Kitronik PROGRAMMABLE MUSIC BOX KIT User manual

PROGRAMMABLE MUSIC BOX KIT
ADD A TUNE TO YOUR PRODUCT WITH THIS
TEACHING RESOURCES
SCHEMES OF WORK
DEVELOPING A SPECIFICATION
COMPONENT FACTSHEETS
HOW TO SOLDER GUIDE
Version 2.
0

Programmable Music Box Teaching Resources
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Index of Sheets
TEACHING RESOURCES
Index of Sheets
Introduction
Schemes of Work
Answers
The Design Process
The Design Brief
Investigation / Research
Developing a Specification
Design
Design Review (group task)
Soldering in Ten Steps
Resistor Values
Why Use a PIC Micro-controller?
Instruction Manual
Evaluation
Packaging Design
ESSENTIAL INFORMATION
Build Instructions
Checking Your Music Box PCB
Testing the PCB
Fault Finding
Designing the Enclosure
Programming Task
How the Music Box Hardware Works
Online Information

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Introduction
About the project kit
Both the project kit and the supporting material have been carefully designed for use in KS3 Design and Technology
lessons. The project kit has been designed so that even teachers with a limited knowledge of electronics should have
no trouble using it as a basis from which they can form a scheme of work.
The project kits can be used in two ways:
1. As part of a larger project involving all aspects of a product design, such as designing an enclosure for the
electronics to fit into.
2. On their own as a way of introducing electronics and electronic construction to students over a number of
lessons.
This booklet contains a wealth of material to aid the teacher in either case.
Using the booklet
The first few pages of this booklet contains information to aid the teacher in planning their lessons and also covers
worksheet answers. The rest of the booklet is designed to be printed out as classroom handouts. In most cases all of
the sheets will not be needed, hence there being no page numbers, teachers can pick and choose as they see fit.
Please feel free to print any pages of this booklet to use as student handouts in conjunction with Kitronik project
kits.
Support and resources
You can also find additional resources at www.kitronik.co.uk.There are component fact sheets, information on
calculating resistor and capacitor values, puzzles and much more.
Kitronik provide a next day response technical assistance service via e-mail. If you have any questions regarding this
kit or even suggestions for improvements, please e-mail us at:
Alternatively, phone us on 0845 8380781.

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Schemes of Work
Two schemes of work are included in this pack; the first is a complete project including the design & manufacture of
an enclosure for the kit (below). The second is a much shorter focused practical task covering just the assembly of
the kit (next page). Equally, feel free to use the material as you see fit to develop your own schemes.
Before starting we would advise that you to build a kit yourself. This will allow you to become familiar with the
project and will provide a unit to demonstrate.
Complete product design project including electronics and enclosure
Hour 1
Introduce the task using The Design Brief sheet. Demonstrate a built unit. Take
students through the
design process using The Design Process sheet.
Homework: Collect examples of musical products that are currently on sale. These may include toys,
games, greetings cards etc. List the common features of these products on the Investigation / Research
sheet.
Hour 2
Develop a specification for the project using the Developing a Specification sheet.
Resource: Sample of musical products.
Homework: Using the internet or other search method, find out what is meant by design for
manufacture. List five reasons why design for manufacture should be considered on any design project.
Hour 3
Read Designing the Enclosure sheet. Develop a product design using the Design sheet.
Homework: Complete design.
Hour 4
Split the students in
to groups and get them to perform a group design review using the Design Review
sheet.
Hour 5
Using the Soldering in Ten Steps sheet, demonstrate and get students to practice
soldering. Start the
Resistor Value worksheet.
Homework: Complete any of the remaining resistor tasks.
Hour 6
Using cardboard, get the students to model their enclosure design. Allow them to make alterations to
their design if the model shows any areas that need changing.
Hour 7
Build the electronic kit usin
g the Build Instructions.
Hour 8
Complete the build of the electronic kit. Check the completed PCB and fault find i
f required using the
Checking Your Music Box PCB section and the fault finding flow chart.
Homework: Read How the Music Box Hardware Works sheet.
Hour 9
Programming task
-
Play music when switch opened.
Hour 10
Build the enclosure.
Hour 11
Build the enclosure
.
Homework: Collect some examples of instruction manuals.
Hour 12
Build the enclosure
.
Homework: Read Instruction Manual sheet and start developing instructions for the music box.
Hour 13
Build the enclosure.
Homework: Complete instructions for the design.
Hou
r 14
Using the Evaluation and Improvement sheet, get the students to evaluate their final product and
state where improvements can be made.
AdditionalWork
Package design for those who complete ahead of others.

