Your Name: ANUKRITI Date:18/06/2019

Note: You are given 60 minutes to finish the following test. Internet usage, cell phones or any other mobile
devices are restricted and not to be used during this test. You can complete this test by-hand or on the
computer; You will require a Gerber-viewer software in order to answer questions 6 and 7. Please submit
this test via email to info@7pcb.com by the deadline specified.

Writing Exam

1) How do you troubleshoot a prototype board with assembly issues for electronic designer? What
are the main issues did you have experienced in the past? (Approximately 200 words)?
ANSWER- Main issues which are faced for an electronic designer-
 Insufficient copper to edge clearance-
To prevent corrosion and protect the copper from interacting with its environment, this copper is
covered with other materials. However, when a PCB is trimmed, if the copper is too close to the
edge, part of this coating can be trimmed as well, exposing the copper layer underneath. This can
cause problems in the functionality of the board. This problem can easily be avoided by making
sure the space between the edge of the copper and the edge of the board, also known as the
copper-to-edge or plate-to-edge clearance, follows acceptable standards for the type of board
being manufactured. A good dfm check will usually catch any potential problems.

 Missing Solder Mask between PADS-

In some circuit boards, the solder mask may be partially or completely absent between pads. This
exposes more copper than is necessary, and can result in solder bridges forming accidentally
between pins during assembly. This can result in a short, as well as reduced corrosion protection,
both of which can negatively affect the functionality and longevity of the circuit board.This defect
is commonly due to a design oversight, where the solder mask is undefined or the settings for a
larger board are carried over to a smaller board, resulting in pad holes that are simply too large
for the smaller PCB. This can be avoided by double-checking the design before sending it to the
manufacturer.

 ACID TRAPS-
“Acid trap” is the common term for acute angles in a circuit. They are referred to this way because
these acute angles trap acid during the PCB etching process, allowing the acid to build up in the
nook of the angle. The angle functionally keeps the acid in the corner for a longer period than the
design calls for, causing the acid to eat away more than intended. As a result, the acid can
compromise a connection, making the circuit defective and causing more serious problems later
on.Most designers are aware of the problems caused by acute angles in a circuit board, and are
therefore trained to avoid them. However, mistakes do happen. Often, acute angles are the result
of simple human error, although some design software programs may also set circuits to acute
angles if the settings are not properly adjusted.

 OTHER ISSUES are Starved thermals,Electromagnetic issues etc.

2.) Explain how surface mount technology and through-hole parts affect PCB design and assembly.

ANSWER- Surface mount assembly performs more efficiently and more cost-effective than through-
hole assembly. Modern electronics have witnessed the application of SMT in majority of electronic
products. When special mechanical, electrical and thermal performance is taken into first
considerations, nevertheless, through-hole mounting still matters.Although technology have been
making consistent progress at any time and newer products will definitely get old ones replaced, it
doesn't mean that traditional technologies have to be totally eliminated. For example, multi-layer
PCBs are more advancing and complex than single-layer PCBs.Advantages of older techniques can
be the main reason for them to play a role in the future.

2) A boy is 6 years old and his sister is three times as old as he is. When the boy is 18 years old,
how old will his sister be?
ANSWER- Sister’s age will be 54 years as (3*18 )

3) Divide 20 by half and add 20. What do you get?

ANSWER is 40+20 =60

4) Out of eight balls, seven balls weigh equal while the one ball is slightly heavier than the others
how would you figure out which one is the heavier by using a balance and only two weighing?
ANSWER-
Classify them into groups group1 -> 3 balls, group2 -> 3 balls and group3 ->2 balls.Weigh the
group1 balls against group2 balls. If the balance shows equal weights on both sides then group3
contains the heavier ball which can be found by measuring the 2 balls in group3 against each
other.Pick the 3 balls from the side which has the heavier weight, it could be the 3 balls of group1
or group2. Take any 2 balls from the heavier group of 3 balls. Put one of the 2 on each side of the
balance and weigh again. If the balance shows equal weight the 3rd ball left out of the 3 is the
heavier one else whichever side of the balance shows more weight has the heavier ball.
Use the Gerber Zip file included in the email to answer question 6 and question 7:

5) How many copper layers are there in the above PCB design?

6) What file is the Top Side Soldermask layer?

ANSWER- SIG TYPE

7) Use the Excel Bill Of Materials Spreadsheet included with this test to calculate the per unit price
of the below Bill of Materials be if the client wants 25 PCBs assembled.

Item Description Quantity Total Price Per Unit

Per PCB Quantity for Break Price for
25 PCBs 25 PCBs
1 Resistor 15 375 0.593 7.5
2 Capacitor 9 225 0.9 8.1
3 NPN Transistor 3 75 0.9 2.7
4 LED 2 50 0.4 0.8
Total: 19.1
Price Breaks:

Resistor
Quantity Price Break
1 $0.10000
10 $0.03000
50 $0.01200
100 $.007000

Capacitor
Quantity Price Break
1 $0.12000
10 $0.05000
50 $0.01500
100 $.009000

NPN Transistor
Quantity Price Break
1 $0.30000
10 $0.08000
50 $0.02500
100 $.002000

LED
Quantity Price Break
1 $0.20000
10 $0.06000
50 $0.03500
100 $.002500