Dangane da fasahar zamani, duniya tana girma cikin sauri, kuma tasirin sa zai iya shiga cikin rayuwar mu ta yau da kullun. The way we live has changed dramatically and this technological advance has led to many advanced devices that we didn’t even think of 10 years ago. Jigon waɗannan na’urorin shine injiniyan lantarki, kuma ainihin shine buga kewaye hukumar (PCB).

PCB galibi kore ne kuma yana da tsayayyen jiki tare da abubuwa daban -daban na lantarki a kai. These components are welded to the PCB in a process called “PCB assembly” or PCBA. PCB ya ƙunshi substrate da aka yi da fiberglass, yadudduka na jan ƙarfe waɗanda ke yin alama, ramukan da suka ƙunshi ɓangaren, da yadudduka waɗanda za su iya zama ciki da waje. A RayPCB, zamu iya samar da yadudduka 1-36 don PROTOTYPES masu yawa da 1-10 yadudduka don batutuwan PCB masu yawa don samar da ƙarar. For single-sided and double-sided PCBS, an outer layer exists but no inner layer.

The substrate and components are insulated with solder film and held together with epoxy resin.The welding mask can be green, blue or red, as is common in PCB colors. Maskurin walda zai ba da damar ɓangaren don gujewa gajeriyar hanya zuwa waƙa ko wasu abubuwan.

Ana amfani da alamun jan ƙarfe don canja wurin siginar lantarki daga wuri ɗaya zuwa wani akan PCB. These signals can be high-speed digital signals or discrete analog signals. Ana iya yin waɗannan wayoyin kauri don samar da ƙarfi/ƙarfi don samar da wutar lantarki.

A mafi yawan PCBS da ke ba da babban ƙarfin lantarki ko na yanzu, akwai jirgin ƙasa mai keɓewa dabam. Components on the top layer are connected to the internal GND plane or internal signal layer via “Vias”.

An haɗa abubuwan haɗin akan PCB don ba da damar PCB yayi aiki kamar yadda aka tsara. The most important thing is PCB function. Ko da ba a sanya ƙaramin resistor na SMT daidai ba, ko ma idan an yanke ƙananan waƙoƙi daga PCB, PCB na iya yin aiki. Sabili da haka, yana da mahimmanci a haɗa abubuwan haɗin gwiwa ta hanyar da ta dace. PCB lokacin haɗa abubuwa ana kiransa PCBA ko PCB na taro.

Dangane da takamaiman bayanin da abokin ciniki ko mai amfani ya bayyana, aikin PCB na iya zama mai rikitarwa ko mai sauƙi. PCB size also varies according to requirements.

The PCB assembly process has both automatic and manual processes, which we will discuss.

PCB Layer da zane

Kamar yadda aka ambata a sama, akwai yadudduka sigina da yawa tsakanin yadudduka na waje. Now we will discuss the types of outer layers and functions.

Understand PCB board assembly process and feel the green charm of PCBD

1-Substrate: Wannan farantin madaidaiciya ne wanda aka yi shi da kayan FR-4 wanda aka “cika” abubuwan ko aka haɗa su. Wannan yana ba da ƙarfi ga PCB.

2- Copper layer: Thin copper foil is applied to the top and bottom of the PCB to make the top and bottom copper trace.

3- Mashin walda: Ana amfani da shi a saman da kasa na PCB. This is used to create non-conducting areas of the PCB and insulate the copper traces from each other to protect against short circuits. Fushin walda yana kuma guje wa walda sassan da ba a so kuma yana tabbatar da cewa mai siyarwa ya shiga yankin don walda, kamar ramuka da gammaye. These holes connect the THT component to the PCB while the PAD is used to hold the SMT component.

4- Screen: The white labels we see on PCBS for component codes, such as R1, C1 or some description on PCBS or company logos, are all made of screen layers. Layer allon yana ba da mahimman bayanai game da PCB.

