Development Of Microcontroller-Based Soldering Iron Workstation

ABSTRACT

This work is building a microcontroller based soldering station which is an electrical device used for soldering tasks. It comprises soldering tools connected to the control unit, de-soldering tools / hot heat blower, soldering tip cleaners, holders, stands, and other accessories. The control unit consists of temperature adjustment knobs, display areas, and an electrical transformer.

The device was first built on a breadboard which is later transfer to vero board and soldered. The device was completely built and coupled, the result during the test shows that the charger was able to respond to its operation.

COVER PAGE

1. CERTIFICATION

III. DEDICATION

1. ACKNOWLEDGEMENT
2. ABSTRACT:

CHAPTER ONE

INTRODUCTION

• BACKGROUND OF THE STUDY
• PROBLEM STATEMENT
• AIM AND OBJECTIVE OF STUDY
• SIGNIFICANCE OF STUDY
• SCOPE AND LIMITATION OF STUDY
• DEFINITIONS OF TERMS

CHAPTER TWO

LITERATURE REVIEW

2.1    INTRODUCTION

2.2    REVIEW OF SOLDERING

2.3    TYPES OF SOLDERING

2.4    MAKING A SOLDER JOINT

2.5    SOLDERING IRON

2.6     TYPES OF SOLDERING IRON

2.7      SOLDERING IRON CHARACTERISTICS

CHAPTER THREE

MATERIALS AND METHOD

3.1    INTRODUCTION

3.2    MATERIALS

3.3    METHODS

3.4      CONSTRUCTION OF WORKSTATION

CHAPTER FOUR

RESULTS AND DISCUSSION

4.1    PROJECT DESCRIPTION

4.2    PROJECT STRUCTURE

• PROJECT CAPABILITIES AND LIMITATION

4.4      TESTING AND EVALUATION OF PROJECT

4.5      EVALUATION BY INSTRUCTORS

CHAPTER FIVE

5.1        SUMMARY, CONCLUSION AND RECOMMENDATIONS

5.1    SUMMARY

5.2    CONCLUSION

5.2    REOMMENDATION

REFERENCES

CHAPTER ONE

1.0                                                   INTRODUCTION

1.1                                     BACKGROUND OF THE STUDY

Electronics came into human as early civilization exists.  Today it’s inconceivable to think of a society living without the power electronics. Electronics, as an enabling technology is becoming more and more important and is the basis for many industrial processes, for the rational use of the energy, for new technologies in individual and mass transportation, areas that are rapidly growing requiring new concepts in order to fulfill cost, reliability and miniaturization.

One of the most important processes in creating electronics circuit is soldering. Soldering involves using a molten filler metal to wet the mating surfaces of a joint, with or without the aid of a fluxing agent, leading to a formation of metallurgical bonds between the filler and the respective components. In this processes, the original formation of the components are eroded by virtue of the reaction occurring between the molten filler metal and the solid components. The quality of soldered joints depends strongly on the combination of filler and component materials, including surface coating that may be applied to the components, and also on the processing conditions that are used. It is precisely for the reason that a sound understanding of the metallurgical changes accompanying the sequence of events that occur in making soldered joints is so vital for developing reliable joining process.

Soldering iron is invented way back in four thousand years ago by using open

flame or heated charcoal. Since there is no control for its temperature, Weller Company invented magnastat soldering iron that uses temperature sensitive magnetic tip. Soldering iron is a powerful weapon in the electronics industry. Soldering technology has generally evolved in an empirical manner, largely by trial and error. Standard soldering workstation plays a vital role in achieving a high quality solder and   creating a laboratory that is conducive for safety and health.

Our daily lives are shaped by electronics system. In the home we have myriad of electronic accessories: radios, televisions, camcorders, CD players, telephone answering machines, microwave ovens, and personal computers. Not so obvious but just a part of our lives are sophisticated electronics controls such us microprocessor engine control our car. We utilize a telephone system that functions with electronic devices to amplify and transfer telephone signals. Our conversations are carried around the world using a combination of microwave or fiber-optic links and satellites. For better and at time for worse, electronics has changed our lives. Although we are in constant touch with what is happening around the world, we are also at the peril of weapon of unimaginable destructive power that rely on electronics developments. An understanding of electronics is imperative not only for designing and using electronic systems but for directing the evolution of electronics systems so that they serve to improve the human condition.

1.2       Statement of the Problem

Akwa Ibom state polytechnic offers electronics technology program which aims to boost its technological advancement to be able to adhere its mission to produce a globally competitive individuals. Soldering workstation is a core factor to achieve a high parameter of instructions and favorable approach to students in learning potential techniques in soldering process.

Electronics laboratory in the Department of Industrial Engineering and Technology has inadequate of this kind of equipment. Instances happen that using non-regulated soldering iron can damage some component of the circuit. Electronics component is highly sensitive even an electrostatic discharge from human body can easily harm the component. Without proper resistance and discharging equipment in the workstation it can create adverse effect on the process specially during testing.

In addition Excessive exposure to lead oxide fumes can result in lead poisoning. Symptoms include loss of appetite, indigestion, nausea, vomiting, constipation, headache, abdominal cramps, nervousness, and insomnia. Lead is absorbed through the mucous membranes of the lung, stomach, or intestines and then enters the bloodstream.

This made the proponent propose the development of microcontroller based soldering iron workstation to provide necessary and correct tool to have a quality and sophisticated output in terms of electronic innovation and projects. In addition, it will lessen the harmful effect of soldering fumes contributing to the overall health safety of the users.  It will benefit the present and incoming students who wish to develop their skills in electronics and keep them safe from hazardous health effect. Providing a better stage for this kind of activity will immense the productivity of the students in pursuit to quality learning.

