Corrosion Test chamber

Introduction
Thermal corrosion Cycling is an innovative and cost effective
process of enhancing the mechanical properties of many
materials commonly used in commercial and industrial
technologies. Thermal Cycling has been determined to
significantly increase the corrosion properties of many ferrous
alloys. The salt spray test is a standardized test method used to
check corrosion resistance. Salt spray testing is an accelerated
corrosion test that produces a corrosive attack to the tested
samples. The appearance of corrosion products (oxides) is
evaluated after a period of time. Test duration depends on the
corrosion resistance of the tested material. Salt spray testing is
popular because it is well standardized and reasonably
repeatable. The correlation between the duration in salt spray test
and the expected life of a material is not necessary simple to
interpret as corrosion is a very complicated process and can be
influenced by many external factors. Nevertheless, salt spray test
is widely used in the industrial sector for the evaluation of
corrosion resistance of finished surfaces.
Background
Salt spray was first used for corrosion testing around 1914. This
traditional salt spray specifies a continuous exposure to a 5% salt
fog at 35o C. In spite of all se refinements, re has long been
general agreement that salt spray test results do not correlate
well with corrosion seen in actual atmospheric exposures. As
demand for improved corrosion protection increased, engineers
and scientists attempted to develop test procedures to more
accurately predict corrosion of materials. In England, during
1960s and 1970s, Harrison and Timmons2, 3 developed
ProhesionTM test, which has been found especially useful for
industrial maintenance coatings. More recently, Society of

Automotive Engineers (SAE) and American Iron and Steel

Institute (AISI) have been studying testing for automotive
applications. ir progress has been encouraging and is well
documented.4, 5, 6, 7, 8, 9, 10 Japanese researchers have also
developed a number of corrosion test methods.

What is Corrosion Testing?

The corrosion testing is intended to be a more realistic way to
perform salt spray tests than traditional, steady state exposures.
Because actual atmospheric exposures usually include both wet
and dry conditions, it makes sense to pattern accelerated
laboratory tests after se natural conditions. Research indicates
that, with corrosion tests, relative corrosion rates, structure and
morphology are more similar to those seen outdoors.
Consequently, tests usually give better correlation to outdoors
than conventional salt spray tests. y are effective for evaluating a
variety of corrosion mechanisms, including general, galvanic, and
crevice corrosion. corrosion testing is intended to produce
failures representative of type found in outdoor corrosive
environments. CCT tests expose specimens to a series of different
environments in a repetitive cycle. Simple exposures like
Prohesion may consist of cycling between salt fog and dry
conditions. More sophisticated automotive methods call for
multistep cycles that may incorporate immersion, humidity,
condensation, along with salt fog and dry-off. Originally, se
automotive test procedures were designed to be performed by
hand. Laboratory personnel manually moved samples from salt
spray chambers to humidity chambers to drying racks, etc. More
recently, microprocessor controlled chambers have been used to
automate se exposures and reduce variability.

Block Diagram:

Thermocoupl
e

Temp
Controlle
r

Power
supply

Essential features of system

Above system is use for simulating atoms passerine

condition switch will be required for taking life tests for
spares rsed in any mechanical or automobile industry. As

already mentioned in block diagram explanation enclosure

dominations are given here. Such type of corrosion test
ambens are available in tapana tools ltd Nasik Bajaj auto ltd
pune tata pune hero Honda etc. also in motor manufacturing
industry se are essential
1. This project should not be run direct under
sun-light
2. Air supply given should be proper, purified
and regulated.
3. water supply should also be pure and feel3
mixing proportion should be appropriate
4. Air and water supply should be continuously
to no22le
Parameter settings required
Ten up range =
1. 25c ------- 30c
2. 30c ------- 40c
3. 35c-------- 60c
For maintaining same heat should be operated
properly add a digital temp indicated should be provided
Compressor air pressure should be 7kglcm2
Air passed air pressure setting at air pressure result
being control unit is 5to6 kglcm2
Technical data
Approximate done sud be if unit
1. With =200mm
2. Height=300mm

