Unlicensed Epd II
Unlicensed Epd II
Unlicensed Epd II
Size-miniature-functional elements Weight Power Supply Inter-intra module connections/communications Environmental limits-dust proof, controlled temp conditions Packaging-transport, storage, anti static bag, special packing Special cables & connectors, electro-mechanical components Thermal Design-component level, board level & system level-heat sinks-forced cooling EMC/EMI concerns
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Industrial Design
Industrial Design is known as the art and science of increasing the beauty and value of mass produced products The professional service of creating and developing concepts and specifications that optimize the function, value, and appearance of products and systems for mutual benefit of both the user and manufacturer
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Critical Goals of ID
Utility-The products human interfaces should be safe, easy to use & easy to understand the function Appearance-Form/shape/line/proportion/color are used to make the product attractive & pleasing Ease of maintenance-The product should communicate how the maintenance/repair process should be addressed Cost-Cost of product to be kept low Communication-Product design should communicate the corporate design philosophy and mission through the visual qualities of the product
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Importance of ID
ID determines the commercial success of any product All products that are used, operated or seen by customer depend on ID for product success ID determines the aesthetic appeal and the quality of the user interfaces of a product
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Need for ID
Ergonomics-Related to human interfaces Aesthetics- Deals with form & finish of the product
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ERGONOMICS NEEDS
Ergonomics or human factors engineering is the science of fitting tasks to man. Ergonomic Needs: Ease of Use-for frequently/infrequently used products Ease of Maintenance
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ERGONOMICS cont.
Number of user interactions for the product to function(More interaction means more dependency on ID) Novelty of the user interactions eg. Improvement in mouse. Safety Issues-Safety considerations are very important-Human anatomy and psychology issues need to be considered.
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Aesthetic Needs
Aesthetic needs deals with form & finish of products.-They are: (a) Product Differentiation-Visual (b) Pride of ownership -image/fashion
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Benefits of Using ID
Increased Product Appeal Better Features Greater customer satisfaction Strong Brand Identity Product Differentiations Price Premium and or Increased market share
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Disadvantage of ID-Because of multiple re-works on account of ergonomics & aesthetics may result in delay in the products introduction in the market which will likely to have an economic cost
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DFX
Design for
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DFM
DFM Economically successful design implies-high product quality while minimizing manufacturing cost. DFM is one method for achieving this goal Effective DFM practice leads to low manufacturing costs with out sacrificing product quality
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DFM cont.
DFM utilizes information of several types such as:-sketches, drawings, product specifications, design alternatives, detailed understanding of production & assembly process, estimates of manufacturing cost, production volumes and ramp-up timing
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DFM cont. DFM requires contributions from all members of development team as well as out side experts DFM is performed through out development Process
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DFM Process
Estimate the manufacturing cost Reduce the cost of components Reduce the costs of assembly Reduce the cost of supporting production Consider the impact of DFM decisions on other factors
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DFM Method
Proposed Design
Good enough ? Y
Once the design is frozen (or released) and any further modifications are considered formal engineering changes or Become part of next generation of the product.
Acceptable Design
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DFM Method cont. Manufacturing Costs Defined Sum of all the expenditures for the inputs of the system (i.e. purchased components, energy, raw materials, etc.) and for disposal of the wastes produced by the system
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Manufacturing System
Finished Goods
Energy
Supplies
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Services
Waste
Components
Assembly
Overhead
Standard
Custom
Labor
Support
Indirect Allocation
Raw Material
Processing
Tooling
Component Cost-This is the cost of standard parts & custom parts Assembly Costs-Cost of goods assembled from parts, labor cost & may incur costs for equipment and tooling Over head cost- for all other costs.
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Total cost
Manifold casting
12.83
5.23
18.06
1960
0.50
18.56
pipe
1.30
0.15
1.45
1.45
valve gasket
Total Direct Cost
1.35
0.14
1.49 0.18
21.18
0.05 5.23
0.13 0.42
15.53
2.60
9.42
1.71
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0.75
14.48
46.16
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Reduce the Costs of Assembly Design for Assembly (DFA) index Integrated Parts (Advantages and Disadvantages) Maximize Ease of Assembly Consider Customer Assembly
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Part is capable of inserted from the top of the assembly Part is self aligning Part does not need to be oriented Part requires only one hand for assembly Part requires no tools Part is assembled in a single, linear motion Part is secured immediately up on insertion
Ideal characteristics of a part for Assembling(to reduce cost of assembly) DFM cont. (DFA)
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A reduction in assembly content reduces the number of workers required and hence the expenditure on supervision/HR cost Standardized component reduce the demands on engineering support & quality control
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Development Time Development Cost Product Quality External Factors Component reuse Life cycle costs
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The impact of DFM on Development CostBy applying good project management practice and the application of sound DFM methods one can develop products with in time and with in budget
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ideal conditions -action to decrease manufacturing cost would improve quality. However, reliability/robustness needs to considered.
