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Technical Description

ELECTRONICS - Skill 16
Manufacturing And Engineering Technology

Lomba Kompetensi Siswa (LKS) Tingkat Nasional ke XXVI 2018


Mataram, Nusa Tenggara Barat

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TD 16 – Rev. 3.0
1. INTRODUCTION
1.1. Name and Description of Skill
1.1.1. The name of the skill competition is
Electronics.

1.1.2. Description of Skill


The electronics industry is very diverse and has evolved into several
specialisms. Some technicians/engineers will work across many aspects of
electronics, but increasing specialization and technical developments means
that specialist technician/engineers are widely employed.

The key areas of specialism which can be seen as careers in their own
right include the assembly and wiring of electronic products, the designing of
prototype circuits to specifications, the installation and commissioning of
equipment including the provision of customer support, service and
maintenance which include a service both in site remotely, monitoring and
testing to specifications subassemblies or systems and approving fit–for-
purpose and simulating outcomes on computers.

Electronics specialists need to work in a wide range of industries by


supporting highly technical specialist equipment. These industries include:
 Aerospace/aeronautics,
 The military,
 Robotics,
 Audio/TV/entertainment,
 Laboratories and hospitals,
 Higher education research laboratories,
 Communications and telecommunications,
 Power,
 Transport,
 Security,
 Manufacturing including instrumentation.

Electronics technicians/engineers must work with a high degree of


accuracy and precision, conforming to detailed specifications and international
quality standards and demonstrating extensive technical ability.

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Due to the constant developments in technology, the electronics
technician/engineer needs to be proactive in ensuring that his/her skills and
knowledge are up-to-date and meet industry standards and expectations.

The technician/engineer may work directly with clients and will therefore
need to demonstrate excellent customer service and communication skills and
work effectively to time schedules. When working with clients, the
technician/engineer may have to explain elements of complex electronics
principles to assist the client to use equipment correctly. Often the nature of the
establishment in which the electronics expert works will require him/her to
respect confidentiality with respect to highly commercially sensitive information
and to demonstrate integrity, honesty and a strong ethical sense.

The electronics specialist will work with a wide range of tools, Specialist
hi-tech equipment and materials. Increasingly, computers and specialist
software for communications technology is embedded into the work. In addition,
tasks will also require the use of specialist hand tools for the assembly and
maintenance of circuits and surface mounted technology.

1.2. The Relevance and significance of this Document


This document contains information about the standards required to
compete in this skill competition, and the assessment principles, methods and
procedures that govern the competition.

Every Competitor must know and understand this Technical Description.


In the event, English or Indonesia is official languange.

1.3. Associated Documents


As this Technical Description contains only skill-specific information it must
be used in association with the following:
 LKS- Competition Rules

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2. THE COMPETENCY SPECIFICATION
2.1. General Competency
 Creativity.
 Critical thinking.
 Honesty and integrity.
 Self-motivation.
 Problem-solving skills.
 Work under pressure.
 Able to do environmentally friendly operation.

2.2. Competency for all modules


Skills to do measurements in electronic circuits (with DVM, scope, etc).
Skills to use materials and tools of electronics industry in ordinary servicing,
installation and repair tasks (hand tools, different soldering and de-soldering
technique). Knowledge in analysis and design of electric circuit, electronic circuit
and digital logic circuit and sensor circuit.

Module 1 - Hardware Design


 Skills to design small modification to basic electronics blocks,
 Skills to draw developed circuit by hand,
 Skills to design of library component using Altium design PCB software.
 Skill to design of Printed Circuit Board using Altium design PCB Software,
 Skill to assembling circuits and Printed Circuit Board into prototype.

Module 2 - Embedded Systems Programming


 Knowledge of circuit boards, processors, chips, electronic equipment, and
computer hardware and software.
 Skills and knowledge in programming of embedded systems by using C-
language and Integrated Development Environments (Atmel Studio 7
Compiler and AVR Dude Downloader).

Module 3 - Fault finding, Repair, and Measurement


 Troubleshooting, determining causes of operating errors and deciding
what to do about it.
 Adjust and replace defective or improperly functioning circuitry and

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electronics components, using hand tools and soldering iron.
 Skills to test electronics units, using standard test equipment, and analyze
results to evaluate performance and determine need for adjustment.

Module 4 – Assembly Project


 Skill in assembling and utilizing mechanical parts such as DC Motor, Fan
Motor, Solenoids, bolt, nut, washer and etc.
 Skill in wiring and forming cables.
 Skill in assembling and using various types of parts and SMD part.

2.3. Theoretical Knowledge


Theoretical knowledge is required but not tested explicitly.
The Competitors‟ Theoretical knowledge should cover :

Fundamental Electronics Principles


 Basics of AC and DC technology.
 Two ports LRC network, resistive networks with up to three meshes.
 RC oscillators.

Components in Electronics
 Properties, behavior, characteristics and application (elementary circuits)
of mechanically,
 Electrically and physically adjustable components i.e. Capacitors,
Resistors, Variable Resistors, Coils, Transformers and Diodes.

Multistage and Special Amplifier Circuits


 Basic amplifier circuits (AC, DC and power amplifiers)
 Differential amplifiers/operational amplifiers
 Ideal operational amplifier: (infinite input resistance, zero output resistance
and infinite open loop gain) Basic circuits with operational amplifier,
analogue adder and sub-tractor, differentiator, comparator, impedance
transducer.
 Real operational amplifier: Offset voltage and offset current, compensation,
common mode gain and rejection, temperature drift and frequency
response.

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Generators and Pulse Shaper
 Generators for sine wave voltage: RC, quartz, LC oscillators; Wien bridge
generator, phase generator.
 Pulse shaper: Schmitt trigger, differentiator, and integrator.

Digital Electronics
 Basic logic gates:
 Level switching function, function table, pulse, diagram, circuit symbols
(table in appendix)
 Properties of basic gates AND, OR, NOT, NAND, NOR, EXCLUSIVE OR
and EXCLUSIVE NOR
 Substituting basic NAND or NOR gates for basic gates.
 Creating switching functions from given circuits and vice versa.
 Making function table from circuit diagrams and switching functions
 Simplifying switching networks using Karnaugh diagram or mathematical
techniques.
 Flip-flops, RS Flip-flop, D Flip-flop and JK Master slave Flip-flop
(especially counter circuits, shift register and frequency divider).