There are 3 types of PCBS according to the substrate classification

1- Rigid PCB:

PCBs sune mafi yawan na’urorin PCB da muke gani a cikin nau’ikan PCBs daban -daban. Waɗannan PCBS suna da ƙarfi, m da ƙarfi, tare da kauri daban -daban. The main material is fiberglass or simple “FR4”. FR4 tana nufin “mai ƙone wuta-4”. Halin kashe kansa na FR-4 yana sa ya zama da amfani don amfani da na’urorin lantarki masu ƙarfin gaske da yawa. The FR-4 has thin layers of copper foil on both sides, also known as copper-clad laminates. Fr-4 laminates sanye take da tagulla galibi ana amfani da su a cikin amplifiers na wutar lantarki, sauya yanayin wutar lantarki, direbobin motar servo, da dai sauransu. A gefe guda, wani madaidaicin madaidaicin PCB wanda aka saba amfani dashi a cikin kayan gida da samfuran IT ana kiransa PCB phenolic phenolic. Suna da sauƙi, ƙarancin ƙarfi, arha kuma mai sauƙin bugawa. Kalkaleta, madannai da mice wasu daga cikin aikace -aikacen sa ne.

2- Flexible PCB:

Made from substrate materials such as Kapton, flexible PCBS can withstand very high temperatures while being as thick as 0.005 inches. It can be easily bent and used in connectors for wearable electronics, LCD monitors or laptops, keyboards and cameras, etc.

3-metal core PCB:

In addition, another PCB substrate can be used like aluminum, which is very efficient for cooling.Ana iya amfani da waɗannan nau’ikan PCBS don aikace -aikacen da ke buƙatar abubuwan da ke da zafi kamar manyan leds, diodes laser, da sauransu.

Installation technology type:

SMT: SMT yana tsaye ne don “fasahar hawan dutse”. Abubuwan SMT sun yi ƙanƙanta sosai kuma sun zo cikin fakitoci daban -daban kamar 0402,0603 1608 don masu adawa da masu ƙarfin wuta. Hakanan, don haɗaɗɗen ics kewaye, muna da SOIC, TSSOP, QFP da BGA.

Taron SMT yana da matukar wahala ga hannayen ɗan adam kuma yana iya zama tsarin sarrafa lokaci, don haka ana yin sa ta farko ta hanyar ɗaukar hoto ta atomatik da robots.

THT: THT tana nufin fasahar rami. Components with leads and wires, such as resistors, capacitors, inductors, PDIP ics, transformers, transistors, IGBT, MOSFET, etc.

The components must be inserted on one side of the PCB on one component and pulled by the leg on the other side, cut the leg and welded. THT assembly is usually done by hand welding and is relatively easy.

Abubuwan da ake buƙata na Majalisar:

Prior to the actual PCB fabrication and PCB assembly process, the manufacturer checks the PCB for any defects or errors in the PCB that could cause the failure. This process is called the Manufacturing design (DFM) process. Masu ƙera dole ne su aiwatar da waɗannan matakan DFM na asali don tabbatar da PCB mara aibi.

1- Component layout considerations: Through-holes must be checked for components with polarity. Like electrolytic capacitors must be checked polarity, diode anode and cathode polarity check, SMT tantalum capacitor polarity check. IC notch/shugaban shugabanci dole ne a bincika.

Sinadarin da ke buƙatar bututun zafi yakamata ya sami isasshen sarari don ɗaukar wasu abubuwa don kada injin zafi ya taɓa.

2-Hole and through-hole spacing:

The spacing between holes and between holes and traces should be checked. Kushin da rami ba za su zoba.

3- Brazing pad, thickness, line width shall be taken into account.

By performing DFM inspections, manufacturers can easily reduce manufacturing costs by reducing the number of scrap panels. This will help in fast steering by avoiding DFM level failures. At RayPCB, we provide DFM and DFT inspection in circuit assembly and prototyping. A RayPCB, muna amfani da kayan aikin OEM na zamani don samar da sabis na PCB OEM, siyar da igiyar ruwa, gwajin katin PCB da taron SMT.

