Active components can serve as significant heat sources in your PCB, directly influencing the board’s equilibrium temperature. Repeated thermal cycling (high-to-low transitions) and prolonged high-temperature operation degrade system longevity, often leading to premature component or trace failures. Implementing an effective thermal management strategy is critical to mitigating these risks.

A key element of this strategy is the strategic placement of thermal vias. These vias enhance heat dissipation away from high-power components such as processors, FPGAs, and power electronics. By optimizing thermal via placement in your PCB layout, you can reduce peak temperatures, eliminate hot spots, and significantly improve system reliability.

What Are Thermal Vias?

Thermal vias are specialized through-hole connections in a PCB designed primarily for heat transfer. Unlike standard vias used for electrical connections between layers, thermal vias are strategically placed to conduct heat away from components and distribute it more effectively across the board or to dedicated heat sinking layers.

Key Characteristics of Thermal Vias:

• Typically smaller in diameter than standard vias
• Often clustered in arrays beneath heat-generating components
• May be filled with thermally conductive materials
• Can span multiple layers of the PCB

Read more about:

• IPC-4761
• Blind Vias
• Via Covering
• Via in Pad
• Via filling

How Thermal Vias Dissipate Heat

Understanding the mechanism behind heat dissipation through thermal vias is crucial for effective implementation. Thermal vias work on the principle of conduction, one of the three primary heat transfer methods (along with convection and radiation).

The Heat Dissipation Process:

1. Heat Generation: Electronic components, such as power transistors or high-speed processors, generate heat during operation.
2. Conduction to PCB: This heat is initially conducted to the PCB surface directly beneath the component.
3. Thermal Via Network: An array of thermal vias beneath the component provides multiple pathways for heat to travel.
4. Vertical Heat Transfer: Heat moves vertically through the vias, utilizing the high thermal conductivity of copper.
5. Layer-to-Layer Spread: As heat travels through the vias, it spreads laterally at each layer, increasing the effective heat dissipation area.
6. Heat Sinking: In many designs, thermal vias connect to internal ground planes or dedicated heat sinking layers, further enhancing heat distribution.
7. External Dissipation: Finally, heat is dissipated to the environment through the PCB surfaces or additional heat sinking structures.

Types of Thermal Vias in PCBs

Thermal vias come in various configurations, each with its own set of advantages and use cases. Understanding these types can help designers choose the most appropriate solution for their specific thermal management needs.

1. Standard Thermal Vias

Standard thermal vias are the most basic and common type. They are essentially normal plated through-holes used for thermal purposes.

Characteristics:

• Unfilled
• Typically 0.3mm to 0.5mm in diameter
• Used in arrays for increased thermal conductivity

Advantages:

• Cost-effective
• Easy to manufacture
• Suitable for moderate heat dissipation needs

Disadvantages:

• Less efficient than filled vias
• Can trap air, reducing thermal performance

2. Via-in-Pad

Via-in-pad technology integrates thermal vias directly into the component’s solder pad, allowing for more efficient heat transfer and space-saving designs.

Characteristics:

• Vias placed within the component’s footprint
• Often used with BGAs and other dense packages

Advantages:

• Improved thermal performance
• Reduced PCB real estate usage
• Shorter electrical paths

Disadvantages:

• More complex manufacturing process
• Risk of solder wicking during assembly

3. Filled and Capped Vias

Filled and capped vias represent the most advanced thermal via technology, offering superior heat dissipation capabilities.

Characteristics:

• Vias filled with thermally conductive material (e.g., copper, silver, or thermal epoxy)
• Capped with copper for a smooth surface

Advantages:

• Excellent thermal conductivity
• Prevents solder wicking
• Allows for component placement over vias

Disadvantages:

• Higher manufacturing costs
• Requires specialized production processes

4. Micro Vias

Micro vias are extremely small thermal vias, typically used in high-density interconnect (HDI) boards.

Characteristics:

• Diameter less than 0.15mm
• Often laser-drilled
• Can be stacked or staggered

Advantages:

• Enables very high via density
• Suitable for fine-pitch components
• Improved signal integrity

Disadvantages:

• More expensive to manufacture
• May have limited depth due to aspect ratio constraints

How to Maximize the Effectiveness of Thermal Vias

To achieve optimal heat dissipation using thermal vias, designers must consider various factors and implement best practices. Here are key strategies to maximize the effectiveness of thermal vias:

1. Optimize Via Placement

• Place vias as close to the heat source as possible
• Use arrays of vias rather than single, larger vias
• Consider the direction of heat flow when placing vias

2. Choose Appropriate Via Size and Spacing

• Balance via diameter with manufacturing capabilities
• Space vias close enough for effective heat spread, but not so close as to compromise board integrity

3. Utilize Multiple Layers

• Connect thermal vias to internal ground planes and power planes
• Use dedicated thermal layers in multi-layer designs

4. Consider Thermal Via Filling

• For high-power applications, use filled vias for improved thermal conductivity
• Choose filling materials based on thermal requirements and budget constraints

5. Implement Proper PCB Stackup

• Place high-conductivity layers closer to heat-generating components
• Use thicker copper layers for improved heat spreading

6. Combine with Other Cooling Techniques

• Integrate thermal vias with heat sinks or cooling fans
• Use thermal vias in conjunction with thermally conductive PCB materials

6 Benefits of Using Thermal Vias in Your PCBs

Incorporating thermal vias into PCB designs offers numerous advantages:

1. Enhanced Heat Dissipation: Thermal vias significantly improve the board’s ability to remove heat from components.
2. Improved Component Reliability: By reducing operating temperatures, thermal vias can extend the lifespan of electronic components.
3. Space Efficiency: Thermal vias allow for more compact designs by reducing the need for large heat sinks or spacing between components.
4. Flexibility in Component Placement: Effective heat management through thermal vias enables more freedom in component placement on the PCB.
5. Cost-Effective Thermal Management: Compared to other cooling solutions, thermal vias are relatively inexpensive to implement.
6. Compatibility with High-Density Designs: Thermal vias are crucial for managing heat in densely packed, high-performance PCBs.

Combining Thermal Vias with Other Thermal Management Strategies

While thermal vias are highly effective, they are often most powerful when used in conjunction with other thermal management techniques. Here are some complementary strategies:

1. Heat Sinks

• Attach heat sinks to components or PCB surfaces
• Use thermal vias to enhance heat transfer to the heat sink

2. Thermal Interface Materials (TIMs)

• Apply TIMs between heat-generating components and the PCB
• Use in combination with thermal vias for improved heat conduction

3. Forced-Air Cooling

• Implement fans or blowers for active cooling
• Design thermal via patterns to work with airflow patterns

4. Liquid Cooling

• For extreme thermal requirements, consider liquid cooling solutions
• Use thermal vias to efficiently transfer heat to liquid cooling channels

5. Thermally Conductive PCB Materials

• Select base materials with higher thermal conductivity
• Combine with thermal vias for optimal heat spreading

6. Power Plane Design

• Optimize power and ground plane design for heat distribution
• Connect thermal vias to these planes for enhanced thermal performance