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3. THE ASSESSMENT STRATEGY AND
SPECIFICATION
3.1. GENERAL GUIDANCE
Assessment is governed by the LKS Assessment Strategy. The Strategy
establishes the principles and techniques to which LKS assessment and
marking must conform.

Jury assessment practice lies at the heart of the LKS Competition. For
this reason, it is the subject of continuing professional development and
scrutiny. The growth of expertise in assessment will inform the future use and
direction of the main assessment instruments used by the LKS Competition: the
Marking Scheme and Test Project.

Assessment at the LKS Competition falls into two broad types:


measurement and judgement. For both types of assessment, the use of explicit
benchmarks against which to assess each Aspect isessential to guarantee
quality.

The Marking Scheme must follow the weightings within the Standards
Specification. The Test Project is the assessment vehicle for the skill
competition, and also follows the Standards Specification.

The Marking Scheme, in outline, will lead the process of Test Project
design. After this, the Marking Scheme and Test Project will be designed and
developed through an iterative process, to ensure that both together optimize
their relationship with the Standards Specification and the Assessment
Strategy. They will be submitted to Jury for approval together, in order to
demonstrate their quality and conformity with the Standards Specification.

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4. THE MARKING SCHEME
This section describes how the Jury will assess the Test Project / modules.
It also specifies the assessment specifications and procedures and requirements
for marking.

4.1. Assessment Criteria


This section defines the assessment criteria and the number of objective
marks awarded. The total number of marks for all assessment criteria must be
100.

Marks
Module Criterion
Subjective Objective Total

A Hardware design - 30 30

Embedded systems
B - 25 25
Programming

Fault finding, repair and


C - 25 25
measurement

D Assembly Project - 20 20

Total 100 100

4.2. Skill Assessment Specification


Specific marking criteria for each project differ. However, major marking
features for each project are as follows.

A. Hardware design - 30 marks


Development of given basic circuit - 5 marks
Design of PCB-board layout – 15 marks
Assembly of PCB (IPC-A-610-F) – 5 marks
Functionality of Designed PCB – 5 marks

B. Embedded Systems Programming - 25 marks


Software functionality - 25 marks

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C. Fault finding, repair and measurement - 25 marks
Finding faulty spots and evidence – 15 marks;
Standard repairing (IPC-A-610-F) – 5 marks;
Validity of measuring results – 5 marks;

D. Assembly Project - 20 marks


Functionality – 5 marks
Assembly quality according IPC-A-610-F – 12 mark
Mechanical Assembly – 3 marks

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5. THE TEST PROJECT
5.1. Test Project Design
5.1.1. Hardware Design
Each Competitor will have to design a PCB. The Altium designer PCB 17
or 18 will be used in competition. Competitor have to make one library
component using Altium designer. The task board must be 100mm x 160mm.
Single layer board to be used. Soldering and fuction design PCB.

5.1.2. Embedded Systems Programming


Programming module using ATmega 16 (Atmel Studio 7) and AVR Dude
downloader.

5.1.3. Fault Finding, Repair and Measurement


The Competitors are expected to work with conventional measuring and
testing equipment to locate, test and replace faulty electronic components on a
printed circuit board, surface mount board or mixed technology board. All
surface mount components to have no more than 20 pins. The Competitors
should be able to document fault finding method/procedure with results. 3 faults
on a single board. All test boards must have similar faults. They are further
expected to record and analyze measured results. Boards must be pre-built
before the Competition. The task board must be 100 mm x 160mm double layer
PCB.

5.1.4. Assembly Project


The Competitors will be asked to assemble a project from a kit of parts.
The standard to be reached is determined by IPC-A-610 issue F (International
acceptability of electronic assemblies) using lead free.

5.2. Time allowed for each module


Time allowed
Module Suggested
(Hours)
Hardware Design 7 1/2 D1, D3
Embedded Systems Programming 4 D2
Fault Finding, Repair, and Measurement 4 D2
Assembly Project 4 D3

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6. SKILL MANAGEMENT AND COMMUNICATION
6.1. Discussion Forum
For more information and question send, all mentor each province send
number of Whatsapp (WA) to inaskills.electronics@gmail.com. Jury will make
WA group for discussion forum.

6.2. Competitor Information


Competitor can get update of test project or other information at
www.inaskills-electronics.com/lks2018.

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7. SKILL-SPECIFIC SAFETY REQUIREMENTS
Skill-specific safety requirements:
 All Competitors must have safety glasses and Cotton Glove

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8. TOOLS BROUGHT BY COMPETITOR
No Tools Specification Qty Unit Discription
Minimal frequency 20
1 Osciloscope dual Channel 1 Set Recomended Digital Osciloscope
MHz
Minimal Range
Analog Function Generator
2 Frequency 0.1 Hz - 1 Set
(AFG)
10Mhz
(1) Install Atmel Studio 7(with usbasp
driver), Altium 17/18, microsoft
office, pdf reader and video player.
Minimal I3 core, Ram
(2) The laptop new OS and just
2 GB, Higher spec.
3 Laptop 1 Set software above are allowed to install.
Will speed up the
(3) Dont put important file to the
desing
laptop, if any file in laptop will delete
and we are not responsible for any
data loss.
4 Multi tester Analaog / Digital 1 pcs
5 Solder Iron Standard 1 pcs Rocomended brand is goot
0 - 12 V Minimal 1 Dont bring big power supply(1
6 Power Suppply 1 pcs
Ampere Ampere is enaugh)
recomended brand is goot or sanfix

Recomended pointed
7 Cutter Piler 1 pcs
and sharp ends

recomended sanfix P-40 or PS 41

8 Pilers Standard 1 pcs

9 De-Soldering Pump Standard 1 pcs

10 Tweezer Standard 1 Set

11 Screw driver set Standard 1 Set


for setting multiturn and Terminal
12 Precision screw driver Standard 1 Set
Block
13 Protoboard Standard 1 pcs
tools for drawing schematics and
14 Stationery Standard 1 Set
documentation

Additional information will be posted on the electronics forum

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9. MATERIALS & EQUIPMENT
9.1. Infrastructure List
The Infrastructure List contents all the information regarding to equipment,
materials and facilities provided by the organizer / responsible and participant.
Some standard components to be provided by organizer/ responsible and
participant.

9.2. Materials
All material test project for competition are provided by organizer and
competitors are not allowed to bring any material for competition.