Majalisar PCB (PCBA) mataki-mataki:

Mataki 1: Aiwatar da liƙa mai siyarwa ta amfani da samfuri

First, we apply solder paste to the area of the PCB that fits the component. This is done by applying solder paste to the stainless steel template. Ana yin samfuri da PCB tare ta kayan aikin injiniya, kuma ana amfani da manna mai siyarwa daidai gwargwado ga duk buɗewa a cikin jirgi ta hanyar mai nema. Apply solder paste evenly with applicator. Sabili da haka, dole ne a yi amfani da manna mai siyarwa mai dacewa a cikin mai nema. Lokacin da aka cire mai nema, manna zai kasance a cikin yankin da ake so na PCB. Grey solder manna 96.5% sanya na tin, dauke da 3% azurfa da 0.5% jan karfe, gubar free. After heating in Step 3, the solder paste will melt and form a strong bond.

Step 2: Automatic placement of components:

Mataki na biyu na PCBA shine sanya abubuwan SMT ta atomatik akan PCB. Ana yin wannan ta amfani da robot da aka zaɓa. A matakin ƙira, mai ƙira ya ƙirƙiri fayil kuma ya ba da shi ga robot mai sarrafa kansa. Wannan fayil ɗin yana da shirye-shiryen X, Y da aka riga aka tsara na kowane ɓangaren da aka yi amfani da shi a cikin PCB kuma yana gano wurin duk abubuwan da aka gyara. Using this information, the robot only needs to place the SMD device accurately on the board. The pick and place robot will pick up components from its vacuum fixture and place them accurately on the solder paste.

Kafin zuwan injinan robotic da injin sanyawa, masu fasaha za su ɗauki kayan amfani ta amfani da tweezers su sanya su a kan PCB ta hanyar duba wurin a hankali da guje wa duk wani girgiza hannu. This results in high levels of fatigue and poor vision for technicians, and leads to a slow PCB assembly process for SMT parts. Don haka yuwuwar kuskure yana da yawa.

Yayin da fasaha ke balaga, mutum -mutumi -mutum -mutumi masu sarrafa kansa waɗanda ke ɗauka da sanya abubuwan da aka gyara suna rage yawan aikin masu fasaha, yana ba da damar sakawa cikin sauri da daidaitattun abubuwa. Wadannan robots na iya aiki 24/7 ba tare da gajiya ba.

Mataki na 3: Reflow waldi

The third step after setting up the elements and applying the solder paste is reflux welding. Reflow welding is the process of placing the PCB on a conveyor belt with components. The conveyor then moves the PCB and components into a large oven, which produces a temperature of 250 o C. Zazzabi ya isa ya narke mai siyarwa. Sannan mai siyar da narkarwa yana riƙe da kayan zuwa PCB kuma yana samar da haɗin gwiwa. After high temperature treatment, the PCB enters the cooler. These coolers then solidify the solder joints in a controlled manner. Wannan zai kafa madaidaiciyar haɗi tsakanin ɓangaren SMT da PCB. Dangane da PCB mai fuska biyu, kamar yadda aka bayyana a sama, za a fara kula da ɓangaren PCB mai ƙarancin abubuwa ko ƙarami daga matakan 1 zuwa 3, sannan zuwa wancan ɓangaren.

Understand PCB board assembly process and feel the green charm of PCBD

Mataki na 4: Duba inganci da dubawa

Bayan sake siyarwa, yana yuwuwar an daidaita abubuwan da aka gyara saboda wasu motsin da ba daidai ba a cikin tire ɗin PCB, wanda na iya haifar da gajerun hanyoyin sadarwa ko buɗewa. These defects need to be identified, and this identification process is called inspection. Dubawa na iya zama ta hannu da ta atomatik.

A. Manual check:

Because the PCB has small SMT components, visual inspection of the board for any misalignment or malfunction can cause technician fatigue and eye strain. Don haka, wannan hanyar ba mai yuwuwa bane ga allon SMT na gaba saboda sakamako mara kyau. Koyaya, wannan hanyar tana yiwuwa ga faranti tare da abubuwan THT da ƙananan ƙarancin abubuwan.

B. Gano gani:

Wannan hanyar tana yiwuwa ga ɗimbin PCBS. Hanyar tana amfani da injina masu sarrafa kansa tare da babban iko da kyamarori masu ƙyalli waɗanda aka ɗora a kusurwoyi daban -daban don duba haɗin haɗin mai siyarwa daga kowane bangare. Dangane da ingancin haɗin gwiwa na mai siyarwa, hasken zai haskaka haɗin haɗin solder a kusurwoyi daban -daban. This automatic optical inspection (AOI) machine is very fast and can process large quantities of PCBS in a very short time.