3. Depth=450mm
Main supply -230vac at 50hz
Compressor air 4.6bar above atmospheric pressure.
Water supply connection -1-3 bar above at morphemic
pressure
Specimen holder tray :- specimen holder to is located
inside corrosion chamber in such a way i.e. it will be a net
which will be suitable to provide moisture to tally
material used for chamber will be properly painted or
powder coated so as to avoid corrosion effect salt
About nozzle spray no22le spray nozzle is key point of
system . It is used for spraying moisture in test chamber.
Our approach o this point is hat , it should make
automizer readily accessible to operator and being of
simple two part construction, easily dismantled for cleaning
purpose. But blockages have remain an unavoidable and
irritating fact of life until w here are developing a new design
of auto miser which makes blockages a thing of past.
Pl. follow figure given,
atomizers made up of simply disassembled for cleaning
and maintenance. Manufactured in one of new generation of
high performance plastics, it features an ingeniously
designed integral salt solution filter inb car parted into body
of atomizer.
This works in conjunction with a profit located in salt
solution reservoir, to ensure that even smallest contaminants

or undisclosed salt cryss will not reach and block automiser.

filter can be easily removed and washed clear of contaminant
whole n being reassembled and reinstalled in cabinet,
quickly and conveniently .
nozzle is mad up of aluminum metal which is also non
corrosive in nature and easy machining.
After assembly, spray nozzle will have two main
connections i.e.
1. One inlet for water supply
2. Anor inlet for air supply
3. Moisture output as a spray

Fixture Arrangement :
The fixture assembly that brings all of the system together. These
come in a variety of configurations, vertical, horizontal, tabletop,
freestanding, or mobile cart.
Implementation details:
1. Initially, all the ms angle of calculated dimensions in mm was
taken.
2. Then it was cut into pieces as per the required dimension
3. All these angle pieces were joined together to form top side
frame of the basic structure.
4. Another ms angle with required dimension was taken
5. It is cut into pieces to form a leg pieces
6. Fabricate the legs with the rectangle from one by one to
form the stand structure.

OPERATIONS INVOLVED

Turning
Facing (flat surface)
Drilling
Gas cutting
Shaping
Welding
Tapping
Thread cutting
TURNING
Turning is the operation of reducing a cylindrical surface by
removing material from the outside diameter of a work piece. It is
done by rotating the work piece about the lathe axis and feeding
the tool parallel to the lathe axis. Due to this operation screw rod
and head are done by the turning operation to get the required
shape.
FACING
Machining the end of the work piece to produce flat surface is
called facing. Due to this, the plate can get flat surface have done
by the facing operation.
DRILLING
Drilling is the operation of producing cylindrical hole in work
piece. It is done by rotating the cutting edge of the cutter known
as drill bit. In this Project the jig plates require holes for locating
indexing plate and screw rod, drill bush assembly. These holes are
done by conventional vertical drilling machine.
THREAD CUTTING

Thread cutting is the operation of forming external thread of

required diameter of rod by using a multipoint tool is called
thread. This process is used in screw clamp to done on the rod
which is used for the movement of the movable plate
FINE GRINDING
It is nothing but the grinding process, which is done as smooth
with fine grains. This is done as the each plate and base plate for
good surface finish. It is done by conventional grinding machine.
GAS CUTTING
It is used to break are cut the plates. In this project it is used to
cut the raw materials such as plates. This done by gas cutting
machine.
SHAPING
Shaping operation is used to reduce the dimensions of the plates.
In this project the plates are in need of shaping process. It is done
by shaping machine.
WELDING
It is the process, which is used to join two, is more similar
materials as well as dissimilar materials. In this project it is used
to join the jig plate one to another. This is done by arc welding
machine.

Scope of work:
The machines have been designed to support human beings
by helping them to do tedious and back breaking works.
However, the industry has made only the limited use of high
technology production concept. There is general need to nature
the development program in automation and robotics. Machines

have been employed in various tasks including material handling

various interior and exterior finishing task, including material
handling the high expectations of the stemmed from the very
serious problems the industry is facing

Continuous declining productivity

A high accident rate.
Low quality
In sufficient control of construction site
Vanishing of skilled work force.

