ECE 477 Digital Systems Senior Design Project Rev 8/09

Homework 4: Packaging Specifications and Design

Team Code Name: FEST Group No. 5

Team Member Completing This Homework: Alexander Kidarsa

E-mail Address of Team Member: akidarsa @ purdue.edu

Evaluation:

SCORE

/

DESCRIPTION

10 /

Excellent – among the best papers submitted for this assignment. Very few corrections needed for version submitted in Final Report.

9 /

Very good – all requirements aptly met. Minor additions/corrections needed for version submitted in Final Report.

8 /

Good – all requirements considered and addressed. Several noteworthy additions/corrections needed for version submitted in Final Report.

7 /

Average – all requirements basically met, but some revisions in content should be made for the version submitted in the Final Report.

6 /

Marginal – all requirements met at a nominal level. Significant revisions in content should be made for the version submitted in the Final Report.

* /

Below the passing threshold – major revisions required to meet report requirements at a nominal level. Revise and resubmit.

* Resubmissions are due within one week of the date of return, and will be awarded a score of “6” provided all report requirements have been met at a nominal level.

Comments:

1.0  Introduction

The main aim of the project is to build something that will allow us to test the quality of a speakerphone. Since the audiences are companies that specialize in speakerphone, a simple design was chosen. The overall PCB is estimated to be pretty small compared to the size of the peripherals, such as microphone and speaker that will be attached to it. Some concerns are made in regards to the shifts that the product will make whilst preparation for testing is made.

2.0  Commercial Product Packaging

This project produces a product that is unique and is not available yet on the market. However some of the design considerations were obtained from other product that has already been released on the market. Whilst the function of the product differs, some of the good design decision will be adapted to the product.

2.1  Product #1

Whirlwind Q-Box Audio Line Tester[1]

This product has a box like structure that does audio line testing. It has 2 XLR inputs for microphone as well as a built-in condenser microphone. It has a built-in speaker and a ¼” jack that can be used for either a microphone or a headphone. It has an LED to confirm phantom or intercom power. It weighs around 2.5 pound and sells at around $280.04. It doesn't allow any recording or an expandable memory unit to allow saving data.

2.2  Product #2

Phonic PAA6 2 Channel Audio Analyzer with Color Touch LCD[2]

This product is also enclosed in a box like structure and weighs lighter than the previous discussed product at 1.1 pound. It has real time spectrum, LEQ, EQ setting and phase checking.

It has 2 built in microphone, USB connectors and an SD card slot. However, it is missing a speaker and a port to allow usage of a different microphone than the one provided. The product costs $1739.99.

3.0  Project Packaging Specifications

The product is enclosed in a basic metal box structure that will have holes to allow peripheral connections. The basic shape of the product is a rectangle that measures around 6.1 inch by 5 inch by 1.5 inch. Connections to power, power button and start/reset button are located at the back to ensure that the device won’t be turned off by accident. SD Card and RJ11 connection are located on the side. Connection to the microphone and speaker are located in the front of the device. Two three-pin XLR connectors are used for the speaker and microphone. The LCD display along with the switches for the different testing modes are located on the top of the device to allow easy viewing and choosing.

The casing will be made using 0.1-inch aluminum sheet. Welding equipment and metal cutters will be needed to form the sheet into a box to house the PCB. The overall product should weight from 1 pounds to 2 pounds depending on the weight of the LCD, PCB and the amount of aluminum required to house the PCB. The PCB will either be glued on the bottom of the aluminum housing or suspended in midair by screws. To ensure that the product does not move as much during testing, rubber soles will be used along with lead to increase the total weight of the product.

The packaging should cost around $30 and the whole product should cost around $150.

4.0  PCB Footprint Layout

Most of the part that were needed and chosen for the project only exists on the packages that we chose or the QFN/BGA. The reason the parts are chosen is that those are the only ones that can be soldered by hand.

The current estimated dimension required for the finished PCB is 4 inches by 3.2 inches. The enclosure is supposed to cover the PCB which will be able to incorporate a bigger PCB should the need arise.

5.0  Summary

The audience for this product is specialized companies that are involved with speakerphones. The device has a minimalistic design with an LCD on top with switches to allow easy access to information as well as test types during testing. The package dimension should be around 6.1 inch by 5 inch by 1.5 inch. The device will interface with an SD Card, RJ11 standard telephone jack, Microphone and Speaker by three-pin XLR connectors. The device housing will be made using 0.1” aluminum sheet and the PCB will either be glued or suspended in mid air by screwing the sides of the PCB to the housing.
List of References

[1]  http://www.markertek.com/Tools-Test-Equipment/Audio-Test-Equipment/Whirlwind/QBOX.xhtml

[2]  http://www.markertek.com/Tools-Test-Equipment/Audio-Test-Equipment/Phonic-America/PAA6.xhtml


Appendix A: Project Packaging Illustrations


Appendix B: Project Packaging Specifications

Materials Needed:

0.1” Alumium Sheet

Tools Needed:

Welder

Metal cutter

Estimated Weight:

1 ~ 2 pounds

Estimated Cost:

Packaging : $~30

Total : $~150


Appendix C: PCB Footprint Layout

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