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5/12/2018 Beagle Esc 4 - slidepdf.com
http://slidepdf.com/reader/full/beagle-esc-4 1/84
Hardware Lessons Learned from
Building Beagle
Gerald ColeyESC-401
5/12/2018 Beagle Esc 4 - slidepdf.com
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Topics Covered What¶s in a name?
Specification
Schematic
PCB Layout Assembly
Testing
Support
Implementing Lessons Learned Questions and discussion
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The Name:
Where did we get the nameBeagleBoard?
5/12/2018 Beagle Esc 4 - slidepdf.com
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How did we arrive at BeagleBoard?
Every project needs a name
Named for my dog. ± Just ³temporary´
± We will fix it later
± Well, It Stuck
A Beagle is: ± Like Tux, non threatening
± Curious
± Loyal ± Fun
± And gives back as much as it receives
Lesson Learned«If you name it, it will stick!
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So, we need an acronym
Bring your own peripherals
Entry-level
ARM Cortex-A8
Graphics & DSP
Linux and open source
Environment for SW innovators
5/12/2018 Beagle Esc 4 - slidepdf.com
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The Specification: A buffet
or just meat and potatoes?
5/12/2018 Beagle Esc 4 - slidepdf.com
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The Goals
Get OMAP3530 into people¶s hands
Low Cost <$150 ± Under the spousal radar
± Reach as many people as we can
Small Size ± Keeps the cost down
± ³Cool´ Factor
Internally focused
± Cortex-A8 + NEON ± DSP
± 3D Graphics
± Accelerators
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First Pass Features
OMAP3530 Processor 3.5´ LCD
± VGA/QVGA ± Touch screen
S-Video Keypad 2 Serial Ports
SD/MMC Ethernet Camera 128MB DDR 128MB NAND USB
± Host ± OTG
USB/DC Power Stereo In/Out Battery w/Charger Full Expansion Bus
COST: $1500
Size: 5´ x 8´
Something has to go!!
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Bring Your Own
Not everyone needs everything
Everything is needed
Bring your Own ± User adds only what they need
± They don¶t have to pay for what they alreadyhave
± Allows for maximum exposure to HW
More than just one component supplier
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Final Pass Features OMAP3530
3.5´ LCD.-VGA/QVGA
± Touch screen USB Touch Screen
DVI-D VGA, SVGA, XGA
S-Video
Keypad ± 1 button USB Keyboard & Mouse
2 Serial Ports ± 1 Port USB & Expansion
SD/MMC 6 in 1 Slot
Ethernet ± USB Dongle & WiFI
Camera ± USB Camera
128MB DDR
128MB NAND
USB Host OTG
USB/DC Power Stereo In/Out
Battery w/Charger ± USB Battery Adapter
Size 5´ x 8´ 3´ x 3´
Full Expansion Bus ± Standard buses
Standard on BeagleBring your own
Just meat and potatoes,
but still room for dessert!!
COST: $149
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The Schematic
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Play It Safe Leverage everything we can
± Used OMAP35xx EVM as base
Maintain compatibility with other platforms
± Common hookup
± Subset used the same
Keep the component count low
Use what is proven to work Leave off what is not needed
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Leveraged Advantages
OMAP35xx Processor Symbol/Design verified
TWL4030/TPS65950 Symbol/Design verified
± Removed a lot of features here SD/MMC Verified
DVI-D verified
UART Verified Lowered the overall risk
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Rules We Used
PCB
Design
PCB
FAB
PCB
ASSEMBLYMemory
Vendors
TI
Failure to include the fab and assembly team members can prove costly since choices
made early in the design will adversely impact the final cost of the assembled board
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The Challenges
OMAP35xx Package
± .4mm Pitch
± Routing
TPS65950(TWL4030)
± .4mm pitch PMIC
POP Implications
Limited area for connectors
± Location driven and not layout driven
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OMAP3530 Package
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What Exactly Is POP?
OMAP
Memory
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PMIC TPS65950 (TWL4030)
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Fixed Location of Connectors
Routing complicated by locations
± Connector not always on the best side
± We tried to make this as easy as possible Not the best locations for routing
± The DVI-D was the longest route
We need to keep the layer count down ± Our goal was to stick with 6 layers
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Recommended Trace and Via Connections
viaBGA
Don¶t gang BGA
pads with ground
plane
Trace should never
be larger than pad
Good
Better
Best
Poor
Better
Watch for solder traps
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Blind and Buried ViasDefinitions and Terminology
Through hole via has access to both external layers
Buried via provides connection within inner layers
Blind via does not pass through the entire board
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Via-in-PadPlaces the via directly in the BGA pad
Greatly improves board routing
Has special requirements for manufacturability
Given a 10mil BGA pad
Use a 4mil microvia
Laser drilled
Via must be filled or capped to minimize void formation
Via-fill Material
Check with board fabricator for their preferences
Fill material can be conductive or non-conductive
Via fill material¶s particle size must be <1mil for complete penetration
You must validate your board fabricator¶s capability to reliably build with this
class of technology
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.4mm Pitch
No routing between pads
Use top layer routing on outside pads
Use vias-in-pad wherever needed
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Soldermask
Exposed pad should be the same size asthe pad on the mounted device
Need to make the pad larger to addstability
Calls for soldermask defined pads
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Surface FinishThe PCB surface finish provides a coating over the outer layer copper
that prevents oxidation and provides an electrically conductivesurface.
