Notebook

 

11.23.2009
Juno Non-Blocking Transmit/Receive (only lightly tested) written in M8C assembly for the CY7C63803-SXC controller onboard Brewmaster's USB to Juno Bridge PCB using PSoC Designer v5.0+SP6.  Physical interface signals USBee DX Capture (676KB) using USBee DX Pod viewable real-time with USBee Suite v1.1.41 (6.5MB, requires .Net Framework v3.5+SP1). Here's the custom Packet Presenter Definition File.

 

11.14.2009
Juno Start, Juno Delay, Juno Read/Write (SPI), Juno Sleep/Wake, Juno Blocking Transmit/Receive, Juno Stop code (only lightly tested) written in M8C assembly for the CY7C63803-SXC controller onboard Brewmaster's USB to Juno Bridge PCB. 

Warning: These blocking routines soon to be deprecated.  Work on servicing data phase via interrupts has already begun.

 

11.8.2009
Async Transmit (for debug) up to 888,888bps/~12usec per byte (CPUCLK=24MHz) code written in M8C assembly for the CY7C63803-SXC controller onboard Brewmaster's USB to Juno Bridge PCB.

 

11.1.2009
Started writing code for the CY7C63803-SXC controller onboard Brewmaster's USB to Juno Bridge PCB.

 

11.17.2008
Debug version of PCB (Revision 20008.37.3) fully assembled: front | back.

 

11.15.2008

PCB (Revision 20008.37.3) surface mount assembly of 1 panel/10 boards:  set frame, attach stencil, apply paste, squeegee, place components, reflow, surface mount devices fully assembled.

Notes:

  1. Strategically applying solder paste throughout cut-out area before printing requires less solder paste (even less than shown) vs. only applying it across the upper length of the stencil and helps retain proper squeegee angle throughput the printing process.
  2. Apply constant pressure to entire cut-out area to prevent lifting while printing.  Notice more accurate amount of paste deposited on left-hand side.  Squeegee held in the right hand.
  3. Place panel on flat surface when placing components.  Panavise induces too much instability when stuffing full panels.
  4. Video entire reflow process through inspection window.  Difficult to document profile with a photo.
  5. No-clean lead-free solder paste may actually require some cleaning after reflow.
  6. Stencil design tips: link 1 | link 2.
  7. Stencil and squeegee cleaning tips: >140C water in conjunction with a pressure spray followed by deionized water followed by an isopropanol rinse.

A few more assembly tools to order:

Description Digikey Part # Newark Part #
FLUX REMOVING PEN LEAD-FREE CW9400-ND 29K6230
WIPES PRESATURATED 6 X8.5 IPA100 95K7293
Anti-Static Cleaner 00Z1513
Cotton Swabs - Single Head 96B1615
Cotton Swabs - Double Head 50F9487
Solvent resistant highly absorbent wipe 50F9485

Holding off a bit to see if anything else shakes out that could be useful to finish PCB (Revision 2008.37.3) assembly.

 

11.8.2008
The remainder of the BOM for PCB (Revision 20008.37.3) arrived, Yeah!!!

These 0805 components are hobbyist friendly, as anticipated.  By design, there's only one 0402 component and by default it is "do not install".

Smart Tweezers arrived, cool.  Immediately started playing with them.

Simply forgot to take solder paste out of the refrigerator last night.  Therefore, assembly of PCB (Revision 2008.37.3) postponed, $#!^!!!

Here's a glimpse of my next PCB design, forecasted as both expensive and "brainless", quite atypical for me.  However, it does fall nicely into the utilitarian category, fitting me to a "T":

Description Digikey Part #
CONN RECEPT USB TYPE A PCB ED90062-ND
HOLDER BATT W/9V SNAP 2CELL AA 2474K-ND
CONN HEADER 5POS .100 R/A TIN WM4303-ND
IC LDO REG LOW NOISE ADJ 8-SOIC LT1763CS8#PBF-ND

Holding off a bit to allow bank account to recover.