16 Thermal Via Design Tips for Efficient Heat Management

1. Conduct Thermal Simulations: Use thermal modeling software to optimize via placement and size.
2. Consider Manufacturability: Design thermal via patterns that are feasible to produce with available technology.
3. Use Larger Diameter Vias for High-Power Components: Increase via size for components with higher heat output.
4. Implement Redundancy: Design with extra thermal vias to account for potential manufacturing defects.
5. Balance Thermal and Electrical Requirements: Ensure thermal via placement doesn’t compromise signal integrity.
6. Adhere to IPC Standards: Follow industry guidelines, such as IPC-2221, for thermal via design.
7. Optimize Via Aspect Ratio: Maintain appropriate depth-to-diameter ratios for effective plating and heat transfer.
8. Consider Thermal Expansion: Account for differences in thermal expansion between PCB materials and components.
9. Use Thermal Relief Patterns: Implement thermal relief connections to balance heat dissipation and solderability.
10. Avoid Voids in Filled Vias: Ensure proper filling techniques to prevent air pockets that reduce thermal efficiency.
11. Implement Teardrop Connections: Use teardrop patterns to strengthen via connections and improve heat spread.
12. Design for Even Heat Distribution: Spread thermal vias evenly to avoid hot spots on the PCB.
13. Consider Top and Bottom Layer Heat Dissipation: Utilize both sides of the PCB for maximum thermal performance.
14. Optimize Copper Weight: Use heavier copper weights on layers connected to thermal vias for better heat spreading.
15. Implement Thermal Fences: Create barriers of thermal vias to isolate heat-sensitive components.
16. Document Thermal Design Intent: Clearly communicate thermal via requirements in PCB design files and documentation.

Thermal Vias Simulation and PCB Examples

To illustrate the effectiveness of thermal vias, let’s explore some simulation results and real-world PCB examples.

Thermal Simulation Example

A thermal simulation of a high-power LED module demonstrates the impact of thermal vias:

• Without Thermal Vias: Peak temperature of 85°C at the LED junction
• With Thermal Vias: Peak temperature reduced to 65°C
• Result: 23.5% reduction in peak temperature, significantly improving LED lifespan and performance

PCB Design Example: Power Supply Board

In a 4-layer power supply PCB design:

• Thermal Challenge: High-power MOSFETs generating significant heat
• Solution: Array of 20 thermal vias (0.3mm diameter) under each MOSFET
• Implementation: Vias connected to internal ground plane and bottom-layer copper pour
• Outcome: 30% reduction in MOSFET operating temperature, enabling higher power output

High-Frequency RF Board Example

For a high-frequency RF amplifier board:

• Thermal Challenge: Maintaining low temperatures while preserving signal integrity
• Solution: Micro vias (0.1mm diameter) in via-in-pad configuration
• Implementation: Stacked micro vias connecting to buried heat-spreading layer
• Outcome: Achieved required thermal performance without compromising RF characteristics

Conclusion: The Critical Role of Thermal Vias in Modern PCB Design

As electronic devices continue to shrink in size while increasing in power and complexity, effective thermal management becomes ever more crucial. Thermal vias represent a powerful, flexible, and cost-effective solution for addressing these challenges in PCB design.

By understanding the principles behind thermal vias, their various types, and best practices for implementation, PCB designers can create more efficient, reliable, and high-performing electronic products. Whether you’re working on a simple consumer device or a complex industrial system, integrating thermal vias into your PCB design strategy can lead to significant improvements in thermal performance and overall product quality.

As technology evolves, we can expect to see further innovations in thermal via design and implementation. Staying informed about these developments and continuing to refine thermal management techniques will be essential for PCB designers aiming to push the boundaries of electronic design and meet the demands of future technologies.

Remember, effective thermal management is not just about preventing failure—it’s about optimizing performance, extending product lifespan, and enabling the next generation of electronic innovations. Thermal vias are a key tool in achieving these goals, and mastering their use is a valuable skill for any PCB designer in today’s fast-paced technological landscape.

Mathematics and science follow a simple rule of precision and accuracy. They mainly give accurate measurements of events, actions, and items. It still leaves a person thinking; therefore, it needs key consideration while designing, manufacturing, and analyzing the physical structure. The uncertainty principle of Heisenberg is found in most mathematical, scientific, and engineering projects. However, this principle states that the speed and position of an item cannot be measured at the same time. Therefore, scientists and engineers are still looking for solutions to measure them altogether.

Determining an ideal value of impedance plays a vital role in designing a PCB, especially a high-speed PCB design. This gives the definition of trace parameter control and the choice of board material. Exclusively calculating and analyzing the impedance of a PCB brings various challenges. However, the impedance control significance of a board makes it necessary to use a reliable and durable method to give efficient results. Thus, let’s dive into some available options and find a solution for calculating the impedance control of a PCB, which gives practical and accurate results.

Methods of PCB Trace Impedance Calculator

Propagation of signals in the layout of PCB occurs in the transmission line. But this task seems quite challenging. The circuits of today comprise compact, multifunctional, and complex designs. This literally implies that a PCB has to encounter various types of signals like DC, RF, and digital, distinct trace types like stripline and microstrip with variant orientation and size. However, there are some considerations to follow, which include clearance and creeping, edges of the board, design of footprint pad, and spacing and width of the trace. Moreover, there may add up more concerns like matching the impedance of output and input connections and the type of material that may affect the impedance. 

Thus, managing these considerations may end up in unmanageable situations. Besides these parameters, it may also include the goals of signal integrity maximization, removing reflection, and reducing the EMI or noise. Other than managing these parameters, the impedance control of PCB still comes first and needs serious interest and a determined approach. To make calculations simple, it’s important to deduct pre-hypothesis. This is associated with each design’s uniqueness which implies that it gives various possibilities for measuring the impedance control of the board. Eventually, the result you will get in the end may vary to a certain aspect because of different techniques. Anyhow, the methods described below are fully practical and applicable.

Methods for Calculation 

· Smith Chart

A Smith chart is one of the oldest methods. It came into being ages before PCB layout software and computers were developed. Its main purpose is to determine the relation of the reflection coefficient between load and source impedance. It then uses a mathematical manipulation series to get the value of impedance for a trace or line. 

· Computer Simulation

The advanced design software of PCB packages contains a feature of impedance control calculation. It gives benefits: you can access the available design parameter and can modify it automatically to perform different simulations. This way, you can choose an ideal design for PCB manufacturing. However, the only drawback of such type tools makes the software much more expensive. 

· Online Calculator

Online calculators prove an ideal than software with design packages of PCB for control impedance. As online calculators offer features to calculate impedance control or parameters of trace with desired impedance. Although it does not act as completely as simulation software, these may place you under the ballpark, which needs a little but necessary tweaking from your manufacturer for the PCB manufacturability. Most online calculators follow the principle of the Design Guide of standard IPC-2141A for Controlled Impedance of PCB with High-Speed.

How Does PCB Trace Impedance Calculator Works?

Each trace possesses a small, almost unnoticeable series of inductance spread alongside the trace, which has a proportional relationship with a trace cross-sectional area. The impedance becomes noticeable as the time of rise increases. In the same manner, each trace also has capacitance alongside the return signal path and the trace. This serves as a function of trace width and material of dielectric between the trace and the return path of the signal. Here again, if the time of rise increases, the generated impedance becomes significant as the electrical current flies across this capacitance.