In recent years the use of new technologies within the

industry has shown great potential although little has been
implemented.
For example robatic systems and other
programmable machines are needed to perform tasks that involve
hazardous of rate or in some way physically dangerous to human
the development of robotics systems in construction advance
very slowly owing to several challenges one of the obstacles in
the development of the required software component such
development for highly trained programme and export software
engineers.

Chamber Environments:
Non-ambient environments are usually chamber exposures.
Cycling between different non-ambient environments can be
performed by physically moving the test specimens from one
chamber to another or, in automated chambers, by cycling from
one condition to another. The temperature and relative humidity
should be monitored. Whenever possible, automatic control
systems should be used. Temperature tolerances should be 3C
or better.

Fog (Spray) Environment:

Salt fog application can take place in a laboratory ambient
environment. The fog nozzle should be such that the solution is
atomized into a fog or mist. Commonly, in addition to NaCl, the
electrolyte solution contains other chemicals to simulate acid rain
or other industrial corrosives.

Humid Environment:
CCT procedures often call for high humidity environments.
Typically they specify 95 to 100% RH. These may be achieved by
using hot water air and salt spray chamber may sometimes be
used to apply a pure water fog.

TEMPERATURE SIGNAL CONDITIONING

Process Transducers:Transducer converts one form of energy into
another form. In our case the physical energy is to be converted
into an electrical signal. For temperature we use Thermocouples
as a transducer .Thermocouple works of seeback effect principle
i.e. when two dis-similar metals are fused together and heated

milivolts are generated at another end. We use J-type i.e. Fe-con

as a thermocouple which uses ferrous & constantan as two dissimilar metals. The milivolts generated at particular temperature
are as below.
0mv 0C
1.28mv Ambient Temperature
5.23mv at 100C
10.77mv at 200C
16.32mv at 300C
21.8mv at 400C
This milivolts signal is given as an input to the
signal conditioning block for further processing.

Analog Signal Conditioning:In analog signal conditioning operational amplifiers

are used.

The electrically received form the transducer is

converted to a proper range.

Thermocouple Conditioning:Please follow the circuit diagram as below.

Circuit Diagram

As shown 4 operational amplifier configurations

are there. For thermocouple sensor, cold junction compensation is
to be done. We are adding the milivolts signals corresponding to
ambient temperature here. One ambient sensor is used. 2N2222
is a transistor having two diodes connected together inside. We
use one of the diodes among the two. As shown this CJC diode
sensor is connected in series with the conducting transistor.
This transistor is mode ON by providing the biasing
vtg at it base.

This biasing voltage should be above 0.7v.

potential divider with two different resistors is used here.

This divider has resistors R1 = 12 K & R2 = 7K5, input = 5vdc; Vout =?
R2
Vout = -------------- Vin
R1 + R2

7k5
Vout = ------------------- x 5vdc.
12k + 7.5k

Vout = -------------- > 0.7V

During calibration, this sensor is allowed to sense

atmospheric temperature. In such situation the output from the
transistor emitter is fed to the non-inverting terminal of the
operational amplifier. The inverting terminal is provided with a
variable signal. This variable signal is provided using a variable
divider as below.
R1

Rx

R2

- Vcc

+ Vcc
2k2

10k
Vout

2k2
Vout

Here, +Vcc = +5vdc and Vcc = - 5vdc.

The total voltage drop = (+5v 0v -5V) = 10V.
This low dc is divided across the potential divider of R1, R2 and
Rx.
Thus, the voltage signal at the variable terminal of
the variable potentiometer can be varied as per the requirement.
As this signal is fed as an input to the inverting input of the
amplifier, the output of amplifier changes depending upon any of
the input either inverting or non-inverting.

Initially 300mv are

adjusted at the central point i.e. wiper of potentiometer. The opamp being in unity gain fashion, generates 300mv at the output.
The signal is equivalent to 30C.

Thus, if no signal from

thermocouple section, output should be equal to 30C. Once this

is set, the atmospheric changes are sensed by the ambient sensor
and

are

shown

on

LCD

module.