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10. SCHEDULE OF COMPETITION

COMPETITION TIME ACTIVITIES

Technical meeting and


C-1 -
Familiaritation
07:45 - 09:45 Preparation
09:45 - 10:00 Briefing
10:00 - 12:00 Hardware Design (1)
C1
12:00 - 13.00 Lunch
13:00 - 16:30 Hardware Design (2)
16:30 - selesai Marking
07:45 - 08:00 Briefing
Embedded Systems
08:00 - 12:00
Programming
12:00 - 13:00 Lunch
C2
13:00 - 13:15 Briefing
Fault Finding, Repair and
13:15 - 17:15
Measurement
17:15 - selesai Marking
07:45 - 08:00 Briefing
08:00 - 12:00 Assembly Project
12:00 - 13:00 Lunch
C3 13:00 - 13:15 Briefing
13:15 - 15:15 Hardware Design (3)
15:15 - 17:15 Evaluation
17:15 - selesai Marking

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11. LAYOUT COMPETITION

Visitors

Visitors
Visitors

Line
Follower
Track

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12. VISITOR AND MEDIA ENGAGEMENT

Following is a list of possible ways to maximize visitor and media engagement:

 Try a trade;
 Display screens outlining the tasks being performed;
 Test Project descriptions;
 Competitor profiles;
 Daily reporting of Competition status;
 Display of interesting electronic project;
 Display of past Test Projects;
 Sponsor install a mini working electronic production line close to the
competition area.

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13. SUSTAINABILITY

This skill competition will focus on the sustainable practices below:

 Recycling.
o Using project from previous competition for different task;
o Encourage use of industry donated components;
o Use datasheets in PDF form
 Use of components available from global suppliers;

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Modul 1
HARDWARE DESIGN

Foto:
Noor Ahwan (Jawa Tengah
Hadi hardiansyah (Jawa Barat)
Helmi Yuliardi (Jawa Tengah)

Test Project document


LKS_2018_HWD_EN

Submitted by:
Name : Tim Elektronika LKS ASC WSC
Member : Ina skills Electronics
Type : Close Project
Time : 7:30 Hours
Point Indonesia
Skill Electronics
: 30LKSPoints
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1. Introduction
This Hardware Design Project will access each competitor‟s skill and capacity.
1. To design circuit based on the given drawing, components and
product specification.
2. To design printed Circuit Board (PCB) layout using Altium Designer
CAD tool.
3. To assemble and test the functionality of product prototype.

2. Description of project and tasks

a. Circuit Design and Schematic Capture (Time limit: 2.0 hrs)


You are to complete 4 designs. Please complete the designs according
to the requirements. Use only components from the parts list for your designs.
You may not need all the components in the parts list. Competitor can use
LTspice to simulate the design. LTspice is freeware and competitor can
download the software at http://www.linear.com/designtools/software/.

Competitors can read component data sheet that is provided with only
personal computer which contains Data sheet pack. The data sheet pack
should be provided by Committee. The hard copies brought by competitor can‟t
be used, but competitors can read the hard copies provided with committee.
When you have completed your designs you are to submit your answers on the
provided Answer Sheets to the expert. You cannot do this until the 1 st hour has
passed. You cannot start your PCB design in this phase of the test project.

b. Design of Printed Circuit Board (Time limit: 3:30 hrs)

 Design printed circuit board of PCB using Altium Designer CAD tool.
 Complete the designs, save PCB in the Desktop
 File folder : LKS_HWD_NOTABLE
 File name : LKS_HWD_NOTABLE

 Please use track widths (including necked track) of 0.3 mm (11.811mil)


minimum for signal and 0.6 mm (23.622 mil) minimum for power and
a minimum clearance of 0.3mm (11.811mil).
 There must be clearly difference size of track for both signal and power.
 Board dimension of 100 x 160 mm is to be used

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 Follow the following design rules:
 Design rule: Pad – Pad clearance is 0,4mm
 Design rule: Pad – Trace clearance is 0,3mm
 Design rule: Trace – Trace clearance is 0,24mm
 Design rule: Copper Pour – Trace clearance is 0,24mm
 Design rule: Copper Pour – Pad clearance is 0,4mm
 Design rule: Board Edge – ALL clearance is 0,5mm
 Rule of Design PCB:
 All SMD components should be placed on the Bottom layer and all
TH components should be placed on the Top layer.
 Signal traces should be as short as possible.
 Components should be grouped together in a logical way by function.
Poor grouping results in long traces, difficulty in routing and a
poor PC board.

Row Driver

8 x 8 Dot Matrix Display

Amplifier

Power

Column
Driver

 Use mitred or rounded corners so noise is minimized. (Does not


apply to T intersections).

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 Sharp angle can cause noise injection into other tracks on the PCB.
Therefore all corners should be rounded or mitred (angled) by 45
deg.

L>W

 While we cannot produce a silk screen layer on our milled boards,


Competitors should ensure reference designators and other needed
information is present in the assembly documentation. All text should
be in the same direction, ideally. There may be times where space
does not permit this, and in this case the competitor should place the
designation in a location that most clearly identifies where the
component is located, or other important information related to the
component.
Text should be readable in two directions only.

J1 D1
1 R1 C4 +
IC2

C3

R2 IC1
C1

Q1 R5
R3
R4

C2 R6

 There should be no overlap of text onto other text or outlines.

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 Polarized or Orientation Component Marking
Components that have a polarity should be marked on the
assembly documentation. Non-polarized components should also be
indicated through markings on the assembly.

Notice that D1 and C4


J1 D1
1 R1 C4 + show markings that
indicate polarization. ICs

IC2

C3
R2 IC1
show markings indicating

C1
orientation.
Q1 R5
R3
R4

C2 R6 Resistors have no marking


indicating orientation or
polarization.

 Jumper Wires

Jumper wires should be short, straight and not diagonal or crooked.

 Do not place jumpers under components.

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 Power track not allowed between pin IC

 T-junction

 There must not be any country/competitor indication on the PCB Layout.


 You are to place the components following the instuction.
 Compelete the design and save to :
 PCB Bottom Layer.pdf (scale 1:1)
 Component Placement Side bottom overlay.pdf (scale 1:1)
 Component Placement Side top overlay.pdf (scale 1:1)
 All schematics. Pdf

c. Build and Test Hardware design project (Time limit: 2.0 Hr)
 Assemble PCB, and check its operation.
 Completing the project, submit all the product and documents.

