A Modification Design of Interlock System of ESPEC PV-212M Oven Rev 9_updated

8/9/2019 A Modification Design of Interlock System of ESPEC PV-212M Oven Rev 9_updated

1/96

Modification Design of Interlock System of ESPEC PV-212M Oven

A Pro ect St!dy

Presented to t"e #ac!lty of t"e

College of Engineering and $ec"nical De%artment

Man!el S& Enverga 'niversity #o!ndation

'niversity Site( )!cena City

In Partial #!lfillment of t"e *e+!irement

for t"e Degree

,ac"elor of Science in Electronics Engineering

E %anded $ertiary Ed!cation E+!ivalency and Accreditation Program

.y

Alvin /ose%" #& Pe0a

Marc" 2 1


2/96

I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3E2

Approval Sheet

$"is s%ecial %ro ect entitled7

MODIFICATION DESIGN OF INTERLOCK SYSTEM OF ESPEC PV-212M OVEN

MAC INE

Pre%ared and s!.mitted .y Alvin /ose%" #& Pena in %artial f!lfillment of t"e re+!irements for

t"e degree of ,ac"elor of Science in Electronics Engineering 8E$EEAP Program9 "as .een

%resented and %assed t"e Oral E amination&

E!"r# Eva!"el$!e L# Co!%ta!t$!oAdviser

A%%roved .y t"e Committee on Oral E amination :it" a grade of ;;;; on Marc" 1 ( 2 1

&e!$l'a N# V$lle!a%( PhD

Mem.er

E!"r# Er)$! Ella*ar E!"r# Sher)$! La"ra+a Mem.er Mem.er

G,$ller+o M# Ra"o r#( RCE( E'#D#C"air%erson

Acce%ted in %artial f!lfillment of t"e re+!irements for t"e degree of ,ac"elor of Science

in Electronics Engineering 8E$EEAP Program9&

........ G,$ller+o M# Ra"o r#( RCE( E'#D# Date Dean( College of Engineering and $ec"nical De%artment


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I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3E<

A/0!o)le'"e+e!t

#irst and foremost t"anks to o!r =od Almig"ty for giving me t"e strengt" and co!rage to

accom%lis" my st!dies and to everyone :"o "ad "el%ed me com%lete t"is %ro ect st!dy&

I :ant to t"ank my loving :ife A>eonete( My One and only da!g"ter A!drey( I t"ank

yo! for all yo!r s!%%ort( care( !nderstanding( %atience( and love t"at gave me strengt" in my

%!rs!it :it" t"is endeavor& $o my s!%erior( *odolfo $o.ias for giving me t"e o%%ort!nity to

earned and com%lete t"is degree& #!rt"ermore( I :o!ld like to t"ank my mot"er #elicidad( fat"er

Medardo( si.lings Allan( /ason( and Mica" for t"e enco!ragement and ins%iration %arted to me asa so!rce of my strengt" in f!lfilling my dream of finis"ing my st!dies&

I also :ant to t"ank my %ro ect st!dy adviser Engr& Evangeline )& Constantino for t"e g!idance

t"ro!g"o!t t"e vario!s revisions of t"is researc"( val!ed criticism and instr!ctions as :ell and to

all my classmates in ECE class of 2 1?-1 on t"eir s!%%ort and c"eerf!lness t"at made t"is

sc"ool electrifying and !ncom%licated for eac" and every one of !s&

)astly I :o!ld like to e %ress also my gratit!de to t"ose :"o "ad given me t"e

o%%ort!nity to com%lete t"is %ro ect st!dy most es%ecially to o!r dean Dr& =!illermo *ago( EC

instr!ctors( Engr& Er:in Ella>ar and Engr& S"er:in )agrama( :it"o!t yo!r s!%%ort and advise

t"ese co!ld not .e %ossi.le&


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I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3E?

De'$/at$o!

$o my ever-.ea!tif!l :ife( A>eonete(

$o my da!g"ter- A!drey(

$o my Pena #amily&

I dedicate t"is man!scri%t to all of yo! as yo! "ave .een and al:ays .e my ins%iration&


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I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3E

Ta le o Co!te!t%$itle Page@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@ 1A%%roval S"eet@@@@@@@@@@@@@@@@@@@@@@@@@@&&&@ 2Ackno:ledgement@@@@@@@@@@@@@@@@@@@@@@@@@@&& <Dedication@@@@@@@@@@@@@@@@@@@@@@@@&&@@@@@ ?

