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PCB design, EMI and EMC

Electronics and Communication Engineering (B.E./B.Tech) · Microprocessors and embedded · free study notes for exams, placements and interviews

In short

A printed circuit board (PCB) is the mechanical and electrical substrate that holds an embedded system together, and above a few megahertz its copper stops behaving like ideal wire and starts behaving like inductors, capacitors and antennas. Electromagnetic interference (EMI) is the unwanted energy a board emits or picks up; electromagnetic compatibility (EMC) is the design discipline that makes a product neither disturb others nor be disturbed itself. Every electronic product sold in India needs EMC evidence — through BIS compulsory registration, TEC's MTCTE scheme for telecom equipment and the applicable IS/CISPR standards — so hardware teams at Bosch, Continental, Tata Elxsi, L&T Technology Services, HAL, BEL, ISRO and medical/automotive suppliers interview heavily on it. In exams it appears as layer stack-up, grounding, decoupling, transmission-line and shielding questions in Microprocessors/Embedded System Design and Electronic Product Design papers; in GATE and PSU papers it surfaces through transmission-line reflection, skin depth and impedance calculations.

Explained

PCB fundamentals and fabrication

Layer stack-up, grounding and return current

Power distribution network (PDN) and decoupling

Signal integrity: transmission lines, reflections and crosstalk

EMI: sources, coupling, and emission/immunity requirements

EMC design techniques and standards in India

Key points

Formulas and examples

Microstrip impedance (IPC approximation): Z₀ = (87/√(εr + 1.41)) · ln(5.98h / (0.8w + t)) Ω — h = dielectric height, w = trace width, t = copper thickness (same units); valid for 0.1 < w/h < 2.0, 1 < εr < 15.
Stripline impedance: Z₀ = (60/√εr) · ln(4b / (0.67π(0.8w + t))) Ω — b = plane-to-plane spacing.
Propagation delay: t_pd = √(ε_eff)/c; for microstrip ε_eff = (εr + 1)/2 + ((εr − 1)/2)(1 + 12h/w)−1/2; c = 300 mm/ns.
Reflection coefficient: Γ = (Z_L − Z₀)/(Z_L + Z₀); V_reflected = Γ·V_incident.
Edge bandwidth (knee frequency): f_knee = 0.35 / t_r — t_r = 10–90% rise time in seconds, f in Hz.
Critical length (transmission-line rule): l_crit = t_r / (6 · t_pd) — t_pd in ps/mm gives l_crit in mm.
Inductive noise (ground bounce): V = L · di/dt — L in H, di/dt in A/s.
Capacitor self-resonance: f_SRF = 1/(2π√(L_total·C)) — L_total = ESL + mounting (via + pad) inductance.
PDN target impedance: Z_target = (V_supply × ripple%) / I_transient, in Ω.
Differential-mode radiated field (far field, 3 m, free space): E (µV/m) ≈ 263 × 10⁻¹⁴ × (f² · A · I)/r — f in Hz, A loop area in cm², I in A, r in m.
Common-mode radiated field: E (µV/m) ≈ 1.26 × (f · L · I_CM)/r — f in Hz, L cable length in m, I_CM in A, r in m.
Skin depth: δ = √(ρ/(π f µ)) — ρ = 1.72 × 10⁻⁸ Ω·m, µ = µ₀ = 4π × 10⁻⁷ H/m for copper.
Trace current capacity (IPC-2221): I = k · ΔT0.44 · A0.725 — A = cross-section in mil², ΔT in °C, k = 0.024 internal, 0.048 external.
Interplane capacitance: C = ε₀ εr A / d — ε₀ = 8.854 pF/m.
dB conversions: dBµV = 20·log₁₀(V/1 µV); dB = 20·log₁₀(ratio) for field/voltage, 10·log₁₀ for power.

Example 1 — Does this trace need termination? A 74LVC buffer with a 1 ns rise time drives a trace on the top layer of an FR-4 board (microstrip, t_pd ≈ 5.6 ps/mm). Trace length = 80 mm.

Example 2 — Reflection from an unterminated input. A 50 Ω trace ends at a CMOS input of effectively 10 kΩ. A 3.3 V step travels down the line.

Example 3 — Decoupling capacitor: is it still a capacitor at 200 MHz? A 100 nF 0603 capacitor with ESL = 1.2 nH is mounted with two vias and short traces adding ≈ 1.3 nH, so L_total = 2.5 nH.

Example 4 — Loop area and radiated emission. A 50 MHz clock drives 20 mA over a trace whose signal-and-return loop encloses 4 cm². Measured at 3 m, take the third harmonic (150 MHz).

Example 5 — Trace width for 2 A on an outer layer. Requirement: 2 A, ΔT = 10 °C rise, 1 oz copper (1.4 mil thick), external trace (k = 0.048).

IssueSymptomFirst fixSecond fix
Radiated emission fail 30–300 MHzBroad peaks at clock harmonicsShrink loop area, solid ground planeSpread-spectrum clock, slow edges
Radiated emission fail above 300 MHzPeaks tied to cable lengthCommon-mode choke at connector360° shield termination, filter at entry
Conducted emission fail 150 kHz–5 MHzSMPS switching harmonicsInput pi filter, X/Y capsSnubber, reduce dv/dt on switch node
ESD failure (IEC 61000-4-2)Reset or latch-up on contact dischargeTVS at connector, guard ringChassis ground path away from logic
Ringing / double clockingOvershoot at receiverSeries termination at driverControlled-impedance stack-up
Analogue noise on ADCReduced ENOB, noisy LSBsPartition placement, single planeFerrite + local LC on AVDD
Parameter2-layer board4-layer (Sig/GND/PWR/Sig)
Return pathGround traces/pour, uncontrolledSolid plane directly beneath
Controlled impedanceVery difficultStraightforward
Typical EMI marginMarginal, often fails10–20 dB better
Decoupling at HFPoor (no interplane C)Good interplane capacitance
Relative bare-board cost1×about 1.6–2.2× in small volumes

Where it is used

Interview questions

Common mistakes

Related topics

Embedded interfaces: UART, SPI and I2C · Microcontroller peripherals: timers, ADC, PWM and interrupts · Transmission lines and waveguides · Antennas and radiation · Power electronics and SMPS design · Electronic measurements and instrumentation

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