Eng 405 Milestone 4:

CAD and Fabrication Instructions

By Lauriana Cojocaru
October 30, 2015

Electrical Analysis Updated

This circuit was made possible by use of a Texas Instruments TLC3702IP op-amp. Its output type
is a Push-Pull, thus enabling me to limit myself to the use of one 9V battery. Making use of an Excel
spreadsheet that calculated the resistor values needed to make possible the test of both AA and
AAA batteries, we concluded that the best values to use in the new schematic were R2 = 3.3 k,
R5 = 1.3 k, and R11 = 13 k.

Von
Vok
Vdead
Vzener
Rload
Tolerance
Pot
R1
R2
R3
Vtop
Vbottom
Vok
Vdead

AA
1.4
1
3.1
5.32

12350
1235
3135
0.668967176
0.500359339
0.665
0.475

AAA
1.4
1
3.42
3.5
5.6
5.88
5%
2703.041083
13000
13650
1300
1365
3300
3465
0.77485929 0.850222053
0.555877317 0.572509865
0.7
0.735
0.5
0.525

Table 1 Calculations

Figure 1 Matching voltage levels for 2 types of batteries

Figure 2 Updated Eagle Schematic

This Eagle Schematic was used to generate a Board Layout. The files are uploaded on BJUOnline.
Figure 3 Updated Eagle Board

Updated Mechanical Drawing

Figure 4 Updated AutoCAD Drawing

Figure 4 Updated AutoCAD Drawing

Design Validation

The prototype for this project worked perfectly when tested.

This op-amp works well as a comparator of dual voltages.
The battery holders are a good innovation and make testing
easier.
Figure 5 The New Prototype

Fabrication Plan
It is very important to have a clearly defined sequence that will be followed during the construction
and assemblage phase of this project. The mechanical enclosure consists of 3 parts: the top panel,
the bottom panel and the lid to the 9V battery compartment.
The top

I will first solder 6 inch wires around the two terminals of the pushbutton
switch. This switch assembly contains a washer, an N-35 decorative nut and
a hex nut. I will cut the panel with the drill with a recommended hole of .468
inches in diameter. I will mount the switch and tighten the washer and nuts.
The AA battery holder is 56 mm long. The holes are placed 5 mm from the
sides for the AA and 3 mm for the AAA holder after the example shown here.
The pushbutton switch has terminals that are connected to wires and the
battery holders have wires, so even if mistakes are done, the wires are long
enough to extend to the proper place in the PCB.

Figure 6 Holes Position

I will also cut 5 mm holes for the 3 LEDs that are placed at the following position on the PCB:
Green LED at x = 31and y = 51, Yellow LED at x = 22 and y = 51, Red LED at x = 13and y = 51. The
exact position of the holes on the top part of the enclosure is dimensioned on the AutoCAD file.
The PCB

On the PCB I will first mount all the through-hole components: the 9 resistors and the Zener diode. I
will solder them. Then I will mount the op-amp which will sit on an 8 pin socket and solder it. I will
then place and connect the 3 LEDs and then lastly connect the wires of the switch, 9V battery strap
and the battery holders to their respective place in the PCB. I will make sure to practice soldering
before working with these components, and to take the test about safety while drilling. As a final
step, I will screw the PCB and the enclosure together with the screws provided by OKW.