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Quality By Design
Quality is defined as the totality of features and characteristics of a product or service that bears on its ability to satisfy stated or implied needs Quality features can be classified into two major categories: 1.The conformance of the features designed in the product to the specifications (process dependent) 2.The designed features it self (design dependent)
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Drawing Release
A key action in introducing a product into manufacturing is the official drawing release phase From an engineering design point of view, there is no turning back. Official drawing release may be considered the moment when design is frozen. The BOM is prepared based on this. Therefore, changes in any of this documentation after the official drawing release will require processing through the established change notice procedure
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employed throughout
Enable frequent users to use shortcuts-to increase the pace of interaction use abbreviation, special keys, hidden command etc., Offers information feed back-for every user action the s/w should respond in the same way e.g., do you want save the file?.
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Sketches are usually line drawings showing the product in perspective with annotations of key features Where as engineering drawing is the principal medium used by manufacturing as criteria for producing the product These drawings are reflections of design engineering drawings but formatted and organized to enhance producibility and protected from mass or blanket change The drawings are generated using a sequential process of checking & approval
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Drawing Release
A key action in introducing a product into manufacturing is the official drawing release phase From an engineering design point of view, there is no turning back. Official drawing release may be considered the moment when design is frozen. The BOM is prepared based on this. Therefore, changes in any of this documentation after the official drawing release will require processing through the established change notice procedure
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Documents
Market Research -Ref for design team Design Documents -- Ref for Engg team Engg Design Document-Ref for purchase/production Testing & Maint document-useful for design team while designing new version of the product
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Test Documents
Useful for engineering team to finalize the design before production Checks confirm the production process Helps design engineers to change any design to meet production requirement Helps in validating the design specifications Test documents-Environmental Testing & EMI/EMC Compliance testing
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Environmental/EMI-EMC Testing
Temperature Cycling Humidity Test Vibration Test Bump test Conducted EMI Test Radiated EMI test
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Electronic Packaging
Electronic Packaging is the means by which system components are interconnected and integrated to create a product with a desired functionality. Electronic packaging must provide for electrical connections between components, physical support of each component, thermal management for the heat dissipated by each component, and connection of the system to the out side world
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Common Definitions
Foot Print-It is the substrate area occupied by the package components. Pitch-Is the periodic dimension that characterizes the spacing between repeating elements of a peripheral or array patterns Substrate-The substrate of an electronic assembly is the system element to which electronic components are attached and their respective I/O are connected together (It therefore consists of the bulk substrate material and one or more layers of conductive routing for the distribution of electric signals or power)
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Cont..
Module-A substrate which attaches to a larger system substrate is called a module. It is a smaller PCA that is connected to a larger PCA (mother Board) PCA-Printed circuit assembly is the most common form of electronic packaging. PCA consists of the printed circuit board (PCB) and the various electronic components that are attached to it such as ICs, discrete components, connectors and modules
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Cont..
PCB-Printed Circuit Board provides electrical interconnections as thin metal tracks on dielectric substrate, which also supports the components Discrete Components-It consists of resistors, capacitors, inductors, diodes,transistors,oscillators,and switches
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Levels of Electronic Packaging Substrate for chip Second level card assembly
chip
chip
module
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Functions of Packaging
To provide electrical connections between various devices To provide mechanical support to the product To facilitate assembly operations To distribute power to all component and chip circuits To protect the circuit from environmental & mechanical damage
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Cont..