The drivers interpret traces in the form of transferred LC circuits and the AC impedance of the trace generated from this dispersed LC circuit. This refers to uncontrolled impedance. However, manufacturers do not try to design the environment for the trace for this very impedance. This allows the capacitance and the inductance to change along with the trace, as this impedance does not usually affect the operations, so you don’t have to spend any money or time designing methods to manage it.

· Controlled Impedance

However, a question arises: what if the impedance affects the operations? In this situation, design a circuit where traces resemble the transmission lines. This allows us to terminate the trace capability of impedance to bypass the reflections. 

While controlling impedance, ensure that the trace has constant impedance at each end rather than changing from time to time, just like in a standard uncontrolled impedance case. Impedance control requires three parts of the geometry of the circuit to control. This includes trace width, the coefficient of dielectric of the substance around the trace, and the value of spacing between the trace signal and the return path signal. For instance, the coaxial cable serves as a transmission line with impedance control.

You can also alter these geometric aspects and get controlled impedance only as far as you keep altering other aspects as necessary. So that the relation between these features does not modify and the value of impedance stays constant. 

How To Confine Trace Impedance with PCB Trace Impedance Calculator?

The process of manufacturing circuit boards with controlled impedance must have the ability to calculate the impedance. The impedance trace calculator of PCBs helps in calculating the trace impedance. You can access these calculators in the CAD software or online. There are various factors to consider while calculating the impedances. This includes trace thickness, trace width, laminate thickness, copper weight, and dielectric thickness. 

Once you get the values of all the parameters, adjust them to a certain level to calculate the impedance. Once you reach a desirable level of impedance, test the effectiveness of the board through test coupons. These coupons are built altogether in the same plane. This way, you get an appropriate value of impedance without facing any trouble while accessing actual board traces. It gives an accurate value if the traces of the test coupon and the traces of the boards are similar.

Generally, the fabricator creates the test coupons over the edges of the manufacturing panel so that you can get the authentic value of impedance through these test coupons without defecting the circuit. 

The trace impedance can also be calculated through a network analyzer, TDR, or test system of controlled impedance with TDR techniques. A specialized and skilled engineer uses test systems of impedance to measure the impedance, which ensures high-end results. 

How Does Design and Layout Affect Trace Impedance?

In an actual PCB design, signal impedance can be quite distinct from the ideal desired value from the design schematic. This occurs because of the substrate’s presence and trace arrangement on the circuit. This increases some significant effects, such as crosstalk. This alters the value of impedance from the desired value. PCB may experience problems of power integrity, like ringing when a PCB shifts high frequencies. The power-delivered net impedance also turns from the desired capacitance behaviors of PCBs at higher frequencies. This takes part in the integrity of power and potential signal problems. 

· Transmission Line Impedance

The transmission line impedance is categorized through the values of impedances. Characteristics impedance plays one of the essential. This simply refers to the transmission line impedance of PCBs in complete isolation from other transmission lines. The value typically equals 50 ohms. Though, it takes distinct types of values based on the standard of signaling in a device. For instance, LVDS mainly features that the impedance differential of distinct parts must equal 85 Ohms.

Some other metrics that define the impedance of transmission lines mainly depend on the alignment of two distinct transmission lines. Because of the capacitance of parasitic effect which arises due to circuit substrate material and the shared inductance between 2 close transmission lines. Transmission lines are also categorized with odd and even values of impedance. Differential and common impedance is linked with other values, which brings the complete value of impedance that defines the transmission line up to five.

· Power Delivery Network Impedance

The network of power delivery may show the impedance capacitive at a very low frequency, which decreases power bus resistance in the series along with the return path of ground and load components at DC. The physical spacing between the traces, internal planes, and power planes in the circuit dominates this impedance. However, as the frequency of driving increases, the mutual inductance inside the circuit enhances the power delivery system’s impedance. Ultimately, the power delivery net impedance may exhibit various peaks at a high frequency. 

Ideally, the power delivery net impedance must be flat inside the band that you will work with. The bandwidth depicts all the frequencies between a knee frequency and a clock rate for digital. Moreover, if the harmonics that contain digital signals read a similar frequency, then a function of transfer for the return signals in the ground layer must be flat. Therefore, the same approach applies to the analog signals which travel throughout the ground planes and the board.

Whereas the spectrum of impedance becomes essential for determining the bandwidth that possesses minimum impedance of power delivery. The spatial impedance distribution in the ground planes plays a more important role, especially in devices with mixed signals. Signals pass through the path which has the least reactance on the return ground when passing through ground planes. Furthermore, the least reactance path in multipoint topology, point-to-point, and a star must lie under the conductors of the circuit. This ensures that the circuit must have a minimum inductance of the loop and have less EMI susceptibility. 

· PCB Substrate Material Selection

Because of the parasitic interference, you have to select the PCB substrate material carefully and design the stack-up. The substrate material has a dielectric constant which affects the design geometry to create transmission lines alongside specific impedance. This directly affects the net power delivery impedance. The conductors inside the planes also define the impedance of the loop in a PCB, which directly affects the EMI susceptibility of the circuit. 

· Impedance Matching Networks

The PCB stack-up affects various features of the design circuit. This includes routing strategy and thermal resistance. PCB design with appropriate substrate material can help in reducing the risk of loss of signals while managing the constant impedance across the circuit. The maintenance of PCB impedance to a certain value during the process of routing is essential. It ensures the matching of impedance throughout the net. Once the signals transfer to a transmission line mode, make sure that the drive, receiver, and transition line must have a constant impedance to avoid the reflections of signals.

Conclusion

Impedance control refers to a method of regulating PCB trace strength by calculating its impedance. The control of impedance has become the standard practice of PCB because of the frequently altering frequencies of high-tech devices and applications. 

Impedance control can be measured by utilizing the test coupons after the manufacturing of the PCB. Test coupons serve as a PCB which gauges the efficiency of the manufacturing process of PCBs. However, test coupons also make on the same line as a PCB, typically on the edges. After the production process, test coupons go through an evaluation process that checks the alignment of layers, internal structure, and electrical connectivity. You can choose coupons from the collection of suppliers or specially created for the PCBs. PCB manufacturers can also design test coupons or can place them on functional panels.

What would you say if someone asked you to define the general purpose of a sensor? Well, a sensor’s job is to detect an electrical signal and behave according to that signal. Now, the significance of sensors is unbelievable for the efficient performance of the electronics. In fact, some sensors even protect the devices from undergoing potential damage and failure.

These sensors are more feasible to use because of their small sizes, weight, and guarantee of safety at the same time. You can use a single sensor to determine current and voltage if the nature of your project is like this. However, we are going to take a look at voltage sensors and the major aspects of these circuits in detail. 

What is a Voltage Sensor Circuit?

The voltage sensor is not a simple circuit to describe. However, we are going to make its definition a lot more perceivable for you so that even if you don’t belong to a physics background, you can understand a voltage circuit quite well. Here we go:

We define a voltage sensor as a setup that is responsible for monitoring the voltage surge and voltage drops. These circuits show accurate readings and voltage traces. Since electronics need precise amounts of voltage to work efficiently, now you know a voltage sensor is a huge deal for such machines.

Some voltage sensors produce pulse waveforms and sine waveforms as well. Now if your project needs a different output, you need some standard voltage dividers to find this output accurately. 

