20220722 Soldering the Top Panel PCB

20220722 Soldering the Top Panel PCB

The Top Panel PCB has arrived and immediately, I began to work on it. This simple circuit took me three hours to figure out why it is not working. I have done the troubleshooting and although it checks out, the error was quite puzzling.

Small PCBs deserves small boxes
My PCB arrived in a small Blue Box from JLCPCB. The boards are very small and so, it deserves this size.
JLCPCB can cut square holes
As usual, I go this board made in 0.8mm thickness and finished in black. It took me a lot of tries to get this image because my hands were shaking with excitement.
Why? If you look slightly to the left, you will see the two very important features of this board; square holes.
Reverse soldering SMD LEDs
In the JLCPCB capabilities, they can only do 3mm x 3mm square holes and this is very much smaller than that! Now, I can reverse solder the two red 0805 LEDs, and flat mount the PCB from the insides of the Main Body.
If I had known of this solution a decade ago, one of my designs would be a reality now.
Flat mounting the PCB from within
When I say flat mounted, it means I can put the PCB behind the Main Body without any obstruction, thus leaving a gap between the board and the well, window.
Look at the beautiful eight solder pads on the right. I have adjusted the length for the four SMD 0805 LEDs. And on the LED, I have replaced the green LEDs with a bigger 5730 LED instead.
Wrong sizes
OK, I did not see this coming and so, I have to either follow the physical item or, find the ones that fit onto the PCB.
These are connectors for a fourth PCB where I hope it can be used for sound.

POST SOLDERING DISCUSSION

The soldering took far longer than it should and this worries me. I have tested every part of the PCB to the point of checking all the connections but it still did not light up. Only when I examined the board again and did a ‘what if’, analysis. I always worry about the 4017 IC being the main culprit and this time, I hope I am wrong. But let’s talk about this PCB now, since it is working.

This board is a re-design from the original and the only similarities are the position of the LEDs and the size of the board. I used the information from Mr. Douchette’s files and in a nutshell, animated the four LEDs on the right. And this board will have to go through one more revision such as revising the custom 5730 footprint so that I can solder it easier, change the resistor values for the 555 IC to have a better sequencing speed. And fixing that puzzling error.

20220722 Soldering the Top Panel PCB
The bigger 5730 LED does make a lot of difference but maybe, it might be a little too bright too.
There is a lot of space in there
Both the 0.8mm thick boards did not have any issues when placed close to each other. In fact, they have about a 3mm gap in between. Later on, when I start to work on this board, I will have to use putty to mount them and not hot-melt glues. JLCPCB stated that this resin has a melting point of 54ÂșC.
All the LEDs are sequenced
I am so wanting to solder the reed switch onto the board now but it is midnight. I force myself not to do this until the 19mm x 8mm hinges arrives.

WHAT REALLY HAPPENED

This tiny wire saved the day
In the end, I took a small piece of wire, soldered it between the (badly soldered) 150R SMD resistor to the board’s Ground point.
On another note, see the two red 0805 LEDs which I reverse solder? They do emit what I would call, back-lighting. If I am dong this for a scale model, I will have to be very alert during light blocking.
Back to the PCB software
This is one of the few revisions that I will do for the next version. The yellow arrows replaces the short black wire. If you loot at it carefully, all the connections of the five resistors just stopped there.
Technically, it is grounded but it's not
But if you look at the circuit diagram, they would be connected to the Ground Plane. The funny thing is, auto-router reported no errors and so, I could not have caught that.

WHAT ARE YOUR TERMS AGAIN?

A decade ago, I coined the term, ‘Scale Lighting’ for my area of Hobby. It means providing almost believable lighting effect for scale models. The analogy of your car’s dashboard becoming a spotlight to you is how I would start my spiel.

And then, there is the term, ‘back-lighting’ for a lack of better imagination. In most LEDs, the light comes from a single point where the electrons jump from a negative charged area to a positive one. So, I tend to imagine this point of light, just like a light bulb filament, is viewable from all angles. While LED light comes out from the ‘front’, take a look at its back. There would be some significant amount of light there.

THE VIDEO

Anyway, here is the video of the Top Panel PCB with the Front Array being tested in the TMain Body.

I forgot to include the section where I tap off the CLOCK PULSE from the Front Array PCB because I have not done it yet.
Posted in 3D Printing, A Piscean Works Blog, Electronics, JLCPCB, Printed Circuit Board, Sci-Fi, Star Trek, TR-595E, Tricorder, Video.

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