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3. PROJECT OVERVIEW
The circuit is a maze controller. There are 2 separated parts:
1. Responsible to control the servo output based on the input frequency.
Channel A creates a reference to X motor and channel B to the Y motor.
2. Responsible to create the start/stop signal. The metallic ball touches
metallic contacts in the beginning and in the end of the maze. The circuit
enables a wave sign in the output when a start pulse is generated (at the
beginning) and disable it when a stop pulse is generated (in the end).
Functionally, the smartphone app generates a sine wave that has its frequency
changed using the phone‟s accelerometer. Each audio channel is controlled by
one axes of the accelerometer.
The smartphone is not necessary, all waves can be created by the function
generator and the output generated signals can be checked using the
oscilloscope. Of course, if the circuit works properly it can be connected to the
smartphone!

Maze Controller
Board

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MAZE CONTROL APP
Data Accelerometer

Frequency Out Audio

Audio R Hz

Audio L Hz

ON/OFF

#app will be uploaded in february

Block Diagram

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Part List

No. Qty. Value / Tipe Part Information

1 1 IC 7402 OR Gate, DIP 14

2 2 IC 7404 NOT Gate, DIP 14

3 2 IC 7408 AND Gate, DIP 14

4 2 IC 7493 Binary Counter, DIP 14

5 2 IC NE555 Single precision timer DIP 8

Quad differential
6 1 IC LM339
comparators, DIP 14

7 1 FCS 9013 Traonsistor, DIP TO-92

8 2 1N4148 Diode

9 1 GREEN LED 5mm

10 1 Relay SPDT 5V

11 2 Header 3x1

12 5 Test Point 1 Pin

13 2 Push Button 2 pin

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No. Qty. Value / Tipe Part Information

14 >1 Resistor standard DIP 1% 1/4W

15 >1 Capasitor standard DIP

16 4 Spacer 10mm Metal spacer M3

17 2 Motor Servo SG90 9G

18 1 3.5mm jack handphone

19 1set Mechanic maze

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4. Competence
 Competitor can understanding :
 Datasheet component (Ex.74ls390)

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 Truth table

 Time Chart

 Competitor can design digital and analog circuit.


 Design PCB Layout following standard rule.

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Modul 2
ASSEMBLY PROJECT

Foto:
Rahmat Hidayat (Sumatera Utara)

Test Project Document


LKS_2018_ASM_EN

Submitted by:
Name : Tim Elektronika LKS ASC WSC
Member : ASC WSC Team ID
Type : Open Project
Time : 4 Hours
Point Skill Electronics
Indonesia Skills : 20LKSPoints
Competition/ SMK Nasional
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1. INSTRUCTIONS
Competitors are given 4 hours to complete an electronics assembly
project. This test project shall access competitors in the following areas:

a. Ability to assemble an electronic project based on given drawings,


specifications and instructions like :

 Schematic Diagrams
 PCB Layout Diagrams
 Assembly Photographs
 Component Part Lists
 Component Data Sheets

b. Ability to verify proper operation of an electronic project after assembly


like :

 Interpret test specifications


 Demonstrate proper operation of complete project

2. DESCRIPTION PROJECT AND TASKS

Assembly of this project is the digital power supply. The microcontroller


used in the circuit is ATMEGA 16, a member of Atmel‟s AVR microcontroller
family. The main features of the power supply are the adjustable output voltage
level and protection current limiter. Character 16x 2 of LCD is used as a control
interface to set the parameters of voltage and current, and as displays for
monitoring the actual values of voltage and current parameters that must be
controlled. The output voltage of this device is 0-13 volts and the current is 1.5
amperes.

The Digital Power Supply Unit conforms to the following specifications:

Digital Power Supply Unit SPECIFICATIONS


NO CRITERIA REQUIREMENTS
1. Rated Input Voltage 220 VAC (+/-) 10%

2. Rated Output Voltage Span 0V to 13VDC

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3. Set Voltage Accuracy Set Voltage (+/-) 100mV

4. Output Voltage Ripple < 50mVAC


The Digital Power Supply Unit can be operated with the following controls:

FRONT PANEL CONTROL


SYM DESCRIPTION FUNCTION

SW1 SWITCH Turn „ON‟ & „OFF‟ Power Supply Unit

Navigate continuously through the following


S2 MENU
modes:

S3 UP Increase Set Voltage

S4 DOWN Decrease Set Voltage

S5 OK Program Run / Function

JA +OUTPUT Power Supply DC Output Voltage (+)

JB -OUTPUT Power Supply DC Output Voltage (-)

LCD 1 LCD PANEL Display File List and the operation of product

Fig 1 : Assembly Project 3D view

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Fig 2 : Block Diagram Assembly Project

3. INSTRUCTION TO THE COMPETITOR


Time limit is 4 hours.

Complete this Assembly Project using given materials and documents.

 Diagram list
 Schematic : Main PCB, Panel PCB
 Component Layout : Main PCB Top, Main PCB Bottom, Panel PCB
Top, Panel PCB Bottom
 Photographs for assembling
 Operating description
 Parts list

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4. Parts list (BOM)
4.1. Main PCB

No. Qty Value Description Part Number


1 1 0.33 Resistor, 5W, 5% R35
2 1 470 Resistor SMD 0805 R2
3 1 1k Resistor SMD 0805 R5
4 1 1k8 Resistor SMD 0805 R31
5 3 4k7 Resistor SMD 0805 R1, R30, R32
6 1 5k6 Resistor SMD 0805 R34
R3, R16, R17, R18, R19,
7 15 10k Resistor SMD 0805 R20, R21, R22, R23, R24,
R33, R26, R27, R28, R29
R4, R6, R7, R8, R9, R10,
8 12 20k Resistor SMD 0805 R11, R12, R13, R14, R15,
R25
Multi turn variable
9 1 10K VR1
resistor
10 2 22pF Capacitor SMD 0805 C10, C11,
11 5 100nF Capacitor SMD 0805 C6, C8, C9, C12, C13
Aluminium electrolytic
12 2 22uF/35V C3, C5
capacitors, 5× 5 dia
Aluminium electrolytic
13 2 330uF/25V C4, C7,
capacitors, 10× 10 dia
Capacitor, Electrolytic,
14 1 2200uF/25V C1
2 mm pitch, 12 mm dia
Capacitor, Electrolytic,
15 1 4700uF/25V C2
2 mm pitch, 16 mm dia
IN4001/ Diode 1 A, footprint
16 2 D2, D6
IN4002 DO-41
Bridge diode 3A, size
17 1 KBPC308 D1
15.9x15.9 mm
3A General Purpose
18 1 1N5401 Plastic Rectifier, D7
footprint DO-201AD
1A General Purpose
19 1 1N4148 Plastic Rectifier, D4
footprint DO-35
20 1 8V2 Diode zener 1 watt DZ1
21 1 RED LED led SMD 0805 D3
SMD Transistor, Q1, Q2
22 2 2N2222
footprint NPN