Working Principle of Voltage Sensor Circuit

For AC voltage: 

When you are working with AC voltage, there are some considerations that you should keep in mind. Don’t worry if you do not know them yet; we are going to discuss these with you for the sake of the quality of your upcoming projects:

• If your voltage sensor uses an AC voltage, then a transformer is important that should consist of sensing elements to make your setup work.
• Other than a transformer, when you want, you should reduce the voltage level to low, which will cause the AC voltage to change into DC voltage. It means you can switch the nature of voltage from AC to DC and vice versa. 

For DC voltage: 

As you know the considerations of the AC voltage, its time to learn about what you are going to do when you are working with DC voltage in a voltage sensor:

• In this case, a transformer is useless; instead, you need an A/D converter which is an important part of a complex voltage sensor.
• Apart from an A/D converter, you need a resistor that consists of a sensing element that will pair up with the DC voltage.
• However, remember to use more voltage than the sensing elements; otherwise, this setup won’t perform as per your expectations.
• Also, power regulation and control are necessary when you are observing DC voltage. 

Characteristics of Voltage Sensor Circuit

It will be just redundant to say that voltage sensors have crucial applications for the well-being of giant industries around us. Isn’t it so obvious to you?? Due to this reason, consumer electronics is no exception. Every type of voltage sensor has a different set of features that make it different from the others. Nevermind, we are going to take a quick look at the general characteristics of voltage sensors for you:

• Excellent wireless nature so that you can connect it with as many external equipment and devices as you want.
• These are able to proactively monitor voltage drops and voltage spikes for the real-time detection of technical problems.
• Microcontrollers also work well with voltage sensors so that the devices can efficiently perform in their natural state. 
• Voltage sensors are always accessible from the market, and producers can fully rely on them.
• These are affordable to use for private projects, which helps students with their assignments as well. 

Different Types of Voltage Sensor Circuits

The following are two major and common types of voltage sensors:

Resistive Type Voltage Sensor Circuits

• The resistive sensors include two circuits normally. One of them is a voltage divider circuit, and the other is a bridge circuit. 
• This circuit also contains a resistor, and it has the simple job of functioning as a sensing element for this circuit. 
• The voltage gets divided into both circuit units of this sensor equally. 
• When the circuit receives the voltage supply, it allows you to find out the output voltage, and resistance helps you with this purpose.
• Unlike the voltage divider circuit, the bridge circuit has a group of four resistors. 

Capacitor Type Voltage Sensor Circuits

• There is a single insulator and two conductors present in this sensor.
• These three components are present in the core of the circuit. 
• You need an appropriate supply for this sensor to get the desired results. 
• The applied voltage will repel the electrons, which will create a detectable difference. 
• If you use a series circuit, you can combine the voltage and capacitance for this type of voltage sensor. 

Benefits of Voltage Sensor Circuit 

The following benefits will convince you to replace typical measuring techniques with voltage sensors to make your projects stand out from your competitors:

• Small size
• Featherweight
• More safety guaranteed
• Hight accurate results
• Non-saturable nature
• Eco-friendly
• Multipurpose circuit for voltage and current

Applications of Voltage Sensor Circuit

• It is reliable for the purpose of Load sensing in various devices.
• Fault identification with a voltage sensor becomes easy, and you can even save your devices from undergoing irreversible damage.
• Power loss detection makes electronics power-efficient, and all this happens due to a voltage sensor.
• Temperature control and regulation with a voltage sensor seem unusual, but it has a great impact on a device’s overall health.
• Power demand monitoring is also a fantastic use case for a voltage sensor.
• A voltage sensor never compromises on safety which becomes more important than ever for the well-being of devices so that they can perform naturally in the long run. 

Frequently Asked Questions (FAQs):

What is the meaning of a Voltage Sensor Circuit?

Voltage sensors are important for monitoring and determining the voltage supply of the electronics. You can find out the AC/DC voltage levels as well. It uses voltage as input and switches as its output. 

What are the various kinds of Voltage Sensor circuits?

Following are the different types of sensors available in the market:

• Temperature sensors
• Vision/imaging sensors
• Proximity sensors
• Radiation sensors
• Pressure sensors
• Position sensors
• Particle sensors
• Photoelectric sensors

What is the working of the Voltage Sensor Circuit in Arduino?

It acts as a voltage divider in Arduino. Moreover, it works on the ratio of resistance 5:1. It has two resistors of 30kilo-ohms and 7.5kilo-ohms. Besides, It reduces the output voltage to factor 5, no matter the input voltage. 

What are the two elements of a Voltage Sensor Circuit?

There are two major parts within a voltage sensor. One is the voltage divider circuit, and the other is the bridge circuit. These two parts play their individual roles in making the sensor perform its role efficiently for the devices, even under unfavorable conditions. 

The counter is widely used in digital devices to count the number of signals or any other event. It stores information and creates flip-flop groups using clock signals. Counters help in measuring the time and frequency as well as commence the counting operation. This enhances the memory location based on the application and device.

Counters have two basic types. Asynchronous counter and synchronous counters. Moreover, the ‘Mod’ refers to the modulus counter, which determines the number of states that needs to apply before calculating the signals. Frequency counters are widely used in digital clocks, timer circuits, frequency dividers, and ana-to-digital converters. 

This article gives you a detailed insight into how a frequency counter works, its types, advantages, features, and applications. So let’s dive into it. 

What Is a Frequency Counter Circuit?

Frequency counters refer to a type of device that integrates various types of radio frequency devices to measure the time and frequency of digital input signals.

They have the ability to measure the time and frequency of repeated input digital signals precisely and accurately. Moreover, the frequency counter also refers to a frequency meter as it calculates the time and frequency of input pulses and square wave signals.

RF range devices also use this. They simply use Prescaler, which minimizes the frequency of the signal and helps a digital circuit to operate. Moreover, it shows the frequency of analog or digital signals over the display screen in Hz.

The counter starts counting the pulses when the number of pulses occurs in a given interval of time. It transfers them to a frequency counter device. This, however, shows the frequency pulse range and sets the counter to zero. It has a digital display which makes it easy to use and operate. Moreover, it gives accurate results at affordable prices.

Block Diagram Explanation of Frequency Counter Circuit

The block diagram of frequency contains threshold, input conditioning, input signal, AND gate, display, flip-flop, decade dividers, latch or counter, and accurate clock or time base.

1. Input

When a counter receives input signals with high-impedance input and low-impedance output, it sends it to an amplifier which converts the input signals into a rectangular wave or square wave for operating in a digital circuit. Thresholds and input conditions are utilized in amplifying and buffering input signals. Moreover, it uses Schmitt triggers to manage the additional counting pulses that occur because of the noise and disruption at the sides. Therefore, controlling the counter sensitivity and trigger level can minimize the counting of extra pulses. 

2. Clock

An accurate timebase or clock helps in creating various timing pulses at specified time intervals. Moreover, it uses high-quality crystal oscillators for accurate and controlled timing signals. This cloak is then applied over the decade divider. 

3. Decade Dividers & Flip Flop

The input and clock signals produce pulses that go through a decade divider. It divides the timing signals. The received output then goes through a flip-flop. It creates a precise enabling pulse to go to the AND gate.

4. Gate

The accurate enabling pulse from the flip-flop and input signal series then goes through the AND gate. Here it creates a pulse series at an accurate time interval. If the input signal has a 1 Mhz frequency and passes through the open gate just for 1 second, it creates 1 million output signal pulses.

