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7.6 QUICK TURN PROTOTYPE PRINTED CIRCUIT BOARDS
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method that allows you to get a robust circuit built quickly. Remember to start small and don t be afraid to experiment with different techniques in order to get the most efficient circuitry.
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7.5 Wire-Wrapping
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An older method used to wire complex circuitry together is known as wire-wrapping: a bared wire is literally wrapped around a long post, which is connected to the pin of an IC or some other component. Wire-wrapping can be used to create very complex circuits, and it is surprisingly robust. However, there are a number of downsides to this wiring method that you should be aware of. Wire-wrapping requires specialized tools, component sockets (with long, square leads), and prototyping PCBs each of which can be substantially more expensive than standard parts. It also takes a surprisingly long time. Professional wire-wrappers with automated equipment plan on each wire connection taking 30 s; starting out with hobbyist tools you will be hard pressed to perform (on average) one wire every 3 minutes. It should also be noted that a complex wire-wrapped board quickly becomes a rat s nest and wiring errors are extremely difficult to find. Finally, wiring power and analog components into a wire-wrapped circuit is difficult and can be extremely time consuming.
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7.6 Quick Turn Prototype Printed Circuit Boards
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Probably the most efficient method of prototyping circuits is to design a simple printed circuit board and have a small number of samples built by a quick turn manufacturer. Depending on your location, you could conceivably have your PCBs within a business day. Quick turn PCBs (like the one shown in Fig. 7-6) are also surprisingly cost efficient you should plan on the PCBs costing $5 per square inch, approximately the same as what you would pay for PCBs, sockets, and wiring for a wire-wrapped circuit. For a beginner, the time spent designing the PCB is similar to that of wire-wrapping a PCB. The big advantage of using quick turn PCBs is the ability to change and replicate the circuit very quickly. Using any of the other prototyping techniques previously discussed, the effort in wiring is only applied to one circuit; the time increases linearly with each additional circuit built. A PCB design can be replicated without any additional investment in time and certainly adds to the professionalism of a robot. An understandable concern about designing printed circuit boards is the time required to learn how to use the design tools, their cost, and learning how to efficiently lay out circuits on a PCB. Currently there are a number of open source software projects and commercial products that allow hobbyists to design PCBs and produce Gerber files (which are the design files used to manufacture the PCBs) for free. There are quite a few books devoted to explaining how PCB layout is accomplished and lists many of the tricks that you should be
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ELECTRONIC CONSTRUCTION TECHNIQUES
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FIGURE 7-6 PCBs, like this one, can be created quickly as well as inexpensively and can be replicated with very little effort.
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aware of. Learning how to design PCBs is a marketable skill and one that will certainly pay off in the future.
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7.7 Headers and Connectors
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Robots are often constructed from subsystems that may not be located on the same circuit board. You must therefore know how to connect subsystems on different circuit boards. Avoid the temptation to directly solder wires between boards. This makes it much harder to work with your robot, including testing variations of your designs with different subsystems. Instead, use connectors whenever possible, as shown in Fig. 7-7. In this approach you connect the various subsystems of your robot using short lengths of wire. You terminate each wire with a connector of some type or another. The connectors attach to mating pins on each circuit board. You don t need fancy cables and cable connectors for your robots. In fact, these can add significant weight to your bot. Instead, use ordinary 20- to 26-gauge wire, terminated with single- or double-row plastic connectors. You can use ribbon cable for the wire or individual insulated strips of wire. Use plastic ties to bundle the wires together. The plastic connectors are made to mate with single- and double-row headers soldered directly on the circuit board. You can buy connectors and headers that have different numbers of pins or you can salvage them from old parts (the typical VCR is chock-full of them!).
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