Shielding from external electro-magnetic radiation and interference Preventing harmful radiation going out of box To remove heat generated from ICs and other components To allow removal and replacement of failed components To facilitate electrical and functional testing of the circuit
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Levels of packaging
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Levels of Packaging
Level 0 Packaging:
Interconnections within semiconductor IC Interconnections on a monolithic silicon die
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Flip-Chip Packaging
Flip-Chip packaging provides the highest interconnection density for a given area and a very high level of miniaturization. The bare die is mounted directly to the substrate, eliminating the need for an intermediate IC package Flip-chip can be cost-effective in very high volume applications. The electrical characteristics of a flip-chip connection are generally better than a wire-bonded device, due to the elimination of performance-sapping conductance and capacitance in leads and wire bonds
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Flip-Chip Packaging
Flip-chips is difficult to test & high mechanical stress due to thermal mismatch. Thermal stress issues are handled by under-filling the assembly with an epoxy Flip-Chips is used where a high manufacturing yield is required & extreme miniaturization is of utmost importance Assembly thickness of less than0.5 mm can be achieved with flip-flop
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Under-fill
SUBSTRATE
Cross-section
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SUBSTRATE SOLDER BALLS BGA packages utilize a small printed circuit carrier as an interposer between IC and the printed circuit substrate. The IC is wire-bonded or flip-chipped to the printed circuit carrier and is encapsulated in a manner similar to a leaded package. The printed circuit carrier routes the peripheral wire-bonds to an array pattern on the underside of the carrier. The array pattern is populated with solder balls that function as leads for surface mount attachment to the printed circuit substrate
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CSP Package
CSP Package is similar to BGA package but with smaller foot-prints than BGA Provide the miniaturization and performance as that of a flip-chip package Have better testability & reduced mechanical stress The interposer layer in a CSP can be used to transform the I/O pattern of the device from peripheral to array
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Discrete Components
All discrete components are designed to be soldered on to a PCB substrate (surface mount variety) Discrete components form a large part of any portable electronic equipment. Functionality, performance, and cost are determined by the selection of discrete components. Discrete components normally have a high tolerance levels. However, in certain systems high tolerance levels are avoided by having a adjustable discrete components
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level 2 packaging
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Cont..
The major parts of third level package are:1.Printed circuit carrier( rigid and flexible) 2.Connectors (signal, power, sockets) 3.Single Chip and multi chip packages 4.Discrete components 5.Power devices such as transformers & batteries 6.Special components such as crystal Oscillators, reset switches, speakers
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Connectors
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Connectors
Connectors are an essential part of electronics packing. A connector serves two purposes: a. Mechanical connection to hold the two circuits together b. Electrical connection to provide signal and power transmission from one circuit to other
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Connectors
Some examples of many uses of connectors are: 1.Insertion of adapter cards on a mother board using a card edge connector 2.Memory installation in SIMM sockets 3.Connecting power supply to various I/O device 4.HDD,FDD and CD_ROM connections to the mother board using cable connectors and pin headers 5.Key board and mouse connection to PC 6.Board-to Board connection using flat cable connector
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Connector Contacts
Gold-plated contacts are used for high reliability applications such as military, tele communications, medical & high end computers Palladium is a low cost alternative to the gold Non-noble metals such as tin-lead plating is used for low end computers, automobile applications & consumer products because of its low cost
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Connectors
The high speed circuits require signal propagation paths that are free of crosstalk and resulting electrical noise. Increased interconnect density means more cross talk. Hence need for proper selection of connectors The contact material for connectors depends on many factors such as: 1.connection density 2.component profile 3.operating environment & reliability
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assignment
FIND NAMES OF ANY 10 TYPES OF CONNECTORS & ITS APPLICATION SHORT NOTE ON CABLES (COAXIAL, UTP,STP,RIBBON, OFC etc.
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Cont..
Average Pin Count-ratio of total number of component terminals to total number of parts, at system level. Gives a idea of integration level and/or digital-ness of the overall product. Low APCs reflect a high number of discretes or other low-pin count devices often characteristics of analog circuits. High APCs means a digital circuit-high pin counts
Connection density-this metric is a ratio of total number of connections to total printed circuit board assembly area in units of connections per cm
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Cont..
Part Density-This metric is a ratio of the total number of parts to total printed circuit board assembly area, in units of components per cm. High part density reflect challenges in surface mount assembly in terms of precision of placement, number of placement and engineering of part clearances. Routing Density=3x(average pin count) x (part density)1/2 part density formula is particularly useful for designer to determine the required wiring resources needed in a substrate based on the average pin count and required pin 1 density of the product
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Displays
In a portable electronic design the user interface is most affected by the selection of displays Pixel resolution determines the level of graphic detail that can be displayed in a single image frame Resolutions varies from low-resolution, monochrome, segmented, character-only display to high resolution, color displays capable of displaying millions of pixels The color range of display determines the number of variations of color that can be displayed
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Displays
Brightness indicates how much light is emitted from the surface of the display Reflective displays have no brightness and rely on reflected ambient light to reveal the contrast and color created on the display surface Emissive displays generate light at each pixel. This light creates the color and contrasts to form the intended image. Trans-missive displays use a backlight which is filtered by the display surface to create color and contrast Transflective displays reflect ambient light back through the filtering display surface to create an image.
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Display Technology
Most portable electronic devices that have a display use a flat panel display (FPD) and, in most cases the FPD is based on LCD technology .Types of FPD: Liquid Crystal Nematic Smectic Chiral Emissive Field Emission Displays Electroluminescent Light Emitting polymers Microdisplays Liquid Crystal MEMS Electroluminescent
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assignment
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