5. Counter & Latch

The output from the gate then goes to the counter. It computes the number of pulses obtained from input signals. However, the latch holds the signals of output while the counter calculates the pulses and displays the figures over the display. The latch goes through 10 stages of counting and holding the pulses.

6. Display

The display shows the output signals received from the latch and the counter and displays them in an understandable format. It shows the signal frequency. It uses display screens like LED or LCD. As every decade counter has one digit, it displays the rest of the information over the display.

Circuit Diagram Explanation of Frequency Counter Circuit

The diagram of the frequency counter includes a counter, two timers, a potential resistor, an 8051 microcontroller, a generator of square waves, and a display (LCD). 

It uses an integrated circuit 1555 timer. It produces clock signals in one second of the specified time interval. Arduino UNO acts as a generator of square waves. Both the IC 555 counter and generator of a square wave refer to an astable multivibrator. Other than that, it uses an LCD of 16×2 inches which shows output signal frequency in Hz. 

It uses an 8051 microcontroller counter and IC 555 timer. The integrated circuit 555 timer produces oscillating signals using a 99% duty cycle and gives output signals with the highest interval period. The discharge resistor and threshold adjust in a way to get the required duty cycle value. It uses the duty cycle formula of

D = (R1+R2)/(R1+2R2)

The 8051 microcontroller counter generates the pulse frequency in Hz. As 8051 contains two timers, of which one acts as 0 timers and one-timer. At the same time, they operate in 0 modes and one mode. Timer 0 helps in producing a delay in time while timer 1 counts the number of pulses coming from the generator of the square wave.

 Operating Principle of Frequency Counter Circuit

The generator of square waves produces a pulse that goes through the 8051 counter. It uses two modes of operation, delay the time and pulse counting. The 8051 counter calculates the input signal number of pulses at a given time interval. The output received from the counter then displays to an LCD of 16×2 which shows signal frequency in Hz. This is how a frequency counter works. 

Major Types Of Frequency Counter Circuit

Frequency counters have two types that help in measuring the signal frequency. These types include Direct counting and Reciprocal. 

· Direct Counting 

This approach serves as the simplest and most common method to measure input signal frequency. First, it counts the input signal cycle every second. Then a common counter circuit is used to measure the frequency. This, however, does not give appropriate results and has limitations in measuring low-frequency resolution. It expands the time of the gate to measure the high resolution. For instance, to measure a high resolution of 1 MHz, then it needs a 1000 seconds interval to measure a one-time signal.

· Reciprocal Counter

This approach overcomes the drawback of the first direct counting approach. It calculates the input signal period rather than measuring the input signal cycles every second. It uses the formula F = 1/T to calculate the pulse frequency. However, the final resolution of frequency depends on input frequency independence and temporal resolution.

It has the ability to measure low frequencies at high resolution quickly. Moreover, it adjusts the trigger phrases and minimizes the noise. It measures input signal time and manages to maintain enough time resolution. Additionally, it does not cost much. 

Other than these two frequency counters also have other types. This includes a panel meter, a frequency counter with a digital multimeter, and a handheld frequency counter. Additionally, a bench frequency counter which is used in electronic test devices, and a PXI frequency counter. It is used in control and test systems and shows frequency in the formality of PXI. 

Advantages of Frequency Counter Circuit

Frequency counters offer various benefits and features. The measurement of square wave generating signal frequency happens in accurate time intervals. Moreover, frequency counters are vastly used in frequency measurement in the radio-frequency range.

It does not only give accurate results but also gives easy and quick. However, based on the usage and application, it costs less. Also, it makes sure that all frequencies must transmit within a band. 

Applications of Frequency Counter Circuit

A frequency counter is used in a variety of applications and devices. Firstly it is used to measure the square wave generating signal frequency. It also measures the signal frequency from an oscillator.

It does not only measure the frequency but gives an accurate measurement. Moreover, it measures input signal frequency over the receiver and transmission line. Due to clock signals, it uses data transmission. Moreover, it only works in the range of RF. In addition, it can also measure high power transmission data frequency.

Frequently Asked Questions 

What is the unit or symbol of word frequency?

Hertz or Hz is used as the unit of signal frequency.

What is the major benefit of a Frequency Counter Circuit?

A frequency counter is used to analyze accurate signal frequency produced from an oscillator or a square wave producer.

Which type of Frequency Counter Circuit is best to measure frequency with high values?

The high-frequency measurement uses an asynchronous and synchronous counter.

What is the meaning of Mod Counter?

Modulus counter refers to a Mod counter that uses clock signals to count a number of times a counter counts pulses sequence. 

What Are The Two Main Techniques Of Frequency Counter Circuit?

Frequency counters use Reciprocal and Direct counting methods. 

Conclusion

Frequency counters refer to a very sensitive device whose accuracy depends on the timebase precision. However, the timebase may vary according to age, instability, poor design, and movement. Therefore, make sure to give extra care to the timebase while working with frequency counter projects.

Soldering can be described as a reliable way for joining copper pipes during plumbing works as well as for assembling electrical components inside a printed circuit board. This creates reliable and strong joints.

However, what will happen when you solder a wrong pipe or component? What if the soldered pipe or component has no use and you want it to serve a different purpose? This is simple; all you need to do is to take out the component by desoldering this solder joint or melting the solder. Whenever you are Desoldering, you must choose the appropriate tool and method for removing these components. By this, re-using the components will be possible.

Otherwise, these components will become damaged during the whole process and using them again will be impossible.

What are Desoldering Wires?

A desoldering wire, which is also called desolder wick, is made up of copper threads which are braided together. Normally, flux is added to aid the flowing of the solder from the jumper, where it isn’t meant to be, into the wick. Therefore solder wick is at times referred to as desolder braid. You can solder virtually everything, and the desoldering wire forms a huge part of the entire process.

This method of soldering wick is useful for taking out any unwanted solder after the soldering process. The making of the soldering wick is made through the intertwining and braiding together of the copper coils. Therefore, it is termed desoldering braid.

Furthermore, soldering wick is manufactured using copper wires because they are great heat conductors. As this solder gets attracted to heat, these copper coils suck the solder up from the surface of the metal.

There are soldering wicks that come with flux. This allows solder to be removed from its surface. Also, when the solder wick doesn’t have a flux, you may dip the wick’s end part into some of the flux so as to enhance the solder removal speed. Three types of desoldering wires are possible to serve different uses. These include:

• No-clean: These are low-residue halogen-free flux coated braids that are spooled on the ESD safe ribbons.
• Unfluxed: The copper braid left untreated and spooled on the ESD safe ribbons
• Regular: This is the rosin flux having treated copper braids

Things to Do To Desolder

Below are some of the things you must do to desolder

• Intertwine few inches of the copper wire and then create a braid
• Then apply some of the flux on this copper braid through the dipping of the end in flux
• Place some of this solder wick on those joints you wish to desolder
• Keep the hot soldering iron at the solder wick’s tick as well as the desired pin
• Wait for some seconds till this solder melts and the melted solder is sucked by the solder wick
• Take this solder wick and then take that part of the wick, which has been covered using solder
• Then, repeat this process until this unwanted solder has been removed.

When handling this solder wick, make sure that it isn’t touched with your bands because of its extreme hotness. Just use some pliers to hold as well as position it.

