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FIGURE 9-1 Photograph of a Protoboard.
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FIGURE 9-2 Photograph of a general purpose printed circuit board.
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Another method for prototyping your circuit with a minimum of effort is to buy an evaluation board for the processor that you want to use in your design. Usually, these evaluation boards have some general-purpose prototyping area with a matrix of holes. The advantage of using the evaluation board is that you can use the resources on the board to get your design up and running. This usually means building your specific circuit portion of the design. The processor part of the design is used from the evaluation board. Another advantage is that these boards usually come with a collection of useful routines that you can plop into your design (I use the word design to refer to the composite hardware software portions). Usually, you also get an integrated debugger that eases your design test. This is not completely true for the AVR family of controllers because the program memory is located inside the controller chip. However, you do get the advantage of a working controller core circuit. The downside of this approach is the cost of the evaluation board.
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202 PROTOTYPING TECHNIQUES
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9.3 Tools of the Trade
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Whether you want to use the evaluation board to prototype your design or you want to use the general-purpose PCB, you will need a set of suitable tools to do a good job. It is very important that even the prototype is fabricated with the same care as the final product, if not more. You don t want some silly, sloppy solder job to be a cause of a nonfunctional design. Since you are testing a new design, you want the influence of other variables to be minimal (like a badly fabricated prototype with shorted interconnections). To do that you need to employ suitable tools to ease the construction. Figure 9.3 is a photograph of some useful tools, including the wire stripper supplied by RS components. These tools are:
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1. Solder iron, 35 watts, with a fine solder tip. A soldering station is highly recommend-
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2. 3. 4. 5.
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ed but is not mandatory. The soldering station offers isolated supply to the solder iron heater, thus reducing the leakage currents from the tip of the solder iron. Such a configuration is useful for use with CMOS components. An ordinary soldering rod can also be used while soldering susceptible CMOS components by temporarily disconnecting the main supply to the solder iron (when it has reached its operational temperature) just at the time of actual soldering and then connecting the supply back again. Fine tweezers for bending component leads. Nipper to cut the component leads. This is probably a fancy name for the regular lead cutter. A nipper has sharp edges that make a neat cut. Wire stripper (more on this in the text). A wire stripper is very handy in stripping a precise amount of wire insulation. Nose plier. Generally useful for tightening screws, etc.
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FIGURE 9-3 Some useful tools.
STEPS FOR PROTOTYPING 203
6. Screwdriver set. 7. M3 nuts and bolts. For fastening brackets onto the PCB as well as to support the PCB. 8. Drill machine (hand operated will do), with an assorted collection of drill bits. Use for
drilling holes in the PCB, enclosures, etc.
9. Bench vice with a 3-inch jaw. For holding the PCB steady, filing hardware or PCB, etc.
9.4 Steps for Prototyping
Now you are ready with all your tools and have your design ready. We can begin by looking at a procedure for prototyping any given circuit. It is important to have all the required components at hand. I usually proceed with the following steps when I am putting together a circuit for the first time:
1. Estimate layout for the circuit. It is elementary to keep components that share connec-
tions closer to each other. This will keep the connections short. How close should the components be placed This is a tough question. Usually, this estimate is intuitive. As an example, two DIP ICs should be placed .2 inch or more apart, depending on the number of interconnections to other components. If connections allow, even a .1-inch separation could be used. After you make an estimate of the placement of components and connectors, it is time to cut a suitable piece of the general-purpose sea of holes PCB. Cutting a piece of PCB a little more than you estimated is not a bad idea. This would take care of any future additions that you may wish to have. Now drill four M3 holes on the corners of the PCB. The four M3-size holes on the PCB corners are populated with 1-inch-long screws such that the PCB is raised about .5 inch above the ground. The other .5 inch of the screw juts above the PCB. With this arrangement, the PCB can be inverted for ease of soldering on the solder side of the board without putting stress on the components on the component side. Usually it is a good idea to start mounting components that have the smallest height profile. Neatly bend the component (resistors, diodes, etc.) leads at right angles and of the right length to slip into the PCB holes. To save space, it is also common to place components like resistors or diodes in a standing position. This requires that the other lead of the component is bent and looped back into an adjacent hole on the PCB. Since this is a prototype, it is all right to use sockets for the ICs. Choice of sockets is crucial, and nothing is gained by going in for cheap alternatives. IC sockets and connectors in general have high failure rates and are best avoided for critical applications. This is a choice that you must make on your own. All other things being equal, a circuit with minimum sockets and connectors is usually more reliable than one which has more sockets, connectors, etc. The downside is the pain in desoldering and replacing any IC. Once you start plopping components onto the PCB and soldering them in place, you have to worry about interconnecting them. The most common method of interconnection is to use ordinary plastic insulation single or multibraid hookup wire. However, we
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