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Electronics only
Hour 1
Introduction to the kit demonstrating a buil
t unit. Using
the
Soldering in T
en
S
teps sheet
,
practice
soldering.
Hour
2
Build the kit using the Build Instructions.
Hour 3
Check the completed PCB and fault fi
nd if required using Checking Y
our
Music Box
PCB and fault finding
flow chart.
Hour 4
Programming task
-
Play music when switch opened.
Answers
Resistor questions
1st Band 2nd Band Multiplier x Value
Brown Black Yellow 100,000 
Green Blue Brown 560 
Brown Grey Yellow 180,000
Orange White Black 39
Value 1st Band 2nd Band Multiplier x
180  Brown Grey Brown
3,900  Orange White Red
47,000 (47K)  Yellow Violet Orange
1,000,000 (1M)  Brown Black Green

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The Design Process
The design process can be short or long, but will always consist of a number of
steps that are the same on every project. By splitting a project into these
clearly defined steps, it becomes more structured and manageable. The steps
allow clear focus on a specific task before moving to the next phase of the
project. A typical design process is shown on the right.
Design brief
What is the purpose or aim of the project? Why is it required and who is it
for?
Investigation
Research the background of the project. What might the requirements be?
Are there competitors and what are they doing? The more information found
out about the problem at this stage, the better, as it may make a big
difference later in the project.
Specification
This is a complete list of all the requirements that the project must fulfil - no
matter how small. This will allow you to focus on specifics at the design stage
and to evaluate your design. Missing a key point from a specification can
result in a product that does not fulfil its required task.
Design
Develop your ideas and produce a design that meets the requirements listed
in the specification. At this stage it is often normal to prototype some of your
ideas to see which work and which do not.
Build
Build your design based upon the design that you have developed.
Evaluate
Does the product meet all points listed in the specification? If not, return to the design stage and make the required
changes. Does it then meet all of the requirements of the design brief? If not, return to the specification stage and
make improvements to the specification that will allow the product to meet these requirements and repeat from
this point. It is normal to have such iterations in design projects, though you normally aim to keep these to a
minimum.
Improve
Do you feel the product could be improved in any way? These improvements can be added to the design.
Design Brief
Investigation
Specification
Design
Build
Evaluate
Improve

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The Design Brief
A manufacturer of childrens toys has designed a circuit that plays a tune
when a switch is opened or closed.
The manufacturer can think of many great applications for this circuit.
For example it could be used to play a tune when your toy box is opened
or when a coin is dropped into a money box.
The manufacturer would like you to research and select a particular use
for the circuit. They would then like you to produce a design that is
suitable for that use. The design must meet all of the requirements of
the selected target market.
Description of the music box
Once the switch is activated it plays a tune. As the music box is programmable the tune that is played can be
changed. It is also possible to trigger the tune on either the opening or the closing of the switch.

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Investigation / Research
Using a number of different search methods, find examples of similar products that are already on the market. Use
additional pages if required.
Name Class

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Developing a Specification
Using your research into the target market for the product, identify the key requirements for the product and
explain why each of these is important.
Name Class
Requirement
Reason
Example:
The box should have some
holes in it.
Example: So that the sound can be heard.