CX – ray inspection:

The X-ray machine allows technicians to scan the PCB to see internal defects. This is not a common inspection method and is only used for complex and advanced PCBS. If not used properly, these inspection methods may result in rework or PCB obsoletion. Ana buƙatar gudanar da bincike akai -akai don gujewa jinkiri, aiki da tsadar kayan.

Mataki na 5: Gyara kayan THT da walda

Abubuwan rami-rami sun zama ruwan dare akan allon PCB da yawa. These components are also called plated through holes (PTH). Jagoran waɗannan abubuwan za su ratsa ramuka a cikin PCB. Waɗannan ramukan suna da alaƙa da wasu ramuka kuma ta cikin ramuka ta alamun jan ƙarfe. Lokacin da aka saka waɗannan abubuwan THT kuma aka haɗa su cikin waɗannan ramuka, ana haɗa su da wutar lantarki zuwa wasu ramuka akan PCB ɗaya kamar yadda aka tsara. These PCBS may contain some THT components and many SMD components, so the welding method described above is not suitable for THT components in the case of SMT components such as reflow welding. So the two main types of THT components that are welded or assembled are

A. Welding da hannu:

Manual welding methods are common and often require more time than an automated setup for SMT. Yawanci ana ba da masanin fasaha don saka sashi ɗaya a lokaci guda kuma ya ba da jirgin ga sauran masu fasaha na saka wani sashi a kan allo ɗaya. Don haka, za a zagaya da’irar kewayen layin taro don samun ɓangaren PTH ya cika a ciki. Wannan yana sa tsarin yayi tsayi, kuma yawancin ƙirar PCB da kamfanonin masana’antu suna gujewa amfani da abubuwan PTH a cikin ƙirar kewayarsu. Amma bangaren PTH ya kasance abin da aka fi so kuma galibi ana amfani da shi ta yawancin masu zanen kewaye.

B. Weldering:

Siffar atomatik ta walda ta hannu ita ce walƙiya. A cikin wannan hanyar, da zarar an sanya sinadarin PTH akan PCB, ana sanya PCB akan bel ɗin jigilar kaya sannan a koma zuwa tanda da aka keɓe. Anan, raƙuman ruwa mai narkar da ruwa ya fantsama cikin madaidaicin PCB inda ɓangaren ke kaiwa. Wannan zai weld duk fil nan da nan. However, this method only works with single-sided PCBS and not double-sided PCBS, as melted solder on one side of the PCB can damage components on the other. Bayan wannan, motsa PCB don dubawa na ƙarshe.

Mataki na 6: Binciken ƙarshe da gwajin aiki

PCB yanzu yana shirye don gwaji da dubawa. This is a functional test in which electrical signals and power are given to the PCB at the specified pins and the output is checked at the specified test point or output connector. This test requires common laboratory instruments such as oscilloscopes, digital multimeters, and function generators

Ana amfani da wannan gwajin don bincika ayyukan aiki da halayen wutar lantarki na PCB kuma yana tabbatar da halin yanzu, ƙarfin lantarki, analog da siginar dijital da ƙirar kewaye da aka bayyana a cikin buƙatun PCB.

Idan kowane sigogin PCB ya nuna sakamakon da ba za a yarda da shi ba, za a jefar da PCB ko a soke shi gwargwadon hanyoyin kamfanin. Yanayin gwaji yana da mahimmanci saboda yana ƙaddara nasara ko rashin nasarar duk tsarin PCBA.

Mataki na 7: Tsaftacewa ta ƙarshe, kammalawa da jigilar kaya:

Now that the PCB has been tested in all aspects and declared normal, it is time to clean up unwanted residual flux, finger grime and oil. Kayan aikin tsaftacewa mai ƙarfi na ƙarfe ta amfani da ruwa mai ɗorewa ya isa ya tsaftace kowane irin datti. Ruwa mai narkewa baya lalata da’irar PCB. Bayan wanka, bushe PCB tare da iska mai matsawa. PCB na ƙarshe yanzu yana shirye don cikawa da jigilar kaya.