1.3       Aim and Objectives of the Study

The main aim of this study is to develop a microcontroller based soldering iron workstation to create an innovative working space for students and instructors working on electronic activities such as repairing, troubleshooting and circuit production of the department of Industrial Engineering and Technology Electronics Laboratory.

Specifically, aims to:

1. Design the microcontroller based soldering iron workstation;
2. Construct the microcontroller based soldering iron workstation;
3. Test the proposed design project; and
4. Evaluate the proposed design project.

1.4       Significance of the Study

The study will be a significant undertaking in creating a health friendly working environment. These studies also help the students and instructors to achieve a high level of work quality and accuracy during the phase of constructing different projects. Considering the needs of the students and interest in quality education, instructor and student are guaranteed a combative mastery. Furthermore this research can provide proposition on the benefits of using microcontroller based soldering iron in conformity with the health regulation.

Moreover this research will be helpful to students who are aiming to become an electronics technician. It will also serve as future reference for researchers in the field of electronics technology. And essentially, this research will enlighten every students the importance of proper working tools and equipment in the workstation.

1.5       Scope and Limitation

This study is limited to the creation, testing and evaluation of microcontroller based soldering iron workstation intent to improve the students learning and overall health condition.

A complete workstation equipped with regulated soldering iron and hot air soldering for integrated circuit and fume filter for direct absorption of soldering iron fumes. It also consists of improvised printed circuit board holder to mount during operation for accuracy and stability of the work. Personal Protective Equipment as well as suit is provided. Furthermore the study constrain to the needs of the students in the standard and proper tools and equipment.

The soldering iron control panel will use Atmel ATtiny85V microcontroller for memory. It is the high-performance, low-power Atmel 8-bit AVR RISC-based microcontroller combines 8KB ISP flash memory, 512B EEPROM, 6 general purpose I/O lines, 32 general purpose working registers, one 8-bit timer/counter with compare modes, one 8-bit high speed timer/counter, programmable watchdog timer with internal oscillator, three software selectable power saving modes, and debug wire for on-chip debugging. By executing powerful instructions in a single clock cycle, the device achieves throughputs approaching 1 MIPS per MHz, balancing power consumption and processing speed.

To regulate its temperature, LM7805 is a series of three terminal positive regulators with several fixed output voltages manufactured by Fairchild Semiconductor Corporation. Each type employs internal current limiting, thermal shut down and safe operating area protection, making it essentially indestructible. If adequate heat sinking is provided, they can deliver over 1A output current. Although designed primarily as fixed voltage regulators, these devices can be used with external components to obtain adjustable voltages and currents.

The workstation is equipped with anti-static device and grounding system for proper electro-static discharging. The workstation measures 24 inches high, 36 inches long and 24 inches wide. The counter top is made of laminated marine plywood with ¾ inch thick. The base composes of rounded aluminum with 1 inch diameter attached to a 1.5 inch diameter size wheel for easy transport. It also includes a cabinet for materials and accessories storage measuring 20 inches high and 20 inches wide.

The study involves all students taking up Bachelor of Industrial Technology major in Electronics of Akwa Ibom state polytechnic of the academic year 2015-2016. The researcher will conduct an overall survey to all respondents to ensure that the project development is conforming to its purpose.

1.6       Definition of Terms

Anti-Static Mat. It provides a path to ground for a charge from conductive or static dissipative items placed on the mat. This are made of single layer homogenous polymer mix, two layer static dissipative rubber material or vinyl with homogenous conductive layer material

Anti-Static Wrist Strap. Sometimes refer to ground bracelet is an antistatic device used to safely ground a person working on very sensitive electronic equipment, to prevent the buildup of static electricity on their body, which can result in electrostatic discharge (ESD).

Capacitor. It is a passive electronic component that stores energy in the form of an electrostatic field. In its simplest form, a capacitor consists of two conducting plates separated by an insulating material called the dielectric. The capacitance is directly proportional to the surface areas of the plates, and is inversely proportional to the separation between the plates. Capacitance also depends on the dielectric constant of the substance separating the plates.

Electrostatic Discharge. Referring to the sudden flow of electricity between two electrically charged objects caused by contact, an electrical short, or dielectric breakdown. A buildup of static electricity can be caused by tribocharging or by electrostatic induction.

Integrated Circuit. An integrated circuit (IC), sometimes called a chip or microchip, is a semiconductor wafer on which thousands or millions of tiny resistors, capacitors, and transistors are fabricated. Its function as a timer, counter, and memory.

Liquid Crystal Display. It is a flat panel display, electronic visual display, that uses the light modulating properties of liquid crystals. Liquid crystals do not emit light directly.

Microcontroller. It is a computer present in a single chip that contains the processor (CPU), non-volatile memory for the program (ROM or flash). Volatile memory for input and output (RAM), a clock and an input-output unit. It control and regulate the temperature of the soldering iron.

Personal Protective Equipment. It is commonly known as PPE, proper device and equipment used by technician during operation to protect from possible serious injury in case of malfunction.

Printed Circuit Board. A rigid flat board that holds chips and other electronic components. The board is made of layers typically two to ten  that interconnect components via copper pathways. The design transferred to a copper clad board for correct and accurate placement of components.

Soldering Iron. It is a hand tool consisting of a handle fixed to a copper tip that is heated  electrically and used to melt and apply solder.

Soldering Lead. It is a kind of metal alloy used to join together metal work pieces.

Soldering Oxide Fume. Refers to the harmful smoke created by the heated soldering lead.

Transistor. It regulates current or voltage flow and acts as a switch or gate for electronic signals. A transistor consists of three layers of a semiconductor material, each capable of carrying a current. A semiconductor is a material such as germanium and silicon that conducts electricity in a “semi-enthusiastic” way.