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Design
Develop your ideas to produce a design that meets the requirements listed in the specification.
Name Class

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Design Review (group task)
Split into groups of three or four. Take it in turns to review each persons design against the requirements of their
specification. Also look to see if you can spot any additional aspects of each design that may cause problems with the
final product. This will allow you to ensure that you have a good design and catch any faults early in the design
process. Note each point that is made and the reason behind it. Decide if you are going to accept or reject the
comment made. Use these points to make improvements to your initial design.
Comment
Reason for comment
Accept or Reject

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Soldering in Ten Steps
1. Start with the smallest components working up to
the taller components, soldering any interconnecting
wires last.
2. Place the component into the board, making sure
that it goes in the right way around and the part sits
flush against the board.
3. Bend the leads slightly to secure the part.
4. Make sure that the soldering iron has warmed up
and if necessary, use the damp sponge to clean the
tip.
5. Place the soldering iron on the pad.
6. Using your free hand, feed the end of the solder onto
the pad (top picture).
7. Remove the solder, then the soldering iron.
8. Leave the joint to cool for a few seconds.
9. Using a pair of cutters, trim the excess component
lead (middle picture).
10. If you make a mistake heat up the joint with the
soldering iron, whilst the solder is molten, place the
tip of your solder extractor by the solder and push
the button (bottom picture).
Solder joints
Good solder joint Too little solder Too much solder

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Resistor Values
A resistor is a device that opposes the flow of electrical current. The bigger the value of a resistor, the more it
opposes the current flow. The value of a resistor is given in  (ohms) and is often referred to as its ‘resistance’.
Identifying resistor values
Band Colour 1st Band 2nd Band Multiplier x Tolerance
Silver 100 10%
Gold 10 5%
Black 0 0 1
Brown 1 1 10 1%
Red 2 2 100 2%
Orange 3 3 1000
Yellow 4 4 10,000
Green 5 5 100,000
Blue 6 6 1,000,000
Violet 7 7
Grey 8 8
White 9 9
Example: Band 1 = Red, Band 2 = Violet, Band 3 = Orange, Band 4 = Gold
The value of this resistor would be:
2(Red) 7(Violet) x 1,000 (Orange) = 27 x 1,000
= 27,000 with a 5% tolerance (gold)
= 27K
Resistor identification task
Calculate the resistor values given by the bands shown below. The tolerance band has been ignored.
1st Band 2nd Band Multiplier x Value
Brown Black Yellow
Green Blue Brown
Brown Grey Yellow
Orange White Black
Too many zeros?
Kilo ohms and mega
ohms can be used:
1,000 = 1K
1,000K = 1M

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Calculating resistor markings
Calculate what the colour bands would be for the following resistor values.
Value 1st Band 2nd Band Multiplier x
180 
3,900 
47,000 (47K) 
1,000,000 (1M) 
What does tolerance mean?
Resistors always have a tolerance but what does this mean? It refers to the accuracy to which it has been
manufactured. For example if you were to measure the resistance of a gold tolerance resistor you can guarantee
that the value measured will be within 5% of its stated value. Tolerances are important if the accuracy of a resistors
value is critical to a design’s performance.
Preferred values
There are a number of different ranges of values for resistors. Two of the most popular are the E12 and E24. They
take into account the manufacturing tolerance and are chosen such that there is a minimum overlap between the
upper possible value of the first value in the series and the lowest possible value of the next. Hence there are fewer
values in the 10% tolerance range.
E-12 resistance tolerance (± 10%)
10
12
15
18
22
27
33
39
47
56
68
82
E-24 resistance tolerance (± 5 %)
10
11
12
13
15
16
18
20
22
24
27
30
33
36
39
43
47
51
56
62
68
75
82
91

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Why Use a PIC Micro-controller?
There are a number of advantages to using a micro-controller, some of these are outlined below:
Complex functionality can be produced at very low cost.
Circuit size can be very small and still provide complex functionality.
It is very easy to make minor alterations to the function of the product.
oFor instance changing the tune that is played.
Flexibility. The circuit could easily be used for a completely different function by simply re-writing the
software.
Easy to develop and debug. Most software packages allow you to simulate the software while it is being
developed, making it much more likely to work when used. It is also possible to break the functionality down
into small steps, which is easier to get right than jumping straight to the final design.