Organic Solderability Preservative (OSP) Thin layer of organic material toprevent copper oxidation. It is removed by the assembly flux. Does nottolerate multiple heat cycles.
Immersion Tin (ImSn) Thin layer of tin directly on top of the copper surface.Produces an extremely flat surface for mounting of surface mountcomponents. Downside is the possible formation of Tin whiskers.
Immersion Silver (ImAg) Thin layer of silver directly on top of the copper surface. Produces a very flat surface. Compatible with no-clean assemblyprocesses. Maintains high solderability after multiple heat cycles. Downsideis that the plating will tarnish over time.
Electroless Nickel Immersion Gold (ENIG) Commonly used finish that isnice and flat for fine-pitch devices. Not easily reworked and more expensive. Hot-air solder leveling (HASL) Immersing the PCB in solder. It is
inexpensive and widely available, but it is not flat and therefore does notwork well with fine-pitch devices
5/12/2018 Beagle Esc 4 - slidepdf.com
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Final BeagleBoard Design
OMAP3 Triton-2
TFP410
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OMAP3530 BGA Footprint
Pad Type Solder Mask Defined
Pad Pitch A 400um
Pad Opening B 254um (10mils)
Pad Dia C 280um (11mils)
Mask Web D 150um
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Via-In-Pad Topology Stacked Microvia-In-Pad Pad 11mils copper (10mil SMD)
Top-Layer2 stacked with Layer2-Layer-3 Top-Layer2 Laser Drill 6mil (0.152mm) Solder-mask defined pads Non-conductive epoxy via plugs, plated over and planarized
Top Signal
Lyr2-GND
Lyr3-SIG
Lyr4-SIG
Lyr5-PWR
Bottom Signal
OMAP3
Top Soldermask
Bottom Soldermask
Blind/Stacked1-3
Blind1-2
BeagleBoard does not use buried vias
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Top
Lyr2-GND
Lyr3-SIG
Lyr4-SIG
Lyr5-PWR
Bottom
T
hru-hole via from top to bottom 18mil radius pad 8 mil drilled hole Plugged, plated and planarized
Must be levelNo dimples
Standard Vias
Not To Scale
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Top Layer-Signal(Area under OM AP3 Chip)
Via 1-6
V-I-P
BGA
PAD
3mil trace
10mil trace
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Bottom Layer
Bypass Capacitor Locations
Capacitor Spec
Type: Ceramic X7R
Size: 402Value: 0.1uF
Bypass Capacitor Location andSolder Pads
Via 1-6
Component
Pad
Min trace width 3 mils
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PCB Fabrication Concerns
High Board cost
± Because they can charge more
± Unknown = $$$$$
± Does not necessarily mean the production $$will be high
Unfamiliar with fine pitch
Soldermask registration critical
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Board Assembly:
Putting it all together
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POP Assembly Concerns
POP was the number one concern
Nitrogen and air were the two options
What should we do? ± Picked the one that was the most applicable
to as many assembly houses aspossible«.Air
POP soldering in air ± Air #1
± Air #2
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Mounting .4mm Parts
No real concerns
Equipment can handle it
Warping of the processor due to POP wasa possibility
± Saw no reason to be concerned
T
here could be an issue with shorts if soldermask not correct
We were comfortable
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Solderpaste Equipment
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Pick and Place Machine
My DATA (MY9)
D-014-1486 F30
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Reflow Oven
Heller EXL
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X-Ray Machine
Glenbrook TechnologiesRTX-113
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POP Mounting Configurations
Method A ± POP onto OMAP3 first reflow ± Back side Second reflow ± Top side third w/POP+OMAP3530 reflow
Method B ± Mount back side reflow ± Mount top side with OMAP3530 reflow ± Mount Memory w/ Pick & Place reflow
Method C ± Mount backside reflow ± Mount topside with OMAP3530 and POP reflow
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Method A ProcessTopGEL
HandMount
Paste SMT Reflow
OMAP3 OMAP3
POP
PasteReflow
Bottom side of board Top side of board
Mount w/SMT
Hand Assembly
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Method B Process
Paste SMT Reflow
Bottom side of board Top side of board
ApplyGel
Reflow
Paste SMT Reflow
SMT
POP Memory
Hand Assembly
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Method C Process
Paste SMT Reflow
Bottom side of board Top side of board
Paste
SMT
Reflow
POP Memory POP Memory
Dipping Arm isused to applypaste
Hand Assembly
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POP Mounting Analysis
Method A ± No real issues seen ± We abandoned it when we ran into issues ± Issues were not related to this process
Method B ± Final method adopted ± Have had excellent results
Method C
