PCB wiring experience summary

PCB wiring is the method of connecting various components through power and signal paths. Think of it as building roads that connect different cities, where each road allows vehicles (signals) to travel from one point to another. In PCB design, just like road construction, the layout must be logical and efficient. For low-frequency circuits, a simple loop is sufficient, while for high-speed signals, the concept of transmission lines comes into play. One of the most common examples is differential signaling, used in USB or Ethernet cables, where two wires carry opposite signals to reduce noise and improve signal integrity. Differential signaling is an ideal model for transmitting high-speed signals between devices. The higher the signal requirements, the more beneficial this technique becomes. However, using differential pairs for every connection can lead to a larger PCB footprint and increased complexity. To address this, multi-layer PCBs are often used, with the bottom layer serving as a ground reference. This approach reduces the number of required signal layers and simplifies routing, making the layout more compact and efficient. Every layout engineer has their own style and approach. On the same board, different engineers may produce vastly different results. While performance is the top priority, aesthetics also play a role. A well-organized layout not only looks better but also makes testing and maintenance easier. An excellent layout engineer is not just a technician but also an artist who balances functionality with visual appeal. The image above shows the TOP silkscreen of a VPX chassis board. From the component arrangement, you can see that decoupling capacitors are placed close to the chips, and DDR memory modules are positioned near the FPGA for optimal signal integrity. Even though the layout might look complex at first glance, it’s designed with both performance and clarity in mind. In reality, a good PCB layout is more than just looking neat—it must function properly and meet all electrical requirements. A poorly laid-out board, no matter how visually appealing, can cause serious issues during testing or operation. High-end boards can cost tens of thousands of dollars, and their success depends on careful planning and execution. It’s not about the number of layers; sometimes, fewer layers are better if they serve the purpose effectively. During the layout process, engineers consider factors such as signal integrity, thermal management, and electromagnetic compatibility (EMC). They also take into account the placement of components, the direction of signal flow, and the impact of each part on the surrounding circuitry. Common elements like silk screens, test points, and notes reflect the attention to detail that goes into a professional design. The basic PCB design process includes: preparation, structural design, component placement, routing, optimization, DRC checks, and finally manufacturing. The order of layout is crucial—starting with the most critical signals, ensuring clean and uniform routing, and then refining for aesthetics. Key PCB layout principles include: 1. Keeping critical signal lines short and thick. 2. Reserving test points for key signals. 3. Avoiding loops and minimizing via usage. 4. Using ground-signal-ground configurations for sensitive signals. 5. Pre-routing high-frequency lines and avoiding parallel traces. 6. Grounding oscillator cases and keeping clock lines short. 7. Using 45° angles instead of 90° for high-speed signals. 8. Optimizing wiring after initial placement and checking for errors. 9. Prioritizing power and ground lines for better performance. A well-designed PCB should meet the following criteria: 1. Function correctly under all conditions. 2. Pass EMC tests. 3. Be cost-effective. 4. Have a clean and organized layout. 5. Be completed efficiently. For high-frequency and high-current applications, such as switching power supplies, it's crucial to separate driving signals from high-power outputs to prevent interference. In analog circuits, similar precautions apply to avoid unwanted feedback or oscillation. PCB wiring relies heavily on the board itself. Signals are kept within the board’s boundaries, typically around 1mm away from the edge, to minimize electromagnetic radiation. This concept is similar to real-world road systems, where signals stay within defined paths to maintain efficiency and safety. In summary, a successful PCB design isn’t judged by the number of layers or components alone. A well-thought-out design that meets performance, cost, and aesthetic standards is the ultimate goal.

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