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‎IOT System PCB/README.md‎

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This directory contains all PCB design files for the IoT Monitoring System used in the Open Solar Cooling Hub. The design was created using Altium CircuitMaker.
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# IoT System PCB – Open Solar Cooling Hub (KiCAD Approach)
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# How to Open and Modify the PCB Design
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# Download CircuitMaker
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Visit the official download page:
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https://circuitmaker.com/Download
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Click “Download CircuitMaker” and follow the instructions for your operating system (Windows only).
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# Install CircuitMaker
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Run the downloaded .exe file.
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Follow the installation wizard steps.
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After installation, launch the software.
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# Sign In or Register
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You will need an Autodesk/Altium account to use CircuitMaker.
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If you don’t have one, register during the first launch.
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This is required since CircuitMaker uses cloud-based project management.
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# Load the Project
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Open CircuitMaker.
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open this link: https://365.altium.com/files/FD40F198-177B-4D2F-B652-184317044322
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Open Solar Cooling Hub PCB Project - Enaccess.PrjPcb
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View and edit schematics using .SchDoc
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Modify PCB layout using .CmpcbDoc
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Generate new Gerber files for manufacturing
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Adjust routing, component placement, and net labels
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Re-export fabrication files via the .OutJob files
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# IoT System PCB – Folder Structure and Content Description
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This folder contains all the files required for:
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- PCB **fabrication**
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- **Assembly** (PCBA)
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- **Start 3D case modeling**
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- Full **project source files** and **schematics**
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The structure follows standard hardware development and manufacturing practices.
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---
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## 1. FAB – Fabrication Files
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Located in:
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`FAB-Open Solar Cooling Hub PCB Project - Enaccess-A.1/`
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These are the files required by PCB manufacturers to fabricate the **bare PCB** (without components).
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### Gerber Files
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| Extension | Description |
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|-----------|--------------------------------------------|
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| `.GTL` | Top copper layer |
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| `.GBL` | Bottom copper layer |
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| `.GTO` | Top silkscreen layer |
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| `.GBO` | Bottom silkscreen layer |
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| `.GTS` | Top soldermask |
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| `.GBS` | Bottom soldermask |
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| `.GTP` | Top paste layer |
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| `.GBP` | Bottom paste layer |
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| `.GKO` | Board outline / keep-out layer |
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| `.GM1`–`.GM16` | Mechanical layers, documentation |
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| `.REP`, `.RUL`, `.apr` | Reports and design rules |
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| `.APR_LIB` | Aperture macros used in CAM process |
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---
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### NC Drill Files
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Located in: `NC Drill/`
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| File | Description |
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|----------------|--------------------------------------|
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| `.DRR` | Drill report summary |
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| `.TXT` | Excellon drill file (for CNC) |
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| `.LDP` | Layer pair definition |
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This repository contains the PCB design files for the IoT Monitoring System used in the Open Solar Cooling Hub, created and managed using **KiCAD**. The project includes schematics, PCB layout, fabrication files (Gerbers, drill files), assembly files (BOM, Pick & Place), and a 3D model for enclosure design. This guide explains how to open, modify, and produce the PCB using KiCAD.
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### ODB++ Format
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Located in: `ODB/`
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This is a **comprehensive PCB manufacturing format** used by advanced fabrication services.
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Contains:
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- Layer definitions (copper, soldermask, silkscreen)
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- Stackups and materials
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- Drill and via data
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- Netlists
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- Profile and board outline
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## Prerequisites
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Use this folder if your manufacturer supports **ODB++** instead of Gerbers.
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1. **Install KiCAD**:
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- Download KiCAD (v7 or later recommended) from [kicad.org](https://www.kicad.org/download/) for Windows, macOS, or Linux.
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- Install and launch KiCAD.
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---
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## 2. ExportSTEP – 3D Mechanical Model
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| File | Purpose |
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|----------------------------|----------------------------------|
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| `IOT B oard FIle.step` | 3D model of the PCB for enclosure design in CAD tools like OpenSCAD, Fusion 360 or SolidWorks |
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2. **Required Files**:
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- `Solar Cooling Project.kicad_pro`: KiCAD project file.
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- `Solar Cooling Project.kicad_sch`: Schematic file.
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- `Solar Cooling Project.kicad_pcb`: PCB layout file.
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- Reference files (from original Altium design for validation):
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- Gerber files (`Solar Cooling Project-F_Cu.gbr`, `B_Cu.gbr`, etc.)