What are the Safety Tips to Take Note of During Desoldering?

Similar to soldering, there are some safety precautions that you must adhere to strictly during desoldering. If you fail to do this, you could have serious injuries.

Work with these safety tips in order to have a safe a great desoldering experience

• User well-ventilated areas during desoldering
• Avoid touching the element or tip of the soldering iron
• After use, ensure the soldering iron is placed on its stand
• When handling the components, use pliers during desoldering
• The solder must not be touched with your hands
• Make use of gloves, masks, and safety glasses
• Don’t put on loose-fitting clothes
• Have a fire extinguisher and first aid kit ready

When Should a Desoldering Wire be Used?

While the desoldering pump or solder sucker functions like the vacuum cleaner, the desoldering wick functions more like mops. The ability of the latter for absorbing solder ensures it is very useful in applications whereby solder splatter cannot be accepted.

This makes this desoldering wick better when cleaning off solder from the SMT pads as well as removing the solder bridge found on the BGA pads and fine-pitch SMT which are usually seen on modern PCBs that have been populated with the SMD components. Though the best way to desolder the SMD components are by making use of the hot air rework stations as well as special desoldering tweezers the desoldering wire or wick is also utilized for this task.

Also, the desoldering pump is clearly useless for all SMD reworks. This is due to the fact that the PCB’s conductive pads are just too flat to allow the sucking out of the solder effectively. It is similar to drinking of soup from your dinner plate using a straw.

Removing Solder Using Desoldering Wire

Using the desoldering wire wrongly might tear patters from the PCB as well as damage some discrete components. To prevent problems like these, ensure these [preventive measures highlighted below are taken.

• Apply flux to whatever joints you want to desolder
• Place your desoldering wire on the joints and place this soldering wire on a wire
• This soldering iron will melt the solder. This is pulled in the desoldering wire. Immediately this solder has been taken out, lift this wire and then iron the board off.

Tips for Proper Removal

Though using it seems easy, utilizing wrong techniques might lead to thermal damages to the printed circuit board and its components. Extending the soldering iron contact to the component or board might lead to thermal damage. Also, if this desoldering wick doesn’t remove the solder, try the steps highlighted below.

• Apply a little solder onto the joint
• Also, apply some solder to the soldering iron tip
• Apply little quantity of solder at the desoldering wire tip. This aids easy removal
• Cut the wire’s soldered tip at a 45 degree angle. This ensures that solder present at its tip isn’t cut off

When you apply some solder to the joint, the tip of the desoldering wire, this helps to cut surface tension as well as permit the easy absorption of the joint’s solder by the wires.

During the process of desoldering, if you need to cut the desoldering wire, cut it at an angle of 45 degrees with the solder still present, this also helps in trimming the wire whenever it is saturated with the solder and will not be able to absorb again.

Choosing the Right Desoldering Wire and Tip

Below are some things to consider when choosing the right desoldering wire and tip

Braid Width

You can find desoldering wick in different widths starting from 0.8 mm and can go above 5 mm. A general rule says that the width of the braid must be slightly larger or equal to the size of the pad. Braids that are smaller won’t wick off solder from the whole pad, whereas the oversized ones would affect the nearby pads that you didn’t plan to solder

Size of Soldering Tip

This same logic is applicable to the tip of the soldering iron. It has to match the width of the braid. When it is too small, the heating becomes slower. This causes the dwell time as well as the risk of damages to the components. Also, the oversized tips may knock the neighboring components off.

Flux Composition

Finally, the composition of the flux utilized for the desoldering wick is important as well. If the workflow is relying on no-clean solder due to the fact that you want to do skip cleaning, then you have to make use of a desoldering wick which has no-clean flux infused with it. Also, if you want to clean the post rework of your PCB assembly, desoldering wick that has been imbued with a rosin flux ill have the fastest wicking action.

Advantages and Disadvantages of Desoldering Wire

Advantages

• Simple, cheap, and easy method
• Great method for taking out solder from the flat surfaces
• Desoldered components can be reused
• Supplied on pre-cut or spool strands
• Soldering wick comes in different sizes; this depends on the quantity of solder that you wish to remove
• The soldering wick’s size can be modified. This depends on the quantity of solder that you wish to remove

Disadvantages

• The soldering wick cannot be reused. The portion that is covered in solder must be cut
• As this soldering wick become very hot, positioning it against its joint could be difficult
• With this method, removing solder out of pinholes could be difficult

Conclusion

In summary, the process of desoldering is utilized in melting the solder as well as removing the materials that have been soldered. By making use of the right methods and tools, you can take out the components without causing any damage and then reuse them.

Electromechanical methods of assembling PCBs refer to the combined efforts of using electronic and mechanical processes for the circuit boards’ operations. This article highlights the basics of electromechanical assembly, the different variants you can choose from and some of the benefits.

What is Electromechanical Parts Assembly?

It refers to the process of using mechanical and electronic components, as well as subassemblies to manufacture an electronic device. The need for this process is buoyed by the need to make electronic devices fully electronic.

At the core of electromechanical assembly process is the creation of a definitive unit and the creation of a seamless integration of the product’s mechanical and electronic aspects.

Here are some quick facts about the electromechanical assembly manufacturing process:

• It allows for the creation of a fully-functional system – one that connects the electronic components to the mechanical elements.
• The assembly process also leads to the creation of a system that utilizes electronic current for performing mechanical operations.

Electromechanical Components List

The list of components used for the electromechanical assembly often alternate between the mechanical and electronic elements. However, it is also possible to use other components, such as subassemblies.

Mechanical Components

The following are some of the mechanical elements used in electromechanical assembly:

• Casings
• Motors and;
• Gears

Electronic Components

The following is a list of some of the electronic components used for electromechanical assembly:

• Sensors
• Printed Circuit Boards (PCBs)

The list of electromechanical components also includes the following:

• Programmable Logic Controllers (PLCs)
• DIN Rails
• Power switches
• Power supplies
• Cable and wire assemblies
• Enclosures
• Electric motors and;
• Varieties of circuitries.

Categories of Components Used in Electromechanical Assemblies

You may have thought that the assembly process uses just the combined components from both electronics and mechanics. However, there are three (3) broad categories of these parts, as discussed below:

Mechanical Components

The function of these parts is to account for the visible (physical) attributes of the electronic device. Parts like fasteners, motors, enclosures and gears are used for this purpose.

Electronic Parts

These components are used to build the electrical functionality of the electronic devices. The likes of capacitors, Integrated Circuits (ICs), Printed Circuit Boards (PCBs) and resistors are used here.

Electromechanical Parts

These are the combined components functioning both as electronics and mechanics. Connectors, switches, and solenoids are examples of the parts that have properties of both mechanical and electrical devices.

Types of Electromechanical Assembly Services

The complexity of the device and the targeted applications are some important considerations for the electromechanical assembly types.

These are some of the common ways to assemble electronic devices:

1. Cable and Harness Assemblies

This process refers to the use of wires or cables meant for transmitting electrical signals within the device.

Some of the cable and harness parts are:

• Ties: these are used to affix the wire harness to the device.
• Wires and Cables: these are designed to convey the signals and electrical current within the device.
• Insulators: these components protect the electronic devices’ components from touching the environment and from touching each other.
• Fuses: these are in place to regulate electrical current, and in extension, reduces the risks of power-induced damages to the device.
• Connectors: these are used to connect the wires and cables in the electronic device.
• Relays: the function of the relays is to turn on and off the power in the high-amperage circuits.

