Supports distribution optimization for Printed Circuit Boards subject to vibration in motorsport applications

This thesis, developed in collaboration with Marelli Europe S.p.A., addresses the optimization of the number and placement of supports for printed circuit boards subjected to vibration loads. In motorsport applications, the current practice relies heavily on the experience of designers to select the support layout, which may result in conservative designs with unnecessary supports. Establishing objective guidelines reduces the subjectivity of this choice, may lower weight and cost, and accelerates the design phase. The study focuses on two of Marelli’s data acquisition electronic control units, each consisting of two printed circuit boards. Finite element modeling is performed at multiple levels of detail, ranging from simplified models that do not require precise component positioning to detailed representations that consider the local distribution of mass and stiffness. Then the simplified models are used in an optimization study to determine the most effective support layouts for rectangular boards. The outcome is a set of design guidelines that link the first natural frequency to the geometry, mass, and stiffness of the board and provide practical recommendations for the choice of the number and position of supports.