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=== "Police Car Badge" === | === "Police Car Badge" === | ||
GitHub Repository: | GitHub Repository: | ||
https://github.com/Rik3Kat/ | https://github.com/Rik3Kat/PoliceCar_PCBArts | ||
'''Idea:''' | '''Idea:''' | ||
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When I was satisfied with my design, I imported the finished layout into KiCad and aligned all the different layers. The actual police car design is placed on the backside of the PCB, whereas the circuit with all its parts, is located on the frontside. After aligning the design, I placed the components on the frontside of the board in an optimal way. Starting with where I needed the LEDs to be and then went from there. After placing all the components, I drew in the circuit tracks to connect all of parts in the same manner visualized in the schematics. | When I was satisfied with my design, I imported the finished layout into KiCad and aligned all the different layers. The actual police car design is placed on the backside of the PCB, whereas the circuit with all its parts, is located on the frontside. After aligning the design, I placed the components on the frontside of the board in an optimal way. Starting with where I needed the LEDs to be and then went from there. After placing all the components, I drew in the circuit tracks to connect all of parts in the same manner visualized in the schematics. | ||
The frontside is covered with copper. This copper layer fulfills the role of the GND circuit tracks, which connects the rest of the circuit with the power supply. Of course there still are the general circuit tracks, that connect everything together, so power can reach all the components and the circuit can function. | |||
Furthermore, there are labels corresponding to each component. When soldering the parts to the board, it is much easier because you know where to exactly place them. There also is a placeholder label for the manufacturer, that is covered up by the battery holder. In the production of the board the label was exchanged with a manufacturing number. Lastly, I put a short warning on the PCB, as a homage to one of my friends. All these labels are placed on the frontside Silkscreen layer. | |||
<gallery> | <gallery> | ||
File: | File:PCB_Frontside1.png | ||
File: | File:PCB_Frontside2.png | ||
</gallery> | </gallery> | ||
Before I explain the backside of my board, I wanted to comment on the components I used for my PCB. Almost all of the parts are SMD components, that have to be mounted only on one side on the board, facing outward. In the case of my project, it is the frontside. The battery holders on the other hand need through holes drilled into the board and copper pads on the backside of the board, so they can be soldered to it. The LEDs I used also need through holes because they are a special type of LEDs, called reverse mount LEDs. They are mounted on the board facing inward. The middle part of the LED is placed into the hole, while the pads of the LEDs still sit on the frontside of the board. With this way they shine through the PCB. I designed it like that because I wanted the side of the PCB board with the actual design to look neat and flat but I also wanted the parts of the layout resembling the siren and headlight to light up/blink. | |||
[[File:PCB_Frontside3.png|400px]] | |||
I altered the footprint for a reverse mounted LED, that already exists in the KiCad footprint library, a bit to better fit the LED I wanted to buy and solder to my PCB. To do that I used the data sheet for the component, that I got from the manufacturer’s website. I repeated the same process for the slider switches footprint but instead of changing an already existing one I made it on my own by recreating the recommended layout found in the parts data sheet. | I altered the footprint for a reverse mounted LED, that already exists in the KiCad footprint library, a bit to better fit the LED I wanted to buy and solder to my PCB. To do that I used the data sheet for the component, that I got from the manufacturer’s website. I repeated the same process for the slider switches footprint but instead of changing an already existing one I made it on my own by recreating the recommended layout found in the parts data sheet. | ||
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Normally when you assign a layer just to be copper it will always have a soldermask layer above it. | Normally when you assign a layer just to be copper it will always have a soldermask layer above it. | ||
To give the body of the police car that silver color I stacked the soldermask and copper layer on top of each other, to expose the metal. For the wheels, the windows, the siren holder and the radiator cowling at the front of the car I just assigned them to be one layer of copper. The soldermask layered above the copper is a bit lighter in color and because the copper layer is about 35µm thick you can see and feel a height difference between the different layers. The windshield has some reflection highlights on it. To do this I created a silkscreen layer above the copper layer of the window. For the sirenlights and the headlights of the police car I made the layer to just be soldermask. This exposes the bare PCB Material. In this case it is FR-4, glass fiber. FR-4 lets the light of the LEDs shine through it, not just through the holes. I also assigned the parts of the design that are made to look like the car doors and engine hood a soldermask layer. With this you can see the bare PCB as well. | To give the body of the police car that silver color I stacked the soldermask and copper layer on top of each other, to expose the metal. For the wheels, the windows, the siren holder and the radiator cowling at the front of the car I just assigned them to be one layer of copper. The soldermask layered above the copper is a bit lighter in color and because the copper layer is about 35µm thick you can see and feel a height difference between the different layers. The windshield has some reflection highlights on it. To do this I created a silkscreen layer above the copper layer of the window. For the sirenlights and the headlights of the police car I made the layer to just be soldermask. This exposes the bare PCB Material. In this case it is FR-4, glass fiber. FR-4 lets the light of the LEDs shine through it, not just through the holes. I also assigned the parts of the design that are made to look like the car doors and engine hood a soldermask layer. With this you can see the bare PCB as well. | ||
<gallery> | |||
File:PCB_Backside 1.png | |||
File:PCB_Backside 2.png | |||
File:PCB_Backside 3.png | |||
File:PCB_Backside 4.png | |||
File:PCB_Backside 5.png | |||
</gallery> | |||
When I was happy with my layout and design of the PCB in KiCad I finally ordered it from JLCPCB. I changed the material of the copper layers to HASL, so the car body is actually silver, not copper. I changed the color of the soldermask layer to black and the silkscreen was already set to white, the color I wanted. | When I was happy with my layout and design of the PCB in KiCad I finally ordered it from JLCPCB. I changed the material of the copper layers to HASL, so the car body is actually silver, not copper. I changed the color of the soldermask layer to black and the silkscreen was already set to white, the color I wanted. | ||
After a while I finally received the PCBs and they look nice. I am just a bit disappointed by the streakiness of the silkscreen layer. | After a while I finally received the PCBs and they look nice. I am just a bit disappointed by the streakiness of the silkscreen layer. | ||
<gallery> | |||
File:KiCad, 3D-Viewer Frontside.png | |||
File:KiCad, 3D-Viewer Backside.png | |||
</gallery> | |||
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Before actually finishing the board, I had to get new capacitors because the ones I bought before did not have the right capacity. | Before actually finishing the board, I had to get new capacitors because the ones I bought before did not have the right capacity. | ||
I had to improvise a bit and the end result looks clunky, since the capacitors a quite big. They lie above the resistors R1 and R4 but because of the plastic at the bottom of the parts they do not interfere with the resistors. It functions how I wanted it to and I am happy with that. | I had to improvise a bit and the end result looks clunky, since the capacitors a quite big. They lie above the resistors R1 and R4 but because of the plastic at the bottom of the parts they do not interfere with the resistors. It functions how I wanted it to and I am happy with that. | ||
When I was finished with the soldering process, I clipped of the pin from the battery holder that was sticking out from the backside of the PCB. But only the top one. The one pin below that I bend to make it look like a door handle. | |||
As a last step I cut out green, orange, red and blue crafting foil in the shape of the sirenlights, the headlights, the car doors and the hood of the car. I stuck the foil onto the board and with this my badge is finally complete. Now it has all the colors I wanted it to have but I could not create, due to the limited option of layers and colors. | |||
Here is a link to a video that demonstrates the functionality of my PCB: | Here is a link to a video that demonstrates the functionality of my PCB: | ||