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Design And Construction Of A DC Soldering Iron

Electrical Electronics Engineering | Industrial Physics | Physics

The design and construction of a DC soldering iron involve the meticulous integration of various components to ensure optimal performance and efficiency. A DC soldering iron is a portable electronic device used for joining components by melting and flowing solder. The key elements encompass a heating element, typically made of ceramic, which is adept at reaching and maintaining high temperatures essential for soldering. The power source, crucial for the functionality, relies on direct current, ensuring a steady and controlled supply of energy. Additionally, a temperature control mechanism plays a pivotal role in regulating the heat, providing versatility for different soldering tasks. The housing, crafted from durable materials, not only encases the components securely but also contributes to the overall ergonomic design for user comfort. The integration of safety features, such as an insulated handle and an efficient heat dissipation system, underscores the importance of user well-being. In essence, the construction of a DC soldering iron demands a judicious amalgamation of heating technology, power supply, temperature regulation, and ergonomic design to deliver a reliable and versatile tool for precision soldering tasks.

This work is on a dc soldering iron. A dc soldering iron joins two metal work pieces by means of a third metal (solder) at a relatively low temperature, which is above the melting point of the solder but below the melting point of either of the materials being joined. This device composes of a heating element, and a copper tip. Soldering iron tips are made of copper core plated with iron. The copper is used for heat transfer and the iron plating is used for durability.

TABLE OF CONTENTS

COVER PAGE

TITLE PAGE

APPROVAL PAGE

DEDICATION

ACKNOWELDGEMENT

ABSTRACT

CHAPTER ONE

INTRODUCTION
BACKGROUND OF THE PROJECT
PROBLEM STATEMENT
OBJECTIVE OF THE STUDY
PURPOSE OF THE PROJECT
ADVANTAGES OF THE PROJECT
SIGNIFICANCE OF THE PROJECT
APPLICATION OF THE PROJECT
PROBLEM OF THE PROJECT
METHODOLOGY
PROJECT REPORT ORGANISATION

CHAPTER TWO

LITERATURE REVIEW

OVERVIEW OF SOLDERING
HISTORICAL BACKGROUND OF THE SOLDERING
GENERAL APPLICATIONS OF SOLDERING
REVIEW OF SOLDERS
REVIEW OF DIFFERENT TYPES OF SOLDERING
DIFFERENCE BETWEEN SOLDERING AND BRAZING

CHAPTER THREE

3.0 METHODOLOGY

SYSTEM BLOCK DIAGRAM
SYSTEM CIRCUIT DIAGRAM
CIRCUIT DESCRIPTION
PARTS LIST
DESCRIPTION OF MAJOR COMPONENTS

CHAPTER FOUR

4.0 TEST AND RESULT ANALYSIS

CONSTRUCTION PROCEDURE AND TESTING ANALYSIS
CASING AND PACKAGING
ASSEMBLING OF SECTIONS
TESTING OF SYSTEM OPERATION

CHAPTER FIVE

CONCLUSION
RECOMMENDATION
REFERENCES

CHAPTER ONE

1.0 INTRODUCTION

1.1 BACKGROUND OF THE PROJECT

Soldering is described as process in which two or more items (usually metal) are joined together by melting and putting a filler metal (solder) into the joint, the filler metal having a lower melting point than the adjoining metal. Soldering differs from welding in that soldering does not involve melting the work pieces. In brazing, the filler metal melts at a higher temperature, but the work piece metal does not melt. In the past, nearly all solders contained lead, but environmental and health concerns have increasingly dictated use of lead-free alloys for electronics and plumbing purposes. Soldering work is performed by soldering iron.

A soldering iron is a hand tool used in soldering. It supplies heat to melt solder so that it can flow into the joint between two workpieces.

A soldering iron is composed of a heated metal tip and an insulated handle. Heating is often achieved electrically, by passing an electric current (supplied through an electrical cord or battery cables) through a resistive heating element. Cordless irons can be heated by combustion of gas stored in a small tank, often using a catalytic heater rather than a flame. Simple irons less commonly used than in the past were simply a large copper bit on a handle, heated in a flame.

Soldering irons are most often used for installation, repairs, and limited production work in electronics assembly. High-volume production lines use other soldering methods.[1] Large irons may be used for soldering joints in sheet metal objects.

For electrical and electronics work, a low-power iron, a power rating between 15 and 35 watts, is used. Higher ratings are available, but in this work we are focusing on dc specifically 12v powered electric soldering iron.

1.2 PROBLEM STATEMENT

Because of inconsistency of power supply in most countries such as Nigeria, electronics hobbyist found it difficult most time to work with their soldering iron due to the fact that all soldering are rated 220v for Nigeria. In other to overcome this problem this device was built. This device involves powering your soldering with a 12v dc source.

1.3 OBJECTIVE OF THE PROJECT

Soldering makes quick and neat connections to electronic equipment, plumbing and jewelry. Heating the metals with a soldering iron melts the solder onto the joint, forming the bond as the solder cools. The main objective of this work is to design a 12vdc powered soldering iron that can be used to perform the mentioned tasks.

1.4 PURPOSE OF THE PROJECT

The purpose of this work is build a hand tool used in soldering, that supplies heat to melt solder so that it can flow into the joint between two work-pieces, which composed of a heated metal tip and an insulated handle.

1.5 ADVANTAGES OF THE PROJECT

Dc soldering iron is lightweight, compact, and portable. Soldering irons supply heat to melt solder. This provides an electrically conductive connection.

1.6 SIGNIFICANCE OF THE PROJECT

D.C Soldering irons are most often used for installation, repairs, and limited production work in electronics assembly. High-volume production lines use other soldering methods. Large irons may be used for soldering joints in sheet metal objects.

1.7 APPLICATION OF THE PROJECT

Soldering iron is used in plumbing, electronics, and metalwork from flashing to jewelry.

Soldering iron provides reasonably permanent but reversible connections between copper pipes in plumbing systems as well as joints in sheet metal objects such as food cans, roof flashing, rain gutters and automobile radiators.

Jewelry components, machine tools and some refrigeration and plumbing components are often assembled and repaired by the higher temperature silver soldering process. Small mechanical parts are often soldered or brazed as well. Soldering is also used to join lead came and copper foil in stained glass work.

Electronic soldering iron connects electrical wiring and electronic components to printed circuit boards (PCBs)

1.8 PROBLEM OF THE PROJECT

Below are the problems of the work:

When using this device, Careful removal of the flux residuals is required in order to prevent corrosion;
Large sections cannot be joined;

Fluxes may contain toxic components;

Soldering joints cannot be used in high temperature applications;
This device has a Low strength of joints.

1.9 METHODOLOGY

To achieve the aim and objectives of this work, the following are the steps involved:

Study of the previous work on the project so as to improve it efficiency.
Draw a block diagram.

Test for continuity of components and devices,

Design of was carried out.
Studying of various component used in circuit.
Construct the circuit.

Finally, the whole device was cased and final test was carried out.

1.10 PROJECT REPORT ORGANIZATION

The project report has been organized into five chapters for orderliness and easy understanding of the information on the report design.

Chapter one contains introduction design objectives, purpose, application, advantages, limitation, significance of the report and report organization

Chapter two dealt on system component analysis literature review and theories/modules of design.

Chapter three contains the system design description of the system building blocks system specification block diagram and the description of the overall operation of the system.

Chapter four describes the implementation testing and results of the project.

Chapter five finally dealt on the cost analysis calculation and recommendation for further improvement and ended with a page for references.