Design And Construction Of A Solder Fume Extractor
The design and construction of a solder fume extractor involves creating a robust system that effectively captures and removes harmful fumes generated during soldering processes. This extractor is crucial for maintaining a safe and healthy working environment, particularly in electronics manufacturing and repair settings. By integrating a powerful fan or blower, a high-efficiency particulate air (HEPA) filter, and a carbon filter, the extractor can efficiently trap and eliminate soldering fumes containing harmful substances such as lead, flux residues, and volatile organic compounds (VOCs). Additionally, incorporating features like adjustable airflow settings, a durable housing with a transparent viewing window, and a user-friendly control panel enhances usability and monitoring. Proper ventilation design, including ductwork and exhaust placement, is also essential to ensure optimal air circulation and fume removal. This project focuses on addressing occupational health and safety concerns by implementing an innovative and practical solution for solder fume extraction in industrial and workshop environments.
ABSTRACT
Soldering in electronics is analogous to fixing of a component using glue. It is actually a general phenomenon in the field of electronics which involves fixing of electronic components into a special board called PCB with the help of instruments like soldering iron and electrical solder commonly called as ‘Solder wire’.
While soldering we all face problem of toxic fumes. These fumes are of lead solder wire and flux. Combinedly, these fumes are highly toxic if excess amount is inhaled. In order to solve this problem, here we had designed a simple circuit called solder fume extractor using an op-amp IC which removes fumes from the soldering area. The work is of automatic type which runs exhaust fan during soldering and stops exhaust fan when soldering iron is kept on soldering stand.
CHAPTER ONE
1.1 INTRODUCTION
Electronics production is heavily concerned with soldering components on to printed circuit boards (PCBs). A small part of the operation is automated, using wave soldering machines, with the majority being manual as operators add individual components using hand soldering irons. Further hand soldering and de soldering is frequently used in rework stations to carry out repairs and upgrades.
All of this soldering activity generates fumes which can cause long term, serious harm to operators if inhaled. Employers may face expensive compensation claims as a result. Most countries recognise this and enforce legislation to ensure that employers protect their employees from these harmful effects. Even in regions without such legislation employers have an ethical duty to provide such protection.
Fume Extraction Systems are designed for electronics soldering applications that generate fume comprising; resin acid particulate and gaseous organic compounds within the Electronics sector. Solutions are available for manual and automated processes including: wave solder, reflow, selective solder and conformal coating applications. T1, TVT2 and T15 offer tip extraction for lead free soldering applications. These are high volume units that are designed to extract and filter the fumes and debris.
This device designed to extract and fumes and debris through small bore hoses and attachments. Ideal for soldering iron tip fume extraction. Due to high concentration of debris generated from up to 100 operators, these systems have been designed to keep the unit compact, but still utilize a comprehensive filter system. With this in mind, the units incorporate a facility for retaining a high concentration of particulate within the filter enclosure. These systems have a built in silencer that has a collar to allow for redirection or external venting of filtered air if required.
The fume extraction units have been designed primarily to extract the fumes generated during hand soldering in the electronics industry. These portable systems come complete with extraction arms and installation kit that contain everything required to set up one or two operators with ease. Minimal installation allows the units to be moved with the work bench when factory layouts need changing due to production challenges. The low noise levels and fully comprehensive filtration units are ideal for factories with changing production demands.
1.2 AIM OF THE PROJECT
The aim of this work is to construct a solder fume extractor using an op-amp IC which removes fumes from the soldering area. The work is of automatic type which runs exhaust fan during soldering and stops exhaust fan when soldering iron is kept on soldering stand.
1.3 OBJECTIVE OF THE PROJECT
At the end of this work, students involved will
- be able construct a device which removes fumes from the soldering area using an op-amp IC
- able to know the effect of fumes on human health
- operating principle of solder fume extractor
- principle, design and connection of an op-amp.
1.4 APPLICATION OF THE PROJECT
The systems are ideally suited for soldering iron tip extraction, vac pens, flexi fume arms and any other number of applications that requires close proximity micro extraction.
1.5 PROBLEMS AND LIMITATION OF THE PROJECT
Solder Fume Extractor can be expensive and cause disruption. This device when using on work area, it need to move the extractor system to the job.
1.6 SCOPE OF THE PROJECT
This solder fume extractor was built using an op-amp IC which removes fumes from the soldering area. The work is of automatic type which runs exhaust fan during soldering and stops exhaust fan when soldering iron is kept on soldering stand.
Apart from the op-amp CA3130 used, two NPN transistors and few other passive component were also used. For fumes removing we had used a small 12V DC exhaust fan.
For automation of the projects solder fumes extractor we have used a sensor called piezo sensor (PZ1). The sensor PZ1 generate voltage when heat is detected (heat generates stress in it). Thus, we had attached a heat sink with piezo sensor PZ1. The PZ1 is connected to two inputs (inverting and non-inverting) of IC1 as shown in figure 1.
1.7 PROJECT WORK ORGANIZATION
The various stages involved in the development of this project have been properly put into five chapters to enhance comprehensive and concise reading. In this project thesis, the project is organized sequentially as follows:
Chapter one of this work is on the introduction to the study. In this chapter, the background, significance, objective, scope, application, limitation and problem of the study were discussed.
Chapter two is on literature review of this study. In this chapter, all the literature pertaining to this work was reviewed.
Chapter three is on design methodology. In this chapter all the method involved during the design and construction were discussed.
Chapter four is on testing analysis. All testing that result accurate functionality was analyzed.
Chapter five is on conclusion, recommendation and references.
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