$a.le of Contents@@@@@@@@@@@@@@@@@@@@@&&@@@@@&)ist of $a.les@@@@@@@@@@@@@@@@@@@@@@@@@@@@&)ist of #ig!res@@@@@@@@@@@@@@@@@@@@@@@@@@@@ BA.stract@@@@@@@@@@@@@@@@@@@@@@@@@&@@@@@&

'3I$ I I3$*OD'C$IO3,ackgro!nd of t"e St!dy @@@@@@@@@@@@@@@@@@@@&& 1O. ectives of t"e St!dy@@@@@@@@@@@@@@@@@@@@@&& 11Conce%t!al #rame:ork@@@@@@@@@@@@@@@@@@@@@&& 11Significance of t"e St!dy@@@@@@@@@@@@@@@@@@&@@&& 1<Sco%e and Delimitation@@@@@@@@@@@@@@@@@@@@@&& 1?

Definition of $erms@@@@@@@@@@@@@@@@@@@@@@@ 1?Acronyms@@@@@@@@@@@@@@@@@@@@@@@@@@@ 1

'3I$ II- *EVIE O# *E)A$ED )I$E*A$'*E A3D S$'DIES@@@@@@@ 1B

'3I$ III ME$6ODS A3D P*OCED'*E*esearc" Design@@@@@@@@@@@@@@@@@@@@@@@@ 2F*esearc" Environment@@@@@@@@@@@@@@@@@@@@@&&& 2FProced!res @&&&@@@@@@&@@@@@@@@@@@@@@@@&@& 2Design Conce%t@@@@@@@@@@@@@@@@@@@@@@@@& 2

'3I$ IV- *ES')$S A3D DISC'SSIO3

Data =at"ering @@@@@@@@@@@@@@@@@@@@@@@@&


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I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3EF

S!mmary of #indings@@@@@@@@@@@@@@@@@@@@@@

'3I$ V CO3C)'SIO3S A3D *ECOMME3DA$IO3SConcl!sions@@@@@@@@@@@@@@@@@@@@@@@@@@ F1*ecommendations@@@@@@@@@@@@@@@@@@@@@@@& F2

*eferences@@@@@@@@@@@@@@@@@@@@@@@@@@&@@@& F<A%%endices A ESPEC PV-212M Oven Mac"ine@@@@@@@@@@@@@@ F? , PCB1 P"otoco!%ler Series@@@@@@@@@@@@&&@@@@ F C DS1< Memory@@@@@@@@@@@@@@&@@@@@@ FF D 3P3 $ransistor ,C ? @@@@@@@@@@@@@@@@@&&& F E MIC*OC6IP PIC1F#B GBB@@@@@@@@@ @@@@@@@& FB # )M


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L$%t o Ta le%

$a.le 3o& $itle Page

1 )ikert Scale for Eval!ation < 2 S%ecification *e+!irements ?F < ,ill of Materials ?B ? S!rvey *es!lts


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I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3EB

L$%t o F$",re%#ig!re 3o& $itle Page

1 Conce%t!al #rame:ork Paradigm 112 ESPEC PV-212M Oven


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10/96


A %tra/t

Alvin /ose%" Pena&( A Modification Design of Interlock System of ESPEC PV-212MOven Mac"ineJ( !n%!.lis"ed Pro ect St!dy for t"e degree of ,ac"elor of Science in ElectronicsEngineering& College of Engineering( !nder t"e E %anded $ertiary Ed!cation E+!ivalency and

Accreditation Program 8E$EEAP9( Man!el S& Enverga 'niversity #o!ndation( Marc" 2 1

ESPEC Oven mac"ine is one of t"e most commonly !sed mac"ines in t"e semicond!ctor

ind!stry today( d!e to its efficiency( versatility and relia.ility& $"e mac"ine can c!re t"e mold

com%o!nd after %rocessing in mold mac"ine to strengt"en t"e %lastic .y .aking t"e !nit&