This

is

cold

junction

compensation section.
Thermocouple sensor is connected at the input of
difference amplifier.

Reference the mv generation table of the

sensor as given earlier.

Suppose we calibrate the unit up to

100C, we require 2000mv as an input to ADC. As 20mv = 1 unit

on LCD.

Thus, 5.23mv is converted into 2000mv.

We do the

amplification in two steps. At initial difference amplifier.

5mv are converted to 100mv i.e. means a gain of
20 is required here, for difference amplifier.

- RF
Vout = -------------- (V2-V1)
R1

- RF
Thus, Vout = -------------- (5mv Say) Let R1 = 10k
10k

- RF
100mv = -------------- (5mv)

10k

RF = 200k
But, 200k being not available we use 220k here.
Also, a multi-tern trimpot is provided for getting a flexible gain.
Thus, the signal available at the output of difference amplifier and
the signal available at CJC output are added together in adder
amplifier.

Please follow the figure.

R1 = 10k
Vout = 2.600mv
Vin = 130mv.
Here, also we require the gain = 20, hence in
summing amplifier.
R1 = 10k, and RF = 220K again.
Thus, we get the appropriate output which goes to
ADC. If we connect thermocouple the output varies linearly from
ambient to maximum as per the change in temperature.

Temperature Calibration:-

Before using any digital process instrument it

should be calibrated properly. Standard calibrators are required
for this purpose. These calibrates are required for this purpose.
These calibrators are also certified by the national committee
such as NABL, ETDC etc.
The steps involved in calibration are given as
under
1)

Initially, short the thermocouple input and adjust ambient

temperature equal to 30C, with the help of multi-turn
potentiometer.

2)

Then connect milivolts source at thermocouple input and

set the milivolts input = 5.23mv and set the output equal
to 100C + 30C ambient, i.e. total 130C with span
potentiometer.

3)

Repeat above (1) and (2) steps sequentially till we get

output = ambient = 30C and maximum = span = 130C.

Spray Nozzle:
A spray nozzle is a precision device that facilitates dispersion of
liquid into a spray. Nozzles are used for three purposes: to
distribute a liquid over an area, to increase liquid surface area,
and create impact force on a solid surface. A wide variety of spray
nozzle applications use a number of spray characteristics to
describe the spray.

Spray nozzles can be categorized based on the energy input used

to cause atomization, the breakup of the fluid into drops. Spray
nozzles can have one or more outlets; a multiple outlet nozzle is
known as a compound nozzle. Single-fluid or hydraulic spray
nozzles utilize the kinetic energy of the liquid to break it up into
droplets. This most widely used type of spray nozzle is more
energy efficient at producing surface area than most other types.
As the fluid pressure increases, the flow through the nozzle
increases, and the drop size decreases. Many configurations of
single fluid nozzles are used depending on the spray
characteristics desired.

Relay:
A relay is an electrically operated switch. Many relays use
an electromagnet to mechanically operate a switch, but other
operating principles are also used, such assolid-state relays.
Relays are used where it is necessary to control a circuit by a lowpower signal (with complete electrical isolation between control
and controlled circuits), or where several circuits must be
controlled by one signal. The first relays were used in long
distance telegraph circuits as amplifiers: they repeated the signal
coming in from one circuit and re-transmitted it on another circuit.
Relays were used extensively in telephone exchanges and early
computers to perform logical operations.
A type of relay that can handle the high power required to directly
control an electric motor or other loads is called
a contactor. Solid-state relays control power circuits with
no moving parts, instead using a semiconductor device to perform
switching. Relays with calibrated operating characteristics and
sometimes multiple operating coils are used to protect electrical
circuits from overload or faults; in modern electric power systems