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No. Qty Value Description Part Number
SOT23_N

Transistor NPN
23 1 BC547 Q3
footprint SOT54
Transistor PNP
24 1 BC557 Q4
footprint SOT54
25 1 DB139 Transistor NPN Q5
26 1 TIP35 Transistor NPN Q6
5 V 1A Step-Down
27 1 MC78M05 Voltage Regulator, U1
footprint 369A-03
12 V 1A Step-Down
28 1 MC78M12 Voltage Regulator, U2
footprint 369A-03
Atmega16A Microcontrollers,
29 1 U3
- AU footprint 44A_N
SMD Crystal, Load
11.059200
30 1 Capacitance 10,0pF to Y1
MHZ
75.0pF
31 1 TMB12A05 Buzzer BZ1
SMD Push button size
32 1 B3F-1020 S1
5 mm
Relay 12 Volt, 5 pin,
33 1 Relay RL1
SPDT, omron
2x5pin Male
10 Pin, male, Pin
34 1 Header With P4
Header, 2.54 mm Pitch
cover ST
1x6Pin male
Header 6 Pin, Male, Pin
35 1 P3
single ST, Header, 2.54 mm Pitch
yellow
T-block 2 2-Pin Terminal Blok, 5
36 2 P1, P5
pin mm Pitch
1x2 white MHDR 1x2, 2.54 mm
37 1 P2
connector Pitch
X1, X2, X3, X4, X5, X6, X7,
38 9 1 pin plug 1 pin test point
X8, X9

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4.2. Panel PCB

No Qty Value Description Part Number

1 1 270 Resistor SMD 0805 R36


Multi turn variable
2 1 5K VR2
resistor
3 1 100nF Capacitor SMD 0805 C14
SN74HC59 Register IC SMD,
4 1 U4
5D footprint D016_N
Tactile Switch size
5 4 B3F-4050 12x12 mm, DC 24 V, SW1, SW2, SW3, SW4,
50 mA
6 4 knob Tactile Switch square knob Switch
TG12864E- 16x2 alphanumeric
7 1 LCD1
01XWBV LCD
2x5 pin
Male 10 Pin, male, Pin
8 1 P6
Header With Header, 2.54 mm Pitch
cover ST
9 3 Plug 1 pin Plug test point 1 pin X10, X11, X12

4.3. Power Supply Box

No Qty Value Description Part Number


1 1 AC Cord Cable
Inlet, 250V, 2.5A,
2 1 770W-X2/12 28x16 mm, Panel P7
Thickness + fuse
Rocker Switch,
3 1 SLE10A2 125VAC, 10A, SPST, SW1
20 mm dia
Step Down
Transformer,
4 1 T1
110/220/230 primary,
0- 18V
Fan DC 12 Volt,
5 1 F1
60x60mm
6 1 Fan nets 60x60 mm
7 2 IDC socket S10 - A1 P4‟, P6‟
Banana socket red,
8 1 JA
8mm dia
Banana socket black,
9 1 JB
8mm dia

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Heat sink for TIP35
10 1
35mmx12.5mm
11 1 1,5 M Wire, 18 AWG, Black
12 1 1,5 M Wire, 18 AWG, Red
13 1 20 cm layer cable, 10 layer
Shrinkable Tubing,
14 1 15 cm
Black, 4mm dia
Shrinkable Tubing,
15 1 15 cm
red, 4mm dia
Spacer, metal,
16 8
Hexagonal, M3x10 mm
Screw Pan Head,
17 7
metal M3x8mm
Screw, Pan Head,
18 4 Brass, Nickel Plated,
M3x35mm
Screw, Pan Head,
19 2 Brass, Nickel Plated,
M4x8 mm
Hexagonal Nut M3,
20 6
metal
21 2 Hexagonal Nut M4
Cable Ties, 2.5x100
22 10
mm
Acrylic Casing 19 x 14
23 1
x 6 cm

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5. Proses Assembly
Pastikan semua komponen lengkap

Fig 20 Semua komponen

5.1. Perakitan Main PCB


Merakit main PCB berdasarkan main PCB skematik dan main PCB list
komponen.
Spesifikasi ketinggian
(1) IC ATmega 16 sudah dipasang oleh panitia.
(2) Kapasitor, buzzer, transistor SMD SOT23, resistor DIP, Resistor SMD Diode, Led,
Socket, connector, Relay, T- block, Switch button, harus menempel pada
permukaan PCB.
(3) Transistors tipe TO 92 adalah 5mm – 7mm dari permukaan PCB.
(4) Transistor SOT 32 dan TO-218 sesuai dengan kondisi manufaktur kaki komponen.

Fig 21 Main PCB Atas

(5) Pasanglah komponen terkecil dan terpendek terlebih dahulu.

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(6) Berikut adalah hasil solderan main PCB

Fig 22 Main PCB Atas, Setelah Assembly

Fig 23 Main PCB Bawah

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5.2. PANEL PCB ASSEMBLY
Perakitan PCB depan berdasarkan Panel PCB skematik dan Panel PCB list
komponen.

a. Assembly kapacitor, Resistor, IC, test point, variable resistor dan header 2 x5 pin
pada sisi bawah dari PCB.

Fig 24 Panel PCB Bawah

b. Assembly Push Button pada sisi atas dari PCB, diberi jarak +- 3mm dari PCB.

Fig 25 Assemble Push Button

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c. Gabungkan LCD dan PCB depan dengan 16 pin Header.

Fig 26 Gabungkan LCD dengan 16 pin header

Assemble LCD pada atas of PCB

Fig 27 Assembly LCD

Fig 28 Panel PCB Atas, Setelah Assembly

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5.3. Assembly dan pengkabelan instalasi power.
a. Assembly Inlet AC, Kipas, Jaring Kipas, Rocker Switch, Transformer, Soket Banana
pada kotak acrylic.