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- Drill files (`Solar Cooling Project-PTH.drl`, `NPTH.drl`)
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- BOM (`BOM_PartType-Open Solar Cooling Hub PCB Project.xlsx`)
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- Pick & Place (`Pick Place for IOT B oard FIle.txt`)
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- Assembly PDF (`Assembly.PDF`)
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- 3D model (`IOT B oard FIle.step`)
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---
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## 3. PCBA – Assembly Files
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Located in:
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`PCBA-Open Solar Cooling Hub PCB Project - Enaccess-[NO VARIATIONS]-A.1/`
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These are used during **component assembly** (manual or SMT machine).
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## Folder Structure and Content Description
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### 📋 Bill of Materials (BOM)
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The project follows standard hardware development practices, with files organized for PCB fabrication, assembly, and modification.
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| File Name | Description |
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|--------------------------------------------------------------|-----------------------------------------|
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| `BOM_PartType-Open Solar Cooling Hub PCB Project.xlsx` | List of all components, part numbers, footprints, and reference designators |
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### Pick & Place File
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| File Name | Description |
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|---------------------------------------|--------------------------------------|
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| `Pick Place for IOT B oard FIle.txt` | X/Y coordinates and orientation for all components |
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### Assembly Drawing
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| File Name | Description |
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|-------------------|-------------------------------------|
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| `Assembly.PDF` | Visual layout of components for QC and hand assembly |
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| Folder/File | Purpose |
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|-------------|---------|
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| `Gerber/` | PCB fabrication layers (copper, soldermask, silkscreen, etc.) |
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| `NC Drill/` | Drill files for PTH and NPTH holes |
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| `PCBA/` | Assembly files (BOM, Pick & Place, Assembly PDF) |
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| `ExportSTEP/` | 3D STEP model for enclosure design |
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| `Solar Cooling Project.kicad_pro` | KiCAD project file |
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| `Solar Cooling Project.kicad_sch` | Schematic file |
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| `Solar Cooling Project.kicad_pcb` | PCB layout file |
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| `README.md` | Project documentation |
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## 4. Schematic & Project Source Files
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These files allow others to **modify, recompile, or regenerate** the PCB from source using **Circuitmaker PCB Designer** or **compatible EDA tools**.
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| File Name | Description |
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|----------------------------------------------|-------------------------------------------|
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| `IOT Schematic File.SchDoc` | Main schematic diagram |
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| `IOT B oard FIle.CMPcbDoc` | PCB layout file |
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| `Open Solar Cooling Hub PCB Project - Enaccess.PrjPcb` | Project file referencing schematic and PCB layout |
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| `Open Solar Cooling Hub PCB Project - Enaccess.PrjPcbStructure` | Project structure definition |
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| `Assembly.OutJob` | Altium job file for exporting assembly files |
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| `Fabrication.OutJob` | Altium job file for generating Gerbers, drills, etc. |
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| `readme` | Notes about the project (may be edited) |
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## How to Open and Modify the PCB Design in KiCAD
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### 1. Open the Project
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1. Launch KiCAD and open `Solar Cooling Project.kicad_pro` in the project manager.
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2. This loads the schematic (`Solar Cooling Project.kicad_sch`) and PCB layout (`Solar Cooling Project.kicad_pcb`).
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### 2. Edit the Schematic
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1. Open the schematic editor (Eeschema) by clicking the schematic icon in the project manager.
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2. Verify components, connections, and net labels against the original BOM and schematic reference (e.g., exported PDF from Altium or `IOT Schematic File.SchDoc`).
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3. **Modify (if needed)**:
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- Add/remove components using KiCAD’s symbol libraries or create custom symbols.
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- Update net labels for clarity.
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- Assign footprints to each symbol via the “Assign Footprints” tool, ensuring compatibility with the BOM and Pick & Place file.
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4. Generate a netlist (File > Export > Netlist) for PCB layout.
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### 3. Edit the PCB Layout
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1. Open the PCB editor (Pcbnew) by clicking the PCB icon in the project manager.
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2. Import the netlist (File > Import > Netlist) to populate components.
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3. **Validate Layout**:
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- Compare the board outline with `Solar Cooling Project-Edge_Cuts.gbr`.
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- Verify component placements using `Pick Place for IOT B oard FIle.txt` (import via File > Import > Placement File).
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- Check routing against Gerber files (`F_Cu.gbr`, `B_Cu.gbr`) using KiCAD’s Gerber Viewer (File > Import > Gerber Files).
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4. **Modify (if needed)**:
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- Adjust component positions in Pcbnew.
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- Reroute traces to optimize the layout.
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- Update the board outline on the `Edge.Cuts` layer.
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5. **Import Drill Files**:
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- Import `Solar Cooling Project-PTH.drl` and `NPTH.drl` (File > Import > Drill Files) to ensure correct via and hole placement.