these functions are performed by digital instruments still called

"protective relays"
A simple electromagnetic relay consists of a coil of wire wrapped
around a soft iron core, an iron yoke which provides a
low reluctance path for magnetic flux, a movable iron armature,
and one or more sets of contacts (there are two in the relay
pictured). The armature is hinged to the yoke and mechanically
linked to one or more sets of moving contacts. It is held in place
by a spring so that when the relay is de-energized there is an air
gap in the magnetic circuit. In this condition, one of the two sets
of contacts in the relay pictured is closed, and the other set is
open. Other relays may have more or fewer sets of contacts
depending on their function. The relay in the picture also has a
wire connecting the armature to the yoke. This ensures continuity
of the circuit between the moving contacts on the armature, and
the circuit track on the printed circuit board (PCB) via the yoke,
which is soldered to the PCB.
When an electric current is passed through the coil it generates
a magnetic field that activates the armature, and the consequent
movement of the movable contact(s) either makes or breaks
(depending upon construction) a connection with a fixed contact.
If the set of contacts was closed when the relay was de-energized,
then the movement opens the contacts and breaks the
connection, and vice versa if the contacts were open. When the
current to the coil is switched off, the armature is returned by a
force, approximately half as strong as the magnetic force, to its
relaxed position. Usually this force is provided by a spring, but
gravity is also used commonly in industrial motor starters. Most
relays are manufactured to operate quickly. In a low-voltage
application this reduces noise; in a high voltage or current
application it reduces arcing.

Pressure Regulator
Pressure regulating components are formed by various
components, each of which has its own pneumatic symbol:
(i) Filter can remove impurities from compressed air before it is
fed to the pneumatic components.
(ii) Pressure regulator to stabilise the pressure and regulate the
operation of pneumatic components
(iii) Lubricator To provide lubrication for pneumatic components

POWER SUPPLY

Power supply is the first and the most important part of our
project.For our project we require +5v regulated power supply
with maximum current rating 500 mA
Following basic building blocks are required to generated
power supply.

Rectifier

Filter

3 Terminal
Vtg. Regulator

230vac

Reg.o/p

STEP DOWN TRANSFORMER :

Step down transformer is the first part or regulated

power supply . To step down the mains 230V A.C. we require
step down transformer. Following are the main characteristic of
electronic transformer.
I
II
III

IV

Power transformer are usually designed to operate from

source of low impedance at a single freq.
It is required to construct with sufficient insulation of
necessary dielectric strength.
Transformer rating are expressed in volt-amp. The voltamp of each secondary winding or windings is added
for the total secondary VA. To this are added the load
losses.
Temperature rise of a transformer is decided on two
well known factors i.e. losses on transformer and heat
dissipating or cooling facility provided unit.

RECTIFIER UNIT:

Rectifier unit is a ckt. Which converts A.C. into

pulsating D.C. Generally semi-conducting diode is used
as rectifying element due to its property of conducting
current in one direction only Generally there are two
types of rectifier.
1 Half wave rectifier

2 Full wave rectifier.

In half wave rectifier only half cycle of mains A.C.
rectified so its efficiency is very poor. So we use full
wave bridge type rectifier, in which four diodes are
used. In each half cycle, two diodes conduct at a time
and we get maximum efficiency at o/p.
Following are the main advantages and is
advantages of a full-wave bridge type rectifier ckt.

ADVANTAGES :

1 The need of center tapped transformer is eliminated.

2 The o/p is twice that of center tap circuit for the
same secondary voltage.
3 The PIV rating of diode is half of the center taps
circuit.
DISADVANTAGES :

1 It requires four diodes.

2 As during each half cycle of A.C. input, two
diodes are conducting therefore voltage drop in
internal resistance of rectifying unit will be twice
as compared to center tap circuit
Filter circuit :

Generally a rectifier is required to produce pure D.C. supply for using at various places in
the electronic circuit, However, the o/p of rectifier has pulsating character i.e. if such a D.C. is
applied to electronic circuit it will produce a hum i.e. it will contain A.C. and D.C. components.
The A.C. components are undesirable and must be kept away from the load. To do so a filter
circuit is used which removes (or filter out) the A.C. components reaching the load. Obviously a

filter circuit is installed between rectifier and voltage regulator. In our project we use capacitor
filter because of his low cost, small size and litile weight and good characteristic. Capacitors are
connected in parallel to the rectifier o/p because it passes A.C. but does not pass D.C. at all.