± Dipping Arm«POP Memory dipped into GEL ± Have a lot of high volume customers doing this ± Did not try as we had no dipping arm
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Panelization
Method A ± 4 boards per panel
± Used it on the first runs
± Had concerns about warping across thescoring that could cause solder shorts
± Nothing ever proven that this was an issue
Method B ± One board per panel
± Method chosen
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Other Parameters
Stencil thickness
± .4mils
Solder Paste ± AMTECH LF -4300 Lead Free
± Chemistry Sn96.5/Ag3.0/Cu.5
Tacky paste flux (memory)
± Amtech Tacky Solder Flux
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Reflow Profile Diagram
Time
50
100
150
200
250
Preheatingstage
Reflow
Peak
T e m p e r a t u r e -
D e g r e e s C
Cooldown
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Board Profile Settings
BOT TOP POP
# Zones In Oven 18 18 18
Pre-Heat Temp. 145 OC 170 OC 150 OC
Pre-Heat Dwell 98 sec 95 sec 100 sec
Reflow 118 sec 115 sec 120 sec
Duration Peak 18 sec 15 sec 20 sec
Peak Reflow Temp. 245 OC 260 OC 250 OC
Cool Down 8 OC/sec 8 OC/sec 8 OC/sec
Speed 52cm/s 55cm/s 50cm/s
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Issues on 1st Run
Solder Shorts under the processor ± Always a power rail
10% Yields
Could it be related to«.? ± POP Package
± Profile
± PCB ± Parts
± Solder
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Solder Shorts
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2nd Run
What is the easiest thing to change?
± Adjusted the temperature profile
Same results 90% Fail
Shorts under processor
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3rd Run
Shotgun approach
Changed PCB Vendor
Went to single board penalization
Changed POP method from A to B
Kept the original profile
Results ± 96% Yields
± No Shorts
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Analysis of 2nd Run
What was the issue? Gut said PCB soldermask
± Contacted first supplier ± No issue w/soldermask per supplier
Ordered more board and ran again with all other methods from Run 3 ± Same problem; 90% fail
Ordered shotguns and raided first supplier ± They admitted that they opened the soldermask ± Had them run another batch w/o changing soldermask
Result ± 96% yields ± No shorts
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Good/Bad SoldermaskGOOD BAD
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Other Issues Along the Way
SMT PCB audio connectors can rip off
± Only happened on two boards
± Pads detached from the board
± Added clear epoxy to connectors
± Adding vias to pads to add strength (Rev B6)
SMT USB connectors can rip off
± Only happened on one board
± Adding vias to pads to add strength (Rev B6)
5/12/2018 Beagle Esc 4 - slidepdf.com
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Final Analysis
Soldermask is the key issue
± PCB suppliers do their own thing
± Make sure that the thing they do is your thing!
All three POP methods should work Panalization should not be an issue, but not
confirmed
± It will be an issue if the soldermask is bad
Beagle profile is a good place to start
± Will need to be adjusted based on equipment used
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Board Testing Process
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Inspection Points
PCB ± Visual inspection
Solder Paste ± Bottom side application
± Top side application Shorts ± After re-flow
AOI ± After final assembly
Manual inspection ± Final inspection
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Assembly Inspection Points
Paste SMT Reflow
Bottom side of board Top side of board
ApplyGel
Reflow
Paste SMT Reflow
SMT
POP Memory
Hand Assembly
PastePCB Paste Shorts
Shorts Visual AOI
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PCB Check
Check soldermask ± Overlap (Soldermask defined pads)
± Soldermask over vias
Check finish ± Discoloring of finish
Dimples in via in pads ± Must be smooth
Check Pads ± Look for dimples in the vias in pad areas
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Solderpaste Inspection
Check paste for smooth applicationCheck for missing paste (not sticking to PCB)
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Shorts Test
Implemented when we had solder shorts
Easy check for main issues we have seen
Check across the caps using a ohmmeter ± Run as a spot check
± Can be done at 100%
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AOI Machine
Testronics 505 Machine Vision
-Works off of a known good board-Check for part orientation-Check for missing parts
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Final Inspection
Bad soldering
Contamination
Misaligned Parts
Wrong parts
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Functional Test
Tests all interfaces onthe boardProgram NAND with
XLoader and UBootTested pre and postburn-in
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Burn-In72 Hour Burn InRoom temperatureRunning UBoot