2. Mounting Rails

Also called the DIN Rails, these are used to mount several other components within the electromechanical assembly.

3. Motor Assemblies

These are the types of electromechanical assembly used for ensuring movement within the electronic device.

4. Switch and Sensor Assemblies

Also called the control panels, they help in bolstering the interactions and controls of the electronic device.

They are broadly categorized into:

Sensor Assemblies

These refer to the parts used for converting light, sound, motion and heat into the corresponding electrical signals.

Examples of the components used for the sensor assemblies are:

• Connection Heads: these parts enable the sensor wires’ connection to the transmitter.
• Sensing Elements: these components are used for detecting proximity and the physical properties, such as radiation and temperature.
• Transmitters: these are used to transfer the data (pieces of information) obtained about the targeted property.
• Housings: these are used to protect the sensor-related components.

Switch Assemblies

These components are primarily used for connecting or disconnecting the power supply to the electrical components.

Examples of the switch assembly components are:

• The Switching Mechanism: this is a pushbutton used for controlling the electronic device’s operations.
• Contacts: these parts allow for the flow of electric current to the device’s switch.
• Wiring Harness: the harness provides the pathway for the entry and exit of electric current from the switch. It is also used for holding the electric switch in position.

5. Power Supply Assemblies

These are the components used for the conversion and distribution of electrical current within the electronic device. These parts include:

• Regulators: these are used for reducing the filter’s ripple voltages.
• Transformers: these components are used for modifying the voltage coming into the system.
• Filters: are used for smoothing out the waves in the Direct Current (DC) output. This happens after the rectification process.
• Rectifiers: used to convert the incoming voltage from Alternating Current (AC) to Direct Current (DC).

6. Box Builds and Integrations

This infers to the process of building full systems of electromechanical assembly called box builds. We can also handle the integrations for you, such as integrating a circuit board into full harnesses, enclosures and a front panel assembly equipped with switches and connectors.

7. Panel Assemblies

This type of electromechanical contract manufacturing requires the integration of the components into panels. The aim of the integration is to streamline the process of distributing power into the connected circuits.

The panel assembly process includes wiring the panel, positioning the components in the back panel and drilling the holes for mounting the hardware.

8. Transformer Assemblies

The process of transformer assemblies involves aiding the transfer of electrical current between multiple circuits.

The process includes the insulation of materials, lamination of the core, making primary and secondary windings.

The Benefits of Electromechanical Assemblies

Despite the complexities, using the electromechanical process of assembling electronic devices comes with some perks, such as:

Device Modernization

Electromechanical assemblies support the reevaluation and upgrade of the existing electronic devices.

Specialized Services

You can get specialized electromechanical assembly services from the Contract Manufacturer (CM). With the longstanding years of experience and the use of specialized equipment, the electromechanical assembly technician has the know-how to optimize the complexity of the electronic devices.

Prototyping

The support for prototyping and testing allows for the early-stage validation of the electromechanical assembly products.

Affordable Electronic Product Manufacturing

You also get to save up on extra costs when using the electromechanical assembly. Thanks to the box build and integration process, you can reduce the overall production costs.

The electromechanical contract manufacturing company will be handling most aspects of the product, such as:

• Component sourcing
• Handling the facility, labor and equipment costs.
• The manufacturer’s access to a set of established supply chain networks also helps you to save costs on logistics.

How to Choose Electromechanical Contract Manufacturing Companies

Want to work with a Contract Manufacturer (CM) for your electronic device production? Here are some of the tips on choosing the best company:

Quality Assurance

The products or electrical devices should meet the minimum quality standards. Therefore, the company should have the relevant facilities and certifications to offer electromechanical assembly services.

Check the Technical Capabilities

This refers to the Contract Manufacturer (CM)’s ability to handle your electronic device project, as per your requirements.

The manufacturer needs the know-how and pieces of equipment to make this work.

Volume of Orders

Does the electromechanical assembly CM have what it takes to produce the volumes (numbers) of electronic devices you want?

First, find out if the company supports micro electromechanical assembly, which means that it allows for the production of a few products.

The manufacturer should also be able to handle large-volume orders.

Track Record

This refers to the Contract Manufacturer (CM)’s many years of experience. It also refers to the different projects it has been able to process, thanks to the extensive years of experience.

The reason for this consideration is that an experienced CM is the one that can easily detect and fix issues, as well as produce your devices, as per the requirements.

Box Build Electromechanical Assemblies

Does the company offer box build solutions? If it does, it makes sense, as it saves you time and money. The specifications of the box build solutions include sourcing the components and managing the entire electromechanical assembly in-house.

How to Get Started with Electromechanical Assembly

Haven satisfied yourself that using electromechanical assembly can improve your electronic projects, start by contacting a professional manufacturer. We will help you make custom-built solutions that match your projects’ preferences, serve the needs of the target market and save you costs.

You can be sure of getting your electronic devices’ electromechanical assembly solutions handled in-house by our experienced engineers and all these will be completed in the shortest lead time possible.

The component placement list (CPL) file is crucial when utilizing the pick and place machine. This file is usually requested to help place SMT components and through hole parts accurately on a PCB. The CPL file also known as pick and place file comprises information such as rotation, the bottom or top side of the PCB, and X/Y locations.

What does a CPL File Mean?

A CPL file is a system file integrated by Windows operating system. The full meaning of CPL is component placement list. This file defines the particular location, rotation, and position you need to populate each component reference designator. The CPL file is also referred to as an XY file or centroid file.

The component placement file describes the location map of the components. This file comprises all necessary details about the orientation and position of every SMT component on the printed circuit board.

The CPL file is usually in the text format (ASCII) and it is composed of two main locations (x and Y). Furthermore, the list file of a component placement is very important for circuit board assembly. This is because it offers some data set which permits users to prepare ahead for the production of their boards. Also, this CPL file is made up of just SMT components.

You can generate this file by making use of several CAD packages. Moreover, there are some of the packages that fail to create or generate the file. There are cases where this file needs to be changed by some assemblers of printed circuit boards. CPL file has some file formats which includes csv, xlsx, as well as xls.

Assemblers of circuit boards can use the CPL file for the easy importation of data without the manual imputation of the important details. To achieve this, you can work with several packages, which includes Altium, KiCad, as well as Autodesk Eagle.

What are CPL Files Made of?

The assembly sample CPL files are made of the following below

The reference designator: This must work with the bill of materials and PCB demarcation

Location: Both values of the X and Y location explains the component of that PCB origin. This is why these locations’ values need its part origin centered in the component.

Rotation: When handling rotation, it must be done counterclockwise for the top area and then clockwisely for the bottom parts. Take note that rotation is usually measured in degrees.

The layer: It helps in describing either the top or bottom side where the component needs to be placed.  You will also find the details below in an assembly sample CPL file.

• X as well as Y position of the component
• The top or bottom side
• The reference designator of the component
• Orientation

How to Export the Component Placement List (CPL) File using Different Software

You can easily export the CPL file from different PCB design software. These guidelines will help you export CPL files from different design packages.