In t"is st!dy t"e researc"er aims to %revent .y%assed o%eration of mac"ine :"en 1degree !nit inside t"e c"am.er can .e taken o!t %remat!rely since t"e door can .e o%en all t"e

time if :anted& In t"is %ro ect st!dy t"e researc"er "as s"o:n design fla: in e isting interlock

t"ro!g" t"e im%lementation of t"e %ro%osed Modification Design of Interlock System t"e

researc"er to %revent .y%assed&

$"e %ro ect feat!res an )ED mod!le :"ic" s"o:s t"e %arameters set in !nlocking t"e

oven( a matri key%ad for t"e in%!t of t"e %ass:ord set .y t"e !ser and a microcontroller :"ic"

:o!ld %rocess t"e data from t"e )ED matri and oven and dis%lay a corres%onding o!t%!t on t"e

)ED mod!le and do a corres%onding action in t"e solenoid valve&

$"e feasi.ility of t"e st!dy :as .ased on t"e res!lt on t"e s!rvey cond!cted on 1

tec"nical res%ondents& $"e s!rvey( :"ic" !sed t"e )ikert Scale( "ad an overall rating of Strongly

Agree& $"is res!lt s"o:ed t"at .ased on effectiveness and f!nctionality( t"e res%ondents strongly

agree t"at t"e %ro ect is effective and f!nctional to its o. ectives&

Keywords 7 C!ring( ESPEC oven( Interlock( Microcontroller( Semicond!ctor


11/96


3!$t I

I!tro',/t$o!

&a/0"ro,!' o the St,'4

Post ,ake Oven C"am.er is !sed e tensively in .aking( "eat treatmentGdrying of mold

!nit( device re+!iring clean air conditions& In addition to t"e standard instr!mentation :"ic"

offers t:o-ste% %rogramming( Class 1 cleanliness is ac"ieved .y em%loying a 6EPA filter and

a .ack-to-front laminar circ!lation system& $"e "ig"-%erformance of ESPEC Oven %rovides

sta.le %erformance even d!ring "eat-!% or cooling at "ig" tem%erat!res of 1 KC 8L< 2K#9&

Es%ec oven is a ma or assem.ly %rocess flo: in 3 P Semicond!ctor& It !se for

strengt"ening t"e mold com%o!nd and test t"e ca%a.ility of t"e !nit in "eat& $"is is set-!% .y

"o!rs .ase on revision of o!r engineer to f!ll com%lete c!ring and "eat resistance&

$"e main iss!e of t"is %ro.lem many s!%ervisors :as disregard t"e %rocess of mac"ine

d!e to a long "o!rs c!ring time of t"e !nit so t"ey sto% t"e mac"ine after %lacid "eating and

ot"ers no safety lock door d!ring o%eration& $"is means t"ey :ant more o!t%!t d!ring t"eir s"ift

and commitment to c!stomer& After !nnecessary !sing met"od of %rocess :"ic" may affect

+!ality of !nit( t"e %ossi.le an iety t"at affect is Crack !nit and incom%lete test in "eating for

relia.ility& So t"at :"y t"e circ!it "as .een design :"ic" called Modification of Interlock

System of ESPEC PV-212M Oven Mac"ineJ t"at "as a s%ecial design se+!ence to avoid t"e

%rocess of oven and safety !ser o%eration&


12/96


O 5e/t$ve% o the St,'4

$"e main o. ective of t"is st!dy is to ena.le t"e researc"er to come !% :it" a :orking

%rototy%e of A!to Interlock circ!it& $"is mod!le s"all act as a triggering com%onent on t"e %art

of t"e ESPEC Oven Mac"ine :"enever t"e mac"ine is !sed&

$"e follo:ing are t"e s%ecific o. ectives7

1& $o modify t"e design of interlock system of ESPEC Oven&

2& $o designa circ!it of modified design Interlock System&


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I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3E1<

$"e researc"er c"ose t"is frame:ork for t"e reader to easily !nderstand all t"e %ossi.le

reso!rces t"at t"e researc"er may !se to com%lete t"is %ro ect( Most of t"e reso!rces are clearly

stated in t"is ill!stration&

$"e researc"ers incl!ded all t"e %ossi.le materials in creating t"e %ro ect& $"ese :ere t"e