Fig 29 Assembly asesoris

Pemasangan Inlet AC, jangan lupa pasang fuse pada koker inlet

Fig 30 Assembly Inlet AC

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Fig 31 Assembly Transformer

Fig 32 Assembly Rocker Switch

Fig 33 Assembly soket banana

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Fig 34 Assembly kipas dan jarring kipas

b. Assembly dan pengkabelan instalasi power.

Fig 35 Pengkabelan instalasi power

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c. Assemble main PCB and panel PCB on the box acrylic.

Fig 36 Assembly main PCB dan panel PCB

Fig 37 Assembly main PCB

Fig 38 Assembly panel PCB

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d. Wiring connection.
Pengkabelan sesuai dengan KKIN_NAS_VI_ASM _06_ID.pdf, Gambar instalasi.

Fig 39 Jalur pengkabelan

Fig 40 Pengkabelan Inlet AC

Fig 41 Pengkabelan transformer primer (0 – 220 V)

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Fig 42 Pengkabelan transformer sekunder (0 – 18 V)

Fig 43 Pengkabelan rocker switch

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Fig 44 Pengkabelan soket banana

Fig 45 pengkabelan soket IDC

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Fig 46 Panjang IDC socket

Fig 47 Panjang IDC socket

40 CM ± 0.5 cm

Fig 48 Panjang DC socket

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Hasil Perakitan

Fig 49 Hasil perakitan

Fig 50 Hasil perakitan

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Modul 3
FAULT FINDING, REPAIR AND
MEASUREMENT

Foto:
Hadi Hardiansyah (Jawa Barat)

Test Project Document


LKS_2018_FFRM_EN

Submitted by:
Name : Tim Elektronika LKS ASC WSC
Member : ASC WSC Team ID
Type : Open Hardware
Time : 4 Hours
Point Indonesia Skills Competition/
: 25 PointsLKS SMK Nasional
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1. Description
Name of project is Frequency analyzer.

Figure 1. PCB “8 Band Audio Spectrum Analyzer”

This project is 8 Band Audio Spectrum Analyzer. A spectrum analyzer


measures the magnitude of an input signal versus frequency within the full
frequency range of the instrument. The primary use is to measure the power of
the spectrum of known and unknown signals.

By analyzing the spectra of electrical signals, dominant frequency, power,


distortion, harmonics, bandwidth, and other spectral components of a signal can
be observed that are not easily detectable in time domain waveforms. These
parameters are useful in the characterization of electronic devices, such as
wireless transmitters.

Spectrum analysis can be used at audio frequencies to analyse the harmonics


of an audio signal. A typical application is to measure the distortion of a
nominally sine wave signal.

The display of a spectrum analyzer has frequency on the horizontal axis and the
amplitude displayed on the vertical axis. To the casual observer, a spectrum
analyzer looks like an oscilloscope and, in fact, some lab instruments can
function either as an oscilloscope or a spectrum analyzer.

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This project uses 8 active band pass filter which consist of 30Hz, 70Hz, 140 Hz,
400 Hz, 1kHz, 2kHz, 8kHz and 16 kHz band pass filter that used LM324 as the
main op-amp.

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Skill Electronics
8 x 10 Matrix LED Display
2. Block diagram

BAND PASS FILTER


30 Hz

BAND PASS FILTER


70 Hz

BAND PASS FILTER 10 step

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140 Hz Bar
Graph
Meter
BAND PASS FILTER
400 Hz 8-Channel
PRE AMPLIFIER
Analog
INPUT and Shift Ground
The block diagram is shown in Fig 2.

Multiplexer
Reference Signal
BAND PASS FILTER
1 kHz

BAND PASS FILTER


2 kHz 8 Line LED Driver

BAND PASS FILTER 8 Line Inverter


8 kHz

Rev. 17-01-2018
BAND PASS FILTER 3 to 8 Line
16 kHz Decoder/
Demultiplexer

3 Bit
BINARY

Figure 2. Block diagram for “ 8 Band Audio Spectrum Analyzer”


COUNTER

CLOCK
SIGNAL

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3. Recording of faults
Record the evidence of each fault using the attached sheets and symbols
shown below.

FAULT DESCRIPTION FAULT DESCRIPTION


SYMBOL SYMBOL

Open Stuck at high voltage


(part, wire or PCB (pin, input, output,
trace) etc.)

Short Stuck at low voltage


(part, wire or PCB (pin, input, output,
trace) etc.)

Part with larger value Incorrect part


(resistor, capacitor, ? number or wiring
etc.) connecting

Part with smaller Wrong Polarity


value
+/-
(resistor, capacitor,
etc.)

Reference component locations accurately. Refer to examples shown


below.

LOCATION CATEGORY SAMPLE

Power +5V / +12V / -5V / -12V / GND


Pin of IC IC2_8
Component of R/C/L R7_1(left/up:1 right/down:2)
Test Point TP1
Between Two Components R1-R2

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Example

DEFECTIVE PART FAULT SYMBOL

Fault #1 IC2_8 - R7_1

BEFORE AFTER

Measurement
#1 Tegangan pada R7_ 1 Tegangan pada R7_ 1
dibawah 1V mendekati 5V

Node: R7_1___

DEFECTIVE PART FAULT SYMBOL

Fault #2 R1

BEFORE AFTER

Measurement 5.00V 5.00V

#2
1.00V/DIV
1.00ms/DIV
GND GND

Node: _TP1______

2ms 4ms

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4. Recording of Measurement
Each measurement should show how to measure by using the symbol as
below.

TOOLS SIMBOL

Power Supply

Voltmeter V

Ammeter A

Oscilloscope

FG
Function Generator

GND

Example measuring schematic:

Vcc
TP2

TP1
5V

CH1 CH2
GND

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5. Best Practice to Make jumper wire
4.1. Wire routing

Unless otherwise specified by high speed/high frequency requirements,


route jumper wires the shortest route in straight legs as possible, avoiding test
points, to points of termination. Allow enough length for routing, stripping and
attachment.

Jumper wire routing on assemblies having the same part number should
be the same pattern. Routing shall be documented for each part number and
followed without deviation.

Do not allow jumper wires to pass over or under any component,


however, they may pass over parts such as thermal mounting plates, brackets
and components that are bonded to the PWB.

Jumpers may pass over solder lands if sufficient slack is provided so they
can be moved away from the solder land for component replacement. Except
for connectors at the edge of the board, do not pass jumpers through
component foot prints unless the layout of the assembly prohibits the routing in
other areas. Do not pass jumpers over patterns or vias used as a test point..