Kicad

When exporting a CPL file from KiCad, the first thing you should do is to open the Kicad file and click on File. After this select Fabrication Outputs and then click on Footprint Position File. A new window will appear, choose the output directory for the file and select Generate File. Doing this will help you generate the pick and place files.

Altium

For Altium, you need to open the .PcbDoc file and click on file, choose Assembly Outputs and click on Generates pick and place files. The Altium version you are using will determine the columns you want to include in the file. The rotation, X-y coordinates, and the Designator columns are needed. You can decide to leave out other information. However, Altium will produce the file in a similar location just like the PcbDoc file.

Autodesk Eagle

Open the .brd file and go to File and choose Export, click on Mount SMD. You will be asked where you want to save the bottom and top pick and place files. While the .mnb file represents the bottom side and the .mnt file represents the top side.

Importance of the CPL File in PCB Assembly

The component placement file saves time and enhances accuracy when programming the pick and place equipment. CPL file comprises the list of all components on the PCB design while stating their X-Y coordinates. The majority of PCB design software packages can generate the component orientation and location from the PCB layout in order to design a CPL file.

The CPL file is crucial for the PCB assembly process as it offers efficiency and quality.

Quality

A CPL file enables a PCB manufacturer to easily import data without the need to input the information manually. Also, the import data can hide any problems as regards the orientation of devices. Silkscreens in the Gerber data are not usually clear or not available in some cases. Also, silkscreens might not be correct in some cases since references are included in the wrong place. The CPL file offers more accuracy.

Efficiency

It takes time to enter the data manually. Therefore, you will have to include engineering processing time before commencing production. This could cause another delay on the delivery dates. Also, the manufacturer will need some clarity if there is any problem with an assembly. The outcome is a possible delay since responses are not timely.

Accuracy

Another important benefit of using the CPL file is that it helps pick and place machines to accurately place components and parts on a circuit board. The details provided by the CPL file are usually accurate. This information will tell the machine the appropriate location for the placement of all the surface mount components.

Conclusion

Two out of the countless benefits of using CPL files is their efficiency as well as quality. Throughout the process of PCB assembly, assemblers of printed circuit boards usually ask for users’ CPL file. It provides the data set needed for the commencement of the process of PCB assembly. For exporting this file, there are different softwares available.

Remote control cars have always been an attraction for kids. Even as adults, you can’t outgrow them. These remote control cars operate on special type remote control circuits. However, these remote control toys are available in the market in wide ranges. However, designing these circuits and manufacturing them on your own gives another type of experience. But it’s quite a difficult and complex process to assemble various types of electronic components. Or you may get confused in the middle of the process, and you may stop it.

Therefore, to make this process easy and communicable. We provide you with detailed information about how you can make a remote control circuit for your remote control cars with just one printed circuit board and some essential components. 

What are Remote Control Circuits?

A remote control PCB as the name suggests, can operate the device remotely, even from a distance. It has wireless connections. But some may also contain wired connections. These remote-control PCBs can be used in LEDs, LCDs, TVs, DVD players, and various types of toys. Devices that contain RC circuits imply that you can use and operate the device freely.

However, these devices can only operate just from a very short specified distance. Otherwise, it won’t work. Some advanced devices with advanced circuits can operate from far, like drones, but some devices use only short circuits that only operate within the specified range. 

Additionally, some devices with old generated RC circuits, like televisions of early ages, use ultrasonic tones. However, devices with the latest RC circuits can use IR remote control, which uses IR digitally coded signals to control the devices. 

IR technology helps in controlling various types of circuit functions along with speed and power. Moreover, some remote controls are specially designed with special types of circuits and can act as universal remote controllers that can work in almost all types of circuits.

Working on Remote Control Circuits

Playing with RC cars looks fun. But how it works and operate amaze you the most. These types of RC cars and devices use radio signals. The transmitter creates these signals and sends the signal to the receiver present in the remote car. These signals, however, operate the car perfectly. 

When a signal reaches the circuit receiver, it identifies and translates the code into desired mechanical action of the car. This is the surface phenomenon a person sees or understands. However, RC cars have more functions inside of them that make them operable. 

In RC cars, the transmitter sends radio signals to a receiver. It uses a specific range of frequencies using a controller. The signal operates through the battery power of the car and controls features like forward, reverse, left, and right. Moreover, touching the controls creates an electrical connection that transmits and connects some specific pulses. The specific pulse quantity is based on some specified actions. 

When a car receives these electrical pulses, it eventually turns that specific part of the car. Furthermore, to enable all these functions, a remote control car needs a motor and an RC circuit board. In addition to this, always remember that the receiver always waits for the signals to receive. Therefore, it fulfills your command instantly at once.  

Making of A Remote Control Car Circuit

The manufacturing process of remote control cars needs various types of electronic components and devices that play an essential role in the functionality of RC cars. 

· Transmitter

The transmitter acts like the brain or central processing unit of RC cars. It refers to a manual controller that helps in transferring signals to the receiver by pressing manual buttons. Moreover, they work similarly to the remotes of televisions.

· Receiver

Remote control cars need receivers. This receiver catches the signals from the transmitter. Firstly the receiver receives the signals and then decodes them into mechanical form. You can also say that receivers here act like antennas. 

· Motor

Remote control cars need a special type of device that is responsible for all their movements. Motor serves as that very crucial part. It manages all movements of a remote control car. Moreover, you can also install various motors in one car based on your needs and preferences. However, if you really decide to utilize two motors, then make sure to grant different duties to both motors. Make sure one motor moves the back wheels while the other one front wheels. Furthermore, some older remote control cars also use four motors in which each controls one wheel.

Another important factor in installing the motor is to choose the right one. Basically, the type of motor depends on the type of remote car you are going to make. Large remote cars use a 12V DC motor as it carries heavy loads all at once. However, small remote cars use 6V Bo motors. 

Considering the RPM is also a very important factor when choosing the right motor. RPM refers to how many times a shaft of a DC motor completely spin in one minute.

The spin cycle contains a 360-degree turn. However, make sure to choose the motor that has low RPM, as it will be easy for you to manage them. Moreover, you must remember that both the torque and speed of a motor are inversely proportional to each other. 

· Power Source 

Remote control cars operate on power sources just like any other fuel cars. The majority of remote control cars use batteries as a power source. These batteries provide electrical power to receivers, electrical motors, and electrical components. Moreover, other than batteries, some remote control vehicles use a nitro engine to operate. This nitro engine uses fuel rather than batteries. 

· Circuit Board

Circuit boards serve as the core component of a remote control car. It identifies different electrical charges and signals among different components of the remote control car.

· Servo 

Servo plays a crucial part in the layout of remote control cars. It helps in converting the power source electric current into movement. Additionally, it is generally responsible for operating remote control vehicles’ steering systems. Also, the servo enables the remote control vehicles to move in the desired direction.

· Speed Controller

This electrical component keeps the remote control vehicle’s RPM and speed in control. Remote control cars that operate on batteries use an electrical speed controller component in them. At the same time, remote control cars that operate on nitrogen engines utilize throttle servos in them. 

Conclusion

After reading the whole article, you have clear ideas about why remote control cars are still famous. Besides this, how these cars work and some important parts that make this cars. 

Moreover, this article also explains the detailed steps that help you make your own perfect functional remote car circuit. You can also get in touch with us if you have any queries regarding the steps.