A voltage regulator is a ckt. That supplies constant

voltage regardless of change in load current. IC voltage regulators
are versatile and relatively cheaper. The 7800 series consists of
three terminal positive voltage regulators. these ICs are designed
as fixed voltage regulator and with adequate heat sink, can
deliver o/p current in excess of 1A. These devices do not require
external component. This IC also has internal thermal overload
protection and internal short circuit and current limiting protection
for our project we use 7805 voltage regulator IC.

7805
7812
1
T3

D1

D3

D2

D4

230VAC
@50HZ

C1

0-10 , 500 mA

Design to step down transformer :

VIN

VOUT

2
GND

1
GND

+5V

3
+

C3

The following information must be available to the

designer before the commences for the design of transformer.
1
2
3
4

Power output
operating voltage.
Frequency Range
Efficiency and Regulation

Size of core :
Size of core is one of the first consideration in regard of core
and winding configuration used. Generally following formula is
used to find area or size of core.

Ai =

(p1/0.87)

Where
Ai = Area of cross section in sq. cm.
P1 = Primary voltage

In Transformer P1 = P2

For our project we required +5V regulated output. So

transformer secondary rating is 12V, 500 mA.
So secondary power wattage is,

P2
so ,

12 X 500 X 10

6w.

w.

Ai

(6/0.87)

2.62

Generally 10% of area should be added to core accommodate all

turns for low Iron losses and compact size.
So,
Ai = 2.88.

Turns per volt

Turns per volt of transformer are given by relation
10,000
Turns/volt = ------------------4.44f B Ai
Here;
F is the frequency in Hz
B is flux density in Wb/m2
A is net area of cross section.
For project for 50Hz the turns per volt for 0.91 wb/m2,
Turns per volt = 50/Ai
= 50/ 2.88
= 17
Thus for primary winding = 220 X 17 = 3800.
For secondary winding = 12 X 17 = 204

Rectifier design :

R. M. S. Secondary voltage at secondary of transformer is 12V.

So, maximum voltage Vm across Secondary is
= RMS voltage *1.41
= 12* 1.41
=16.97
D.C. output voltage at rectifier o/p is
Vdc = 2Vm/3.14
= 2*16.97/3.14
= 10.80 v
PIV

= 2 Vm
= 2 X 16.97
= 34V

Design of filter capacitor

Formula for calculating filter capacitor is,

1
C=

----------------------------4. 3 r f RL

r = ripple present at o/p of rectifier.

(Which is maximum 0.1 for full wave rectifier ?)
f = Frequency of mains A.C.
R = I/p impedance of voltage regulator IC.

1
C = ------------------- = 1000F
4 3 0.1*50*28

IC 7805 (Voltage regulator IC):-

Specifications :-

Available o/p D.C.voltage = + 5V

Line regulation
= 0.03
Load regulation
= 0.5
Vin maximum
= 35 V
Ripple Rejection
= 66-180(db)

TESTING AND TROUBLESHOOTING

Before soldering in components:

Check that component agree with the parts list (value and
power of resistors, value and voltage rating of capacitor,

etc.) if in any doubt double check the polarized components

(diodes, capacitor, rectifiers etc)
If there is a significant time elapse between circuit, take the
trouble to read the article; the information is often given in a
very condensed from. Try to get most important point out of
the description of the operation of the circuit, even if you
dont understand exactly what is supposed to happen.
If there is any doubt that some component may not be exact
equivalent, check that they are compatible.
Only use good quality IC sockets.
Check the continuity of the tracks on the PCB (and through
plated holes with double sided boards) with a resistance
meter or continuity tester.
Make sure that all drilling, filling and other heavy work is
done before mounting any components.
If possible keep any heat sinks well isolated from other
components.
Make a wiring diagram if the layout involves lots of wires
spread out in all directions.
Check that the connectors used are compatible and that
they are mounted the right way round.
Do not reuse wire unless it is of good quality. Cut off the ends
and strip it a new.

After mounting the component:

Inspect all soldered joints by eye or using a magnifying glass

and check them with a continuity tester. Make sure there are
no dry joints and no tracks are short circuited by poor
soldering.
Ensure that the positions of all the component agree with the
mounting diagram
Check that any links needed are present and that they are in
the right positions to give the desired configuration.