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Instruction Manual
Your music box is going to be supplied with some instructions. Identify four points that must be included in the
instructions and give a reason why.
Point to include
:
Reason:
Point to include
:
Reason:
Point to include
:
Reason:
Point to include
:
Reason:

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Evaluation
It is always important to evaluate your design once it is complete. This will ensure that it has met all of the
requirements defined in the specification. In turn, this should ensure that the design fulfils the design brief.
Check that your design meets all of the points listed in your specification.
Show your product to another person (in real life this person should be the kind of person at which the product is
aimed). Get them to identify aspects of the design, which parts they like and aspects that they feel could be
improved.
Good aspects of the design
Areas that c
ould be improved
Improvements
Every product on the market is constantly subject to redesign and improvement. What aspects of your design do you
feel you could improve? List the aspects that could be improved and where possible, draw a sketch showing the
changes that you would make.

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Packaging Design
If your product was to be sold in a high street electrical retailer, what requirements would the packaging have? List
these giving the reason for the requirement.
Requirement
Reason
Develop a packaging design for your product that meets these requirements. Use additional pages if required.

PROGRAMMABLE MUSIC BOX KIT
ADD A TUNE TO YOUR PRODUCT WITH THIS
ES
S
ENTIAL INFORMATION
BUILD
INSTRUCTIONS
CHECKING YOUR PCB & FAULT-
FINDING
MECHANICAL DETAILS
HOW THE KIT
WORKS
Version 2.0

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Build Instructions
Before you start, take a look at the Printed Circuit Board (PCB). The components go in the side with the writing on
and the solder goes on the side with the tracks and silver pads.
Start with the three resistors. The text on the PCB shows where R1, R2 etc go. Ensure that you put the
resistors in the right place.
PCB Ref
Value
Colour Bands
R1 & R4
22K

Red, r
ed,
o
range
R2
10K

Brown, b
la
ck, o
range
Solder the Integrated Circuit (IC) holder into IC1. When putting this into the board, be sure to get it
the right way around. The notch on the IC holder should line up with the notch on the lines marked
on the PCB.
Solder the programming connector into the board where it is labelled ‘PROG’.
The battery clip should be soldered into the ‘POWER’ terminal. First start by feeding the wire
through the strain relief hole (feed from the solder side). The red wire must go to the ‘+’ terminal
(also marked ‘red’) and the black wire must go to the ‘–’ terminal (also marked ‘black’).
The buzzer should be soldered into the ‘SOUNDER’ terminal. First start by feeding the wire through
the strain relief hole (feed from the solder side). The red wire must go to the ‘+’ terminal (also
marked ‘red’) and the black wire must go to the ‘–’ terminal (also marked ‘black’).
Cut and strip two pieces of wire to the required length for connecting to the switch. Solder the end
of one piece of wire to the terminal of the switch labelled ‘COM’ (this is printed on the plastic body
of the switch). Then solder one end of the other piece of wire to the terminal of the switch labelled
‘NO’. Now solder the other ends of the wires to the terminals labelled ‘INPUT1’ on the PCB. It does
not matter which wire goes to which terminal on the PCB.
The IC can be put into the holder, ensuring that the notch on the chip lines up with the notch on the holder.
PLACE RESISTORS
1
SOLDER THE IC HOLDER
2
SOLDER THE SOCKET
3
ATTACH THE BATTERY CLIP
4
SOLDER THE BUZZER
5
SOLDER THE BUZZER
6
INSERT THE IC INTO HOLDER
7