Spring 2011 ECET 360 Laboratory Syllabus

NOTE: There may be changes in both the timing and topics on this lab syllabus.

Week Lab Topic 1 Intro to the labs: Lab Safety; ESD/EOS Protection/Prevention; Component intro 2 Manual Soldering of SMD’s; Deposition of Solder Paste; Reflow oven use 3 Hand Soldering, etc., cont’d 4 Reflow Oven Profiling 5 ECAD Design of SMT board 6 Hand Soldering of ICs 7 PCB Artist Footprint Development, BGA and microvias-in-pad 8 Pin in Paste soldering 9 Lab Project Proposals and Decisions Spring Break 10-15 Project Work based on each lab–project group’s schedule.

The circuit board layout portions of the lab may require lab time beyond that provided the course, depending on how familiar the student is with ECAD. The board design work will use PCB Artist for schematic capture and PCB layout. Various hand, assisted hand, and automated devices are available for paste deposition, parts placement, soldering and reflow. Standard ECET lab test instrumentation will be available for test purposes.

Lab Grading Labs will require performance evaluations (of what quality are the solder joints you created on a board?) and written reports. The lab is worth 40% of the overall course grade. The points available in lab are as follows: Week 1 = 10 points, Week 2 = 90 points, all other weeks 100 points, including project weeks. Project week points will be based on both accomplishments of each week’s goal(s) and being on-time with those accomplishments.

ECET360 Lab Report Grading (see ECET360 Lab Report Format on the following pages): In general:  Another ECET student should be able to pick up your report and, following the procedure you have written, duplicate your results.  A complete “C” report (70-79 pts) will contain procedure and experimental results  A complete “B” report (80-89 pts) will contain procedure and experimental results, and an evaluation of the results  An complete “A” report will contain procedure and experimental results, an evaluation of the results, and o analysis of the results including suggestions for improving the results, and/or o ways to usefully extend the requirements of the lab, and/or o show creativity in data gathering or in otherwise conducting the experiment. Incomplete reports will of course lose points. FOR ALL REPORTS:  If you see something “funny” in the results, record the amount of funny and the other process events occurring at the same time, as well as your analysis of the reason(s) for the funny results.  Do not assume and/or state that the data are correct if you have reason to believe there is a problem with either the experimental procedure and/or the results. Explain any issues that could cause incorrect data, and state the issues, results of your analysis, and any resolution (or potential resolution) of the problem in your report. Lab Report Format for ECET 360

Lab Reports are to contain: 1) First physical page is the Cover Page, with no header or footer. The cover page needs the names of team members, class name & number (ECET 360), lab number with the title of the lab, date(s) performed, lab section information, and lab instructor name.

2) Second physical page is the lab sign off page or pages.

3) Third physical page is the start of the typed report. It and all following pages need page numbers and the initials of the participants who are responsible for the report.

Body Format Purpose: First sentence should state the purpose of the experiment. The next sentence(s) should explain why that is important.

The purpose of this experiment was (reason for doing this) . (that reason) is important because (why it is important) .

List of Equipment: The list of equipment needs to include all major or non standard equipment used to perform the experiment described in the procedures. Include tools like the hot air pens and solder paste dispenser, but don’t include tools like pliers or wire cutters. The list should follow the format:

Equipment Designator - Description

Examples: Metcal 1160 - Hot Air Soldering Pens SMT-6000 - Vacuum assisted hand placement machine Weller WSD 161 - Soldering Iron Station

Procedures: The procedures need to be a numbered list of the steps it takes to perform the task / experiment in YOUR OWN WORDS.

Make sure to reference each piece of equipment used that is in the list of tools and include what settings (temperature, pressure, timer, etc.) where used.

Results, Data and Analysis: Results, including data taken, whether quantitative or qualitative. E.g. quantitative temperature data may lead to a thermal profile while soldering results may lead to qualitative solder joint evaluations.

Data should be presented in tables or graphs, which ever is appropriate for the situation. For example use a table for calibration of the hot air pens, and a graph for calibration of the reflow oven.

Data can also come in the form of observations. In some labs there are parts where you can’t measure anything, but instead you are intended to observe what happens when one material is used versus another, or different techniques are used to accomplish the same task. It maybe difficult to quantify results in these cases, so you can record your observations, analyze what took place, and explain why. Data table titles are to be located above the table using the designation “Table X”, where “X” is the number of that as it appears in the report, followed by a descriptive title for the table.

Table X – Title for Table X Item Expected Measured Percent Error (Units) (Units) (%) item 1 data data item 2 data data

Anytime there is a Measured value that can be compared to an Expected value you should include a Percent Error column.

Percent Error = [(Measured – Expected) / Expected] *100 Keep the sign convention!! If Measured is less than Expected, then the % Error will be negative.

Reports must consider the acceptability of the data. Any data not considered acceptable or “normal” must be commented – if you see something funny, record the amount of funny, and comment on your best reasons for the funny results, based on expected results. Funny may be, e.g., equipment malfunction, or may include recognizable errors. Error sources may include:  Inexperienced operators  Inconsistent environments,  Variations in material composition,  Measurement error which is not discovered during the performance of the lab  Inaccuracies in recording data, Etc.

Graph and Figure titles should be located immediately below the graph or figure. Use the designation “Figure X” for both graphs and pictures, where “X” is the number of that figure as it appears in the report, followed by a descriptive title for the figure.

Temperature (0C)

Time (seconds)

Figure X – Descriptive title for figure X.

Every data table and figure must be referenced in the text you write and explained. Don’t include a picture or a graph without talking about it.

Conclusions: This is where you explain the results from the experiment in detail. Note any problems encountered, how they were solved, and answer any questions asked in the lab. This is your opportunity to demonstrate what you learned from this experience.

See also “An “A” report will contain.....” on the first page of this laboratory syllabus