 Check all ICs in their sockets (see that there are no pins bent
under any ICs, no near ICs are interchanged etc.)
Check all the polarized components (diodes, capacitor etc)
are fitted correctly.
Check the wiring (watch for off cuts of components leads) at
the same time ensure that there are no short-circuits
between potentiometer, switches, etc. and there immediate
surrounding (other components or the case). Do the same
with mounting hardware such as spacers, nuts and bolts etc.
Ensure that the supply transformer is located as closely as
possible to the circuits (this could have a significant
improvement in the case of critical signal level).
Check that the connections to the earth are there and that
they are of good contact.
Make sure the circuit is working correctly before spending
any time putting it into a case.
And if it breaks down:

Recheck everything suggested so far.

Re-read the article carefully and carefully anything about
which you are doubtful.
Check the supply voltage or voltages carefully and make
sure that they reach the appropriate components especially
pins of the ICs (test the pins of ICs and not the soldered
joints).
Check currents (generally they are stated on the circuit
diagram or in the text). Dont be too quick to suspect the ICs
of overheating.
If possible check the operation of the circuit in the separate
stages as a general rule follow the course of the signal.
While checking voltages, currents, frequencies or testing the
circuits with an oscilloscope work systematically and take
notes.
And dont forget to switch the power on and check the fuses.

PCB DESIGN
Designing of PCB :

I)

II)
III)
IV)

V)
VI)
VII)
VIII)
IX)
X)
XI)
XII)

XIII)
XIV)

XV)
XVI)

After selection of electronic circuit, make a block

diagram of various circuits to know various interconnections required, which will help in reducing the
number of wires.
The designer should have the complete idea of the
circuit regarding the function and signal flows through.
Keep each and very component you need, while
starting the designing.
Use of templates is essential if you are new designer, if
the design is manual i.e. hand made and not with
software such as Orcas, Auto CAD, Pads, Ideas, Circuit
maker, etc.
Standard PCB size should be decided in the beginning
only.
Preferably, layout ands artwork should be in 1:2 scales.
Sequential stage after PCB size is decided.
Component placement.
Track routing i.e. layout.
Artwork making with ink or ready made tapes and pads.
While routing the tracks, carrying AC mains voltage,
consider the safety rules ands regulations.
In analog and digital systems together, care should be
taken that analog and digital ground will not mix each
other affecting the stability ands fluctuations in the
display.
In power system i.e. high current, the track width and
the track spacing should be as maximum as possible.
While placing the components on the PCB preferably
the load on PCB, should be evenly distributed to avoid
the problems at completion stage during wavesoldering i.e. warping of PCB etc.
To avoid weakening of the pup tool, the perforation
length should be kept minimum i.e.<40 mm.
For the manually shouldered components vent i.e. cut
pads should be provided to avoid the blocking of the
holes during shouldering

COMPOMENT PLACEMENT :
I)

Preferably, place the component in X-Y direction

subjected to mechanical construction.
II)
All components should be flat mounted i.e. flat
placed to avoid of leads and for easy
requirements. However in case of space limitation
the components such as resistors, diodes, etc.
may be mounted vertically which doesnt affect
the performance.
III) In case separate analog and digital ground.
IV) Orientation of multi-lead components(e.g.
switches, Ics) should be connected in between the
analog and digital ground .
V) Sufficient clearance is provided around component
so that inversion or replacement ands repair is
easy.
VI) The design should such that minimum jumpers are
allowed.
VII) It is preferable that, components like present,
coils, and trim pots, etc. which alignment of
calibration are placed in such that, they are
accessible after the assembly of the PCB on
cabinet also.
If the components are not flush mounted, provide the sleeve for
leads.

Advantages:
Cyclic corrosion test methods were originally developed as labor
intensive manual procedures. Automated, multi-functional
chambers are now available and can perform CCT tests in a single
chamber. Some of the advantages of automated systems are that
they:
Eliminate manual moving of test specimens from one chamber
to another
Eliminate laborious spraying of test specimens
Eliminate variability in results from excessive specimen handling
Allow more predictable transition times