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Final Results
96%+ yield
Kept single board penalization
Kept assembly POP process Kept Profile
Now have three suppliers of PCB
± DDI (Dynamic Details, Inc) ± MEI
± Streamline
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REV A...Each Revision Only 50 units built
Rev A...Initial Version Rev A1«Normalized LED brightness levels
Rev A2...Changed resistor loading options for S-Video
Rev A3«Lowered pull-up values for the I2C busses
Rev A4...Lowered value of USB cap due to turn on issues ± Too much current drain
Rev A5...Incorrect inductor value on TPS65950 switchers
± Typo in BOM
Issues to be fixed:
± DC Voltage jack
± 1K pull-up on wait line
± Plated through hole issues
± Remove 4 test points
± User0 and User1 LEDS shorted
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REV B ...Each Revision
Rev B1«Initial Release ± Fixed outstanding Rev A issues
Rev B2«USB Host not working reliably ± Removed from BOM and assembly ± Questions around the layout
Rev B3«Added a few caps back in from B2 Rev B4...Some USB HUBS not connecting on OTG Port
± Noise level too high«Added a capacitor onto USB power rail
Rev B5...Serial Port disconnects after a while ± Removed a capacitor on the 32KHZ Clock
Rev B6«PCB spin to change package of U9 and U11 Issues To be Fixed:
± USB Host
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Big Issue Emerges REV B
Failures of the serial port and EDID
Traced to a bad package on TXS0102
± Delamination issue
60% Failure rate
Started 72 burn in process to weed out
Still have 1% making it out Only solution is to move to a different
package
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1st Rev C Proto
Attempted to fix USB Host
± Significant improvement
± Still not 100%
This version became the board for Rev B6
± Replaced U9 and U11 package
± Changed Revision to B1
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2nd Rev C
PCB In FAB
Moved USB Host to port 2 ± Aligned with other platforms
± Success on Port2
Added native LCD access ± Lot of demand for this feature
± Ability to interface to different displays withsmall paddle boards (LVDS, TTL, etc.)
± Kept current expansion header
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Support Process
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Key Issues from Users
Serial Port Issues
± Confusion over cables
± Serial port failures
OTG to host connectors
± Need ³special´ cable
± Brought on by lack of USB Host port
Connecting another video output
± LCD
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The Returns
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RMA By Subsystem
Audio««««..0 DVI-D««««..2 Serial Port««..19
Memory«.««..0 S-Video«.««..0 SD/MMC«««.0 USB OTG««...0
User Issue««..9 PMIC«««««3 Nothing Found...1
34 Total««..1.7%
Serial Port«..1.0%
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The Serial Ports
60% of returns for this reason
Issue with a small number of boards dueto part problem
This issue masks other real issues
± Wrong IDC Cable
± Wrong SERIAL Cable
± Wrong terminal setup
± Well, it works on that other board?
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Implementing the LessonsLearned:
What¶s Next?
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Changes Being Made
Documentation
± Troubleshooting Section for Serial Port
± Pictures
± Step by Step process
Diagnostic SW
New Translator Package
± PCB Change REV B6
LCD Interface (Rev C)
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Design Material Available
Schematics ± PDF Version http://www.beagleboard.org/uploads/BBSRM_B5.pdf
± OrCAD Version http://www.beagleboard.org/uploads/BEAGLE_ORCAD_B4.zip
BOM ± Excel http://www.beagleboard.org/uploads/Beagle_BOM_B4.xls
PCB Files ± PCB Gerber Files http://www.beagleboard.org/uploads/Beagle_Allegro_B.zip
± PCB Allegro Files http://www.beagleboard.org/uploads/Beagle_Gerbers_B.zip
Viewers ± PDF ± OrCAD ± Gerber
± Allegro
PCB Design Guideline http://focus.ti.com/dsp/docs/dspsupporttechdocsc.tsp?sectionId=3&tabId=409&familyId=1526&abstractName=spraav1
System Reference Manual http://www.beagleboard.org/uploads/BBSRM_B5.pdf
± Rev B6 on its way
http://beagleboard.org/hardware/design
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Can you do OMAP3?
Take the BeagleBoard and build it
± Verifies if the PCB Fabricator can do it
± Verifies if the Assembly house can build it
± All material needed is provided
All needed SW is available
± Diagnostics
± Kernels
± Distributions
5/12/2018 Beagle Esc 4 - slidepdf.com
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Thanks To:
Contract Manufacturer CircuitCo www.circuitco.com
PCB Fabricators
Marcel Electronics mei4pcbs.com
Dynamic Details www.ddiglobal.com
Streamline www.streamlinecircuits.com
PCB Layout
ION Design www.iondesign.com Keith Gutierrez , Texas Instruments