 

11.5.2008
Tips for the storage of solder pastes
  1. Buy pastes according to manufacturing date, not expiry date.
  2. Store in refrigerator at 5-10C. This doubles the possible storage period from the manufacturing date.
  3. Most pastes should not be frozen. Cold storage lengthens storage time as chemicals will react more slowly and paste is more stable against separation. Storage that is too cold (<5C) may cause crystallization of rosins/resins. Storage that is too warm may cause a loss of solvents and possible reaction of activators.
  4. Use airtight containers.
  5. Use a first-in/first-out storage system.
  6. Never store beyond the usable date.
  7. Store syringes/barrels in upright position to limit danger of air bubbles. Older formulations may require horizontal storage with (occasional) rotation to avoid flux separation.
  8. Store paste in the dark as light can polymerize rosins.
  9. Shelf life of paste depends on storage temperature, for example:
    1. At 7C, some pastes can be stored for six months.
    2. At 20C, some pastes can be stored for only one month.
    3. At 30C, some pastes may be stored for just two weeks.

 

11.1.2008
Most of the BOM and assembly tools for Brewmaster's USB to Juno Bridge PCB (Revision 2008.37.3) arrived, Yeah!!! 

 

10.28.2008
Handy PCB trace reference:
 
  10mil trace 20 mil trace 100 mil trace 42 x 42 (~0603) 60 x 60 (~0805)
Capacitance 2.2 pF/in 3.3 pF/in 11.6 pF/in 0.24 pF 0.45 pF
Inductance 9.9 nH/in 7.2 nH/in 2.4 nH/in 0.19 nH 0.21 nH

 

 

10.25.2008
Ordered BOM, assembly tools, and smart tweezers ($303.60) for Brewmaster's USB to Juno Bridge PCB (Revision 2008.37.3).

 

10.24.2008
Lab bench tools ($253.75) needed for SMT assembly and rework for Brewmaster's USB to Juno Bridge PCB (Revision 2008.37.3):
 
Description Digikey Part #
Sn96.5Ag3.0Cu0.5 SOLDER NO-CLEAN .020" 25AWG 1LB KE1131-ND
TWEEZER CURVED PRECISION TIP EROP7SA-ND
MAGNIFIER W/CURVED TWEEZER TIP 243-1019-ND
CUTTER 4" DIAGONAL OVAL SEMI FL 612N-ND
BRAID DESOLD LEAD-FREE .05"X5' EB1189-ND
FLUX REMOVER PEN FOR NO-CLEAN CW9100-ND
TAPE KAPTON HIGH TEMP 1/2" 3M541312-ND
MAGNIFIER PROVUE ILLUMINATED 243-1025-ND

Tools already purchased to assist with assembly and rework: Metcal SP-200 Soldering Station ($201.50) with SSC-626A Replaceable Tip Cartridge ($16.14), Madell 850D Hot Air Rework Station ($266.26) and Panavise ($27.99).

 

10.16.2008
Puhui Technology T-962 Infrared IC Heater & Reflow Oven arrived after a brief stint pending customs inspection.  Immediately began playing with the oven.  Check out the cool wave tracks during operation, :) 

Wow, finally "need" to order the BOM for Brewmaster's USB to Juno Bridge PCB (Revision 2008.37.3), Yeah!!!

 

10.1.2008
Desktop Stencil Kit for Brewmaster's USB to Juno Bridge PCB (Revision 2008.37.3) arrived, cool...  Immediately placed Sn96.5Ag3.0Cu0.5 solder paste in refrigerator (10C nominal)... will play with that once the reflow oven arrives off the boat coming from Hong Kong. 

Which reminds me, still need to order the BOM and a few assembly tools.

 

9.30.2008
Brewmaster's USB to Juno Bridge PCB (Revision 2008.37.3) boards arrived...  Immediately started playing with them :)  Here are some quick photos of the top & bottom after cut out of the panel

Ordered a low-end reflow oven ($360 + $100s&h) to help with assembly.

 

9.28.2008
Ordered Desktop Stencil Kit w/lead-free solder paste ($218) and pick & place hand tool for Brewmaster's USB to Juno Bridge PCB (Revision 2008.37.3). 

The kit includes laser cut 5mm stainless steel plate / stencil (+/-0.00025 tolerance on holes), one board holder, solder paste, temperature marker, squeegee, ESD-safe gloves and alcohol wipe.  The pick & place hand tool includes vacuum bulb and vacuum cups with diameters of 3/8", 1/4", and 1/8".