4.1.1. Target

 Wire routed shortest route.


 Wire does not pass over or under component.
 Wire does not pass over land patterns or vias used as points.
 Wire does not cross component footprint or lands.

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4.1.2. Defect
 Wire routed under or over components.
 Routing of wire(s) overhang or wrap over the edge of the board.
 The wire is loose and can extend above the height of adjacent
components.

4.2. Supported Holes


4.2.1. Target :
 Wires soldered into a PTH/Via hole

4.2.2. Defect :
 Wire soldered into PTH with component lead

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4.3. Wrapped Attachment
4.3.1. Target :
 Wire is wrapped a minimum of 90° on a flat lead or 180° on a round lead.
 Acceptable solder connection at wire/lead interface.
 Wire contour or end is discernible in the solder connection.
 Wire overhang of component termination does not violate minimum
electrical clearance.

4.3.2. Defect :
 Wire is wrapped less than 90° on flat or less than 180° on round leads.
 Wire overhang violates minimum electrical clearance

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Answer Sheet

Competitor Name Table Number Signature

Fault-Answer Sheet

DEFECTIVE PART FAULT SYMBOL

Fault #1

BEFORE AFTER

Measurement
#1

Node: _______

DEFECTIVE PART FAULT SYMBOL

Fault #2

BEFORE AFTER

Measurement
#2

Node: _______

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DEFECTIVE PART FAULT SYMBOL

Fault #3

BEFORE AFTER

Measurement
#3

Node: _______

DEFECTIVE PART FAULT SYMBOL

Fault #4

BEFORE AFTER

Measurement
#1

Node: _______

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DEFECTIVE PART FAULT SYMBOL

Fault #5

BEFORE AFTER

Measurement
#5

Node: _______

DEFECTIVE PART FAULT SYMBOL

Fault #

BEFORE AFTER

Measurement
#

Node: _______

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Measurement-Answer Sheet

Measurement #

Schematic Measurement

Measurement Output

Vertical
Settings:

/div

Horizontal
Settings:

/div

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Verify graph output

Calculate the voltage using the formula

......

Calculate the frequency using the formula

......

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Schematic #1

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Schematic #2

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Schematic #3

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PCB TOP & BOTTOM

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PCB TOP

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PCB BOTTOM

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#Info Tambahan

Silahkan download datasheet, schematic pdf, PCB dan video pada website:

www.inaskills-electronics.com/lks2018

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Modul 4
SOFTWARE DESIGN

Foto:
Handriko (Bangka Belitung)

Test Project Document


LKS_2018_ESP_EN

Submitted by:
Name : Tim Elektronika LKS ASC WSC
Member : ASC WSC
Type : Open hardware & Colse Firmware
Time : 4 Hours
PointIndonesia Skills Competition/
: 25 Points
LKS SMK Nasional
Skill Electronics Rev. 17-01-2018 74 of 91
1. Description
Hardware used is Line Follower V1.2 robot (LF V1.2). LF V1.2 is a small
robot. LF V1.2 is a small robot with a size of 100 x 100 mm. Type of motor used
is N20 with speed 1000Rpm at 12V. The main control of this robot is a
microcontroller type ATmega16/32 and there is include a downloader type
USBAsp on this robot, so that directly connected to the computer when the user
is doing the programming. This robot can work with a voltage power of 6 to 12
Volts, but in competition later, this robot uses voltage 7.4V (LIPO 2S 850mA).
Competitor have to program the Line Follower following instruction until can run
normally in the track.

Figure 1. Line follower V1.1

2. Description of project and tasks


The task is split into 2 programming tasks.
1. Functions to control the hardware.
2. Running robot following line track.

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3. Software
All competitors are required to use Atmel studio 7. Template, libraries and
tutorials will be uploaded on the website www.inaskills-electronics.com/lks2018.
In the competition participants will be given a template by the jury.

4. Interface
This Line follower use interface:
 6 light sensor (ADC)
 LCD Character 16x2
 4 push button
 2 Motor with gearbox (PWM)

5. Schematic
5.1 Power Supplay

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5.2 Controller

5.3 Sensor

5.4 User Push Button

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5.5 4 bit LCD 16x2

5.6 Motor logic controller

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5.7 Driver motor DC

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5.8 Pasive Buzzer

5.9 Downloader

5.10 USB and connector

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6. Detail hardware

Sensor

Roda
Roda
Ø34 mm
Ø34 mm

Downloader
Atmega
USB Asp
16/32

V booster

USB
Ball Caster
Downloader
H=10mm

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7. Track design competition

120,0

100

START
18
FINISH

12
240,0

60
17
20

52
15
26 mm

10
31
20 mm

10
21

START

100

#Design changed 30% during the competition

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8. PCB Design

6.1 PCB TOP & BOTTOM

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6.2 PCB TOP

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6.3 PCB BOTTOM

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List Components.

Comment Designator Value Footprint Quantity


8-Bit AVR U7 Atmega 8 32A_M 1
Microcontroller
8-Bit AVR U6 Atmega16 44A_M 1
Microcontroller
Capacitor C11, C12, C20, C21 22pF C0805 4
Capacitor C5, C15, C18, C19, C22, C26, 100nF C0805 10
C27, C29, C33, C34
Capacitor C4, C6, C7, C8, C13, C14, 100nF C1206 8
C30, C32
Polarized Capacitor C1, C2, C3, C17 470uF CAPOL-X-7343-43 4
(Surface Mount)
Polarized Capacitor C28 220uF CAPOL-X-7343-43 1
(Surface Mount)
Capasitor C16 1000uF capSMD10 1
Resistor R31, R33 150K Chip_R0805 2
Resistor R32, R34 100K Chip_R0805 2
Resistor R41 1.5K Chip_R0805 1
Resistor R42 680 Chip_R0805 1
Resistor R10 1K8 Chip_R0805 1
Resistor R35, R36, R37, R38, R39, R40 68K Chip_R0805 6
Schottky Diode D2 SS36 DO214AC 1
Default Diode D5, D23, D24, D25, D26, D31, M7 DO214AC 10
D32, D33, D34, D35
Default Diode D1 1N5402 DO-201-15 1
Double-Pole, Double- S5 Switch 6pin ON OFF DPDT-6 1
Throw Switch
C9, C10 470uF D_tantalum 2
Crystal Oscillator Y1, Y2 12MHz HC-49/SM 2
Header, 2-Pin P1 Header male 2x1 HDR1X2 1
Header, 3-Pin, Dual P2 Header male 3x2 HDR2X3_CEN 1
row
Magnetic Transducer LS1 Pasive buzzer SMD KLJ-9025 1
Buzzer
Inductor L1 47uH L-MS127 1
Liquid Crystal Display LCD1 LCD 16x2 neumaric LCD 1602 1
LED D10, D11 Blue led LED0805 2
Typical INFRARED D19, D20, D27, D28 LED LED0805 4
GaAs LED
Typical INFRARED D3, D4 LED LED_0805 2
GaAs LED
USB 2.0, Right Angle, J1 Mini USB Mini USB AB - 1
SMT, AB Type, 440479
Receptacle, 5 Position,
Black
Motor, General Kind B1, B2 Motor DC 12V N20 Motor + 2
1000Rpm Wheel 2
Dual Full Bridge Driver U9 L298P SO20_M 1
Resistor R1, R9 1K R0805 2
Resistor R11, R12 4K7 R0805 2
Resistor R2 8K2 R0805 1
Resistor R26, R27, R28, R29 680 R0805 4