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6. **3D Verification**:
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- View the PCB in 3D (View > 3D Viewer) and compare with `IOT B oard FIle.step`.
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- Assign 3D models to footprints if needed (Footprint Properties > 3D Settings).
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### 4. Generate Fabrication and Assembly Files
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1. **Gerber Files**:
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- In Pcbnew, go to File > Plot.
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- Select layers: `F.Cu`, `B.Cu`, `F.Silkscreen`, `B.Silkscreen`, `F.Mask`, `B.Mask`, `Edge.Cuts`.
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- Output to a `Gerber/` folder.
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- Verify against original Gerbers using a Gerber viewer (e.g., KiCAD’s Gerber Viewer or Gerbv).
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2. **Drill Files**:
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- In Pcbnew, go to File > Fabrication Outputs > Drill Files.
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- Generate Excellon drill files for PTH and NPTH.
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- Output to a `NC Drill/` folder.
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3. **Bill of Materials (BOM)**:
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- In Eeschema, go to Tools > Generate Bill of Materials.
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- Export as CSV or XLSX to `PCBA/BOM.xlsx`.
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- Cross-check with `BOM_PartType-Open Solar Cooling Hub PCB Project.xlsx`.
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4. **Pick & Place File**:
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- In Pcbnew, go to File > Fabrication Outputs > Component Placement File.
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- Output to `PCBA/Pick_Place.txt`.
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- Verify against `Pick Place for IOT B oard FIle.txt`.
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5. **Assembly Drawing**:
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- In Pcbnew, go to File > Plot and export a PDF of the board layout to `PCBA/Assembly.pdf`.
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6. **3D Model**:
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- In Pcbnew, go to File > Export > STEP.
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- Save to `ExportSTEP/Solar_Cooling_Project.step`.
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### 5. Validate Outputs
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- **Gerber Comparison**: Use a Gerber viewer to ensure KiCAD-generated Gerbers match the original Altium Gerbers.
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- **BOM and Pick & Place**: Confirm component lists and placements align with the original files.
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- **Fabrication Test**: Send Gerber and drill files to a PCB manufacturer (e.g., JLCPCB) to verify acceptance.
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- **Assembly Check**: Provide BOM, Pick & Place, and Assembly PDF to an SMT service for validation.
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## Summary of Folder Contents
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## How to Use the Outputs
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| Folder / File | Purpose |
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|----------------------------------------------|---------------------------------------------|
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| `Gerber/` | PCB fabrication layers |
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| `NC Drill/` | Hole/via definitions |
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| `ODB/` | Consolidated PCB data |
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| `ExportSTEP/` | 3D mechanical model |
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| `PCBA-.../BOM.xlsx` | Component sourcing |
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| `PCBA-.../Pick Place.txt` | SMT assembly automation |
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| `PCBA-.../Assembly.PDF` | Human-readable component placement |
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| `.SchDoc`, `.CMPcbDoc`, `.PrjPcb`, `.OutJob` | Editable source files for schematic/layout |
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- **Fabrication**: Send the `Gerber/` and `NC Drill/` folders to a PCB manufacturer (e.g., JLCPCB, PCBWay).
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- **Assembly**: Provide `PCBA/BOM.xlsx`, `PCBA/Pick_Place.txt`, and `PCBA/Assembly.pdf` to an SMT assembly service.
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- **Modify/Rebuild**: Use `Solar Cooling Project.kicad_sch` and `.kicad_pcb` in KiCAD to edit the design and regenerate outputs.
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- **Enclosure Design**: Use `ExportSTEP/Solar_Cooling_Project.step` in CAD tools like FreeCAD or Fusion 360.
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## How to Use
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### To fabricate the board:
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Send the contents of the **Gerber**, **NC Drill**, and optionally **ODB** folders to a PCB manufacturer like JLCPCB.
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## Licensing
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### To assemble components:
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Send the **BOM**, **Pick & Place**, and **Assembly PDF** to an SMT service provider like JLCPCB.
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### To modify or rebuild the design:
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Open the schematic and PCB files using **Circuitmaker**, then use the **OutJob files** to regenerate outputs.
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This project is licensed under the **CERN Open Hardware License v2.0**. Ensure all modifications and derivatives retain this license.
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## Licensing Note
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All design files are licensed under the **CERN Open Hardware License v2.0**.
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## Notes
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- If the existing `.kicad_sch` or `.kicad_pcb` files are incomplete, reference the original Altium outputs (Gerbers, BOM, etc.) to rebuild the schematic and layout.
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- Use KiCAD’s built-in libraries or external sources (e.g., DigiKey, SnapEDA) for symbols and footprints not included in the project.
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- For complex modifications, consult the original Assembly PDF and 3D STEP file to ensure accuracy.
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