 

9.13.2008
Here's the final Bill-of-Materials (BOM) with clickable Digikey links:
 
TITLE USB to Juno Bridge
PCA # NA Revision 2008.37.3
SCH # NA Revision NA
DATE 9/10/2008
Item Qty Reference Description Manufacturer Mfr Part # Digikey Part #
1 1 C1 CAP CERAMIC 4.7UF 6.3V X5R 0805 Kemet C0805C475K9PACTU 399-3134-1-ND
2 1 C2 CAP 1500PF 50V CERAMIC X7R 0805 Kemet C0805C152K5RACTU 399-1150-1-ND
3 1 C3 CAP CER 2.2UF 10V 10% X7R 0805 Murata GRM21BR71A225KA01L 490-1696-1-ND
4 1 R1 RES 620 OHM 1/8W 5% 0805 SMD Panasonic - ECG ERJ-6GEYJ621V P620ACT-ND
5 1 R3 RES 1.0 OHM 1/8W 1% 0805 SMD Panasonic - ECG ERJ-6RQF1R0V P1.0DCT-ND
6 1 D1 LED RED CLEAR 0805 SMD LITE-ON Inc LTST-C170CKT 160-1176-1-ND
7 1 D2 LED GREEN CLEAR 0805 SMD LITE-ON Inc LTST-C170GKT 160-1179-1-ND
8 1 J1 CONN PLUG USB 4POS RT ANG PCB Molex/Waldom 48037-0001 WM17117-ND
9 2/200 J2, J3 JUMPER WIRE 0.1" LONG PKG OF 200 3M 923345-01-C 923345-01-ND
10 1 SW1 6MM LIGHT TOUCH SW H=7 Panasonic - ECG EVQ-PAC07K P8011S-ND
11 1 U1 IC USB PERIPHERAL CTRLR 16-SOIC Cypress Semiconductor CY7C63803-SXC CY7C63803-SXC-ND
12 1 PCB PRINTED CIRCUIT BOARD Advanced Circuits 2008.37.3 NA
DO NOT INSTALL
13 1 R2 RES 10K OHM 1/16W 5% 0402 SMD Panasonic - ECG ERJ-2GEJ103X P10KJCT-ND
15 1 J4 CONN RECEPT 12POS 2MM PCB GOLD Hirose Electric Co Ltd DF11-12DS-2DSA(06) H10186-ND
16 2 GND, GND TEST POINT PC MINI .040"D BLACK Keystone Electronics 5001 5001K-ND

 

 

9.12.2008
Bill-of-Materials ($413.30) for Brewmaster's USB to Juno Bridge PCB (Revision 2008.37.3). 

Here's a scan of my attempt for a component placement illustration for PCB (Revision 2008.37.3). 

Asked board house to panelize ($0) and add e-test ($140) in preparation for full turnkey assembly quote ($3,176.53).  Needless to say, another plan needs to be constructed to assemble these boards (partially solved, see Desktop Stencil Kit above). 

Cobbled together a hand-written schematic for PCB (Revision 2008.37.3). 

Oh, and one final review of the PCB (Revision 2008.37.3) revealed an error (will live with it) in the silkscreen.

 

9.10.2008

Ordered Brewmaster's USB to Juno Bridge PCB.  Here's screen capture, order confirmation ($207), and board layout design files (Revision 2008.37.3) for PCB Artist.

 

8.31.2008
Began designing USB to Juno Bridge Printed Circuit Board (PCB) for my buddy Mikey's beer making hobby

 

8.26.2008
Software I2C Master "C" code snippets (origin 8052).  Physical interface signals captured using USBee DX Pod.

 

8.26.2008
Software SPI Master "C" code snippets (origin 8052).  Physical interface signals captured using USBee DX Pod.

 

8.26.2008
Low-level radio driver "C" code snippets (origin 8052) for Unigen Juno M / Juno W, and Cypress CYWM6934 / CYWM6935 RF Modules.  These low-cost 2.4GHz radio modules contain Cypress WirelessUSB CYWUSB6934 and CYWUSB6935 (respectively), 13MHz crystal, matching network, PCB trace antenna, and 2mm connector (mate).  Physical interface signals captured using USBee DX Pod.