Design And Construction Of A Rechargeable Soldering Iron

ABSTRACT

This work is on a rechargeable soldering iron. A rechargeable 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 battery and battery charger, 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. The main aim of a rechargeable soldering iron is to provide an instant backup during power failure or mains outage.

TABLE OF CONTENTS

COVER PAGE

TITLE PAGE

APPROVAL PAGE

DEDICATION

ACKNOWELDGEMENT

ABSTRACT

CHAPTER ONE

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

CHAPTER TWO

LITERATURE REVIEW

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

CHAPTER THREE

METHODOLOGY

• SYSTEM BLOCK DIAGRAM
• SYSTEM CIRCUIT DIAGRAM
• CIRCUIT DESCRIPTION
• PARTS LIST
• RECHARGEABLE POWER SUPPLY
• DESCRIPTION OF MAJOR COMPONENTS USED

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

1.1                                                        INTRODUCTION

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 rechargeable electric soldering iron.

1.2                                                  PROBLEM STATEMENT

Unsteady power supply is the one of the major problem of developing countries such as Nigeria. The main aim of building a rechargeable soldering iron is to provide an instant backup during power failure or mains outage. But due to the above mentioned problems, a modern day rechargeable soldering iron can not only provide uninterrupted power supply but also protects soldering iron from the above mentioned problems.

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 rechargeable 12v 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 rechargeable 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

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

1.5                                         SIGNIFICANCE OF THE PROJECT

Rechargeable 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.

1.6                                          APPLICATION OF THE PROJECT

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

Rechargeable 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)

1.7                                              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.

1.8                                       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.