Resistors - Carbon Film
• Fixed form
• Ceramic carrier with thin, pure carbon film around
• Pros
• High Voltage and Temperature properties
• Cons
• Low Range of Values
• Applications
• High Voltage and Temperature Applications
• High voltage power supplies, radar, xrays and lasers
Resistors - Metal Film
• Fixed form, axial resistors
• Created by coating a ceramic rod with thin film of metal layer (Ni Cr)
• Pros
• Good stability, accuracy and reliability
• Low Noise, High Linearity
• Cons
• Low voltage
• Should be operated between 20-80% of its power rating
• Applications
• Active filters and bridge circuits
Resistors - Metal Oxide Film
• Fixed form, axial resistors
• Created by coating a ceramic rod with thin film of metal oxides like tin
oxide
• Pros
• Better performance than Carbon Film and Metal Film resistors in Power Rating,
Voltage Rating, Overload Capabilities, Surges and High Temperatures
• Cons
• Lesser Stability as compared to Metal Film
• Poor properties for low values and tolerance
• Low noise tolerance
• Applications:High Endurance
Resistors – Wire wound resistors
• An insulated metallic wire, wound around a non conductor
• The wire has high resistivity and is made from alloys like Nickel
Chromium, Nickel-Chromium-Manganese
• Pros
• Accurate Values, Excellent properties for low resistance, High power ratings
• Cons
• Parasitic Influences
• Applications
• Circuit breaker applications, Precision instruments like stereo systems,
Current Sensing etc
Resistors - Reading its value
Through Hole Resistors Surface Mount Device (SMD) Resistors
• Operating Voltages
– Operates between 0 to VCC with 5% tolerance (0
to 4.75-5.25V)
– Logic 1: 2 V to 5 V
– Logic 0: 0 V to 0.8 V
• Speed: High
– Propagation delays are 10 nS when driving a 15
pF/400 ohm load
• Power Consumption: High
– About 10mW per gate
Complimentary Metal Oxide Semiconductor (CMOS)
• Operating Voltages
– Between 0 and VDD
– Logic 1: 3-18V
– Logic 0: 0-1.5V
• Speed: Slower than TTL
– 25nS to 50nS
• Power Consumption: Low
– At 1MHz and 50pF, power dissipation is generally 10nW
per gate
• Be Careful…
– Electrostatic Discharge – Damages CMOS
– CMOS Capacitance – Propagation Delay
Emitter Coupled Logic
• Input Mode
– Floating, High Impedance, Tri-state
– Pull up & Pull Down Resistors
– Hysteresis
• Output Mode
– Push-pull
– Open Drain and Open Collector
– High Drive
• Interrupt Mode
Input Mode - Pull Up Configuration
• Used in digital circuits to ensure that a well defined logic level is maintained at the
pin
• Value
– Factors that influence it
• Strong Pull-up: Low value leads to high current flow thereby high power dissipation
• Weak Pull-up: High Value of pull-up coupled with leakage current may render the input
voltage insufficient
• Larger Values will create a lagged response time because of the RC effect brought on by
the line capacitance
– Rule of the thumb
• Set the Pull-up value 10 times smaller than the pin’s input impedance
• 4.7K Ohm is a good starting point
• For CMOS Logic Families, this value can be increased because of low leakage current, to
the order of 10K to 1M
• Applications
– Interfacing a switch to the controller
– ADC interfacing to allow controlled current to flow into the resistive sensor
Input Mode - Pull Down Configuration
• Output stage of an IC
• Can only sink current
• Requires a external (sometimes internal) pull-up resistor to
function
• Uses
– Driving busses without fear of shorting
– Level shifter or logic translation
– Adequate current drive
• Cons
– Slow as compared to push-pull because of RC effect
Eagle Libraries
• Components being used in Schematic and Board Designs are stored as libraries
• A library contains 3 elements
– Package – Mechanical Footprint of the component
– Symbol – Representation for Schematic
– Device – Integrates both Symbol and Package into one file
• Library is represented with .lbr file
• Package details of the component is to be referred from the datasheet of the
component for creating a library
References
• Resistors: http://www.resistorguide.com
• Capacitors: http://www.capacitorguide.com/
• Logic Families: http://www.learnabout-
electronics.org/Digital/dig30.php
• Inductors: http://www.learnabout-
electronics.org/ac_theory/inductors01.php
• Diodes: http://www.learnabout-
electronics.org/Semiconductors/diodes_20.php