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Comment Designator Value Footprint Quantity
Resistor R3, R16, R17, R20, R21, R25, 220 R0805 7
R30
Resistor R4, R5 1K5 R0805 2
Resistor R6, R13, R18, R19, R22, R23 10K R0805 6
Resistor R7, R8, R14, R15, R24 68 R0805 5
Sensor U0, U1, U2, U3, U4, U5 QRE1113g / Sensor LF 6
TCRT5000
SMD Solder Jumper CB1, CB2, CB3 SJ 3
Switch S0, S1, S2, S3, S4 SMD 2 Pin SKQY_SMD Tact 5
Switch
Zener Diode D6, D7 3V3 SOD-80 2
Zener Diode D8, D9, D18 1N4148 SOD-80 3
Quad 2-Input NOR U10 CD4001 SOIC14A_M 1
Buffered B series Gate,
14-Pin SOIC
NPN Bipolar Transistor Q1, Q2 9013/3904 SOT23_M 2
Precision 500mA U11 L78M05 TO-252 1
Regulator
SIMPLE SWITCHER® U8 LM2576-ADJ TS5B_M 1
3A Step-Up Voltage
Regulator
Roda Pololu roda 34mm 2
Battry Lipo 2S 850mA 1
Charger Charger Lipo 2S 1
Ball caster Metal H10mm 1
Pcb PCB LF Inaskills Design 1

Hit sink 9x9mm 2


pengikat battery Valco Strap 10mmx150mm 2

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#Info Tambahan

Silahkan download\ template, tutorial, schematic pdf, dan video pada website:

www.inaskills-electronics.com/lks2018

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INFORMASI PENTING

1. Baca dan pahami secara baik rule pedoman LKS.

2. Baca dan pahami secara baik Technical Description (TD) bidang


Electronics.

3. Software yang digunakan dalam LKS 2018 sesuai dengan TD.

4. Peserta wajib membawa alat sesuai dengan yang tercantum pada TD,
tolong selalu aktif dalam group/ email/ website ina skills terutama tujuh
hari sebelum perlombaan untuk memastikan perubahan dari panitia
tentang alat sesuai dengan kebijakan angaran dari direktorat.

5. Alat yang dibawa oleh peserta dari sekolah harap dibawa pada saat
familiarisasi alat.

6. Peserta dibolehkan merubah tataletak alat dan pengkabelan pada work


station/ meja kerja sesuai dengan kebutuhan peserta.

7. Software penunjang harus diinstal pada saat peserta masih berada


didaerah/ tempat latihan, dikarenakan waktu familiarisasi yang singkat.
Juri tidak bertanggung jawab jika pada saat lomba terjadi ketidak siapan
software pada komputer peserta.

8. Peserta dan pembimbing masing masing harus membawa laptop. Laptop


peserta akan ditinggal ditempat lomba saat familiarisasi hingga
perlombaan selesai (tidak diperkenankan dibawa kepenginapan saat
kompetisi). Untuk latihan di tempat penginapan peserta bisa
menggunakan laptop pembimbing. Catatan: untuk laptop peserta
disaranan disk dalam kondisi kosong atau tidak ada data yang penting.

9. Selalu aktif untuk membuka website www.inaskills-electronics.com untuk


mendapatkan tutorial tutorial dan informasi tambahan penting dalam
persiapan LKS 2018.

10. Saat kompetisi peserta tidak diperkenankan membawa HP dan memory


stick diarea tempat lomba tanpa seizin juri.

Indonesia Skills Competition/ LKS SMK Nasional


Skill Electronics Rev. 17-01-2018 89 of 91
11. Saat perlombaan berlangsung tidak ada buku atau kertas diatas meja
dan semua tas harus dimasukan dalam loker yang telah disediakan oleh
panitia.

12. Utamakan keselamatan dan kesehatan kerja. sarung tangan akan


disediakan oleh panitia.

13. Jika peserta terdapat melakukan kecurangan dengan bukti yang jelas
maka akan dikenakan pengurangan nilai atau diskualifikasi.

14. Persiapan LKS yang sangat singkat, tolong manfaatkan waktu sebaik
baiknya, perkuat dasar/ basic.

15. Jadwal istirahat peserta menyesuaikan waktu ibadah setempat. Bagi


Muslim harap untuk membawa sendal jepit dan sajadah serta mukena
bagi perempuan.

16. Jika peserta dari dearah kesulitan dalam pencarian bahan latihan, bisa
menghubungi kami. Jangan sampai bahan menghambat kita dalam
belajar.

Indonesia Skills Competition/ LKS SMK Nasional


Skill Electronics Rev. 17-01-2018 90 of 91
SELAMAT BERLATIH !!!
Soal akan berubah minimal 30%

Mungkin ada informasi tambahan mengenai persiapan LKS NASIONAL 2018,


Mohon selalu membuka web inaskills

www.inaskills-electronics.com/lks2018

Forum group WA silahkan hub email: inaskills.electronics@gmail.com

Dengan format pesan

Asal Sekolah :

Provinsi :

Nama Pembimbing :

TTL Pembimbing :

No Handphone Pembimbing :

Nama Peserta :

TTL Peserta :

No Handphone Peserta :

Indonesia Skills Competition/ LKS SMK Nasional


Skill Electronics Rev. 17-01-2018 91 of 91

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