.asic electronics com%onent !sed in t"e circ!it like diode( resistor( ca%acitor( transistor and

*elay& $"e researc"er also needs to foc!s on some of t"e advance com%onent :"ic" is t"e

EEP*OM and Micro Controller 'nit( :it" t"e "el% of a t"ird %arty :"o is more familiar in

%rogramming lang!age&

S$"!$ $/a!/e o the St,'4

$"e tec"nicians es%ecially t"e %rocess line s!stainance :ill .enefit from t"is st!dy .y

%reventing t"e incom%lete %rocess of t"e mac"ine and +!ality of t"e !nit& $"ro!g" t"is action( it

:ill .e a lesser amo!nt of crack com%onent d!e to incom%lete c!ring and safety o%eration&

$"e st!dy is also .eneficial to 3 P as a :"ole& $"e savings t"at :ill .e reali>ed in

creating in-"o!se fa.rication of t"e %ro ect :ill "ave a .ig im%act in t"e de%artmentNs cost

savings %rogram& ,y %reventing incom%lete c!ring of !nit( t"e c!stomer :ill give a "ig"

re%!tation to t"e com%any&

$"is st!dy :o!ld serve as a g!ide or reference in t"e cond!ct of ot"er similar a%%lication

t"at mig"t .e needed .y tec"nical %eo%le or st!dent in t"eir line of :ork or career( %artic!larly in

man!fact!ring ind!stries&


14/96

I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3E1?

,y %racticing t"is st!dy( t"e researc"er :o!ld .e a.le to refres" "is kno:ledge a.o!t

electronic circ!its and com%onents( en"ance t"e skills in t"e a%%lied as%ect of electronics( and

develo% t"e str!ct!ral a%%roac" of creating a tec"nical %a%er&

S/ope a!' 'el$+$tat$o!% o the St,'4

$"is st!dy deals :it" t"e creation of a Modification of Interlock system Circ!it :"erein

t"e ESPEC Oven mac"ine :ill %erform :"en t"e tem%erat!re 1 degree Celsi!s :as sta.le t"e

interlock :ill activate close and after finis" "o!rs c!ring t"e door :ill o%en& If :"en t"e

mac"ines sto% :it"in t"e incom%lete c!ring time( t"e state of interlock close :ill al:ays activate

only %rocess can access to release t"e lock .y in%!t t"e %ass:ord code&

$"is is t"e first time t"at researc"er attem%t to create a design :it" micro-controller !nits

s%ecially in command a ESPEC Oven mac"ine %erformed a task !sing a se%arate circ!it .oard&

In t"is circ!it design t"e microcontroller !nit :ill !se as t"e main %art of t"e circ!it :"ic" :ill .e

t"e controller of all t"e in%!t signals to %erform anot"er design task&

$"!s t"is st!dy is limited for ESPEC Oven Mac"ine :"ic" is located on Central

Assem.ly de%artment at t"e %ost mold c!re area :"ere t"e researc"er is c!rrently assigned& $"e

%ro ect st!dy :ill .e limited for one !nit ESPEC Oven e+!i%ment only and after sim!lation and

eval!ation( it :ill fan o!t to ot"er e isting same e+!i%ment t"at needed to %erform t"e A!to-

Interlock system&


15/96


De $!$t$o! o Ter+%

,!y-off is t"e %rocess of ins%ecting a ne: e+!i%ment to .e %!rc"ased according to t"e

re+!ired s%ecifications %rior to t"e delivery of t"e e+!i%ment to t"e site of t"e %!rc"aser&

Ca%acitor is an electrical device t"at can store energy in t"e electric field .et:een a %air

of closely s%aced cond!ctors called %lates& "en voltage is a%%lied to t"e ca%acitor( electric

c"arges of e+!al magnit!de .!t o%%osite %olarity .!ild !% on eac" %late&

Connector is an electrical connector is a device for oining electrical circ!its toget"er& In

com%!ting it can also .e kno:n as a %"ysical interface&

Es%ec PV-212M Oven Mac"ine is t"e tem%erat!re c"am.er t"at c!res t"e molding

com%o!nd and itNs also test t"e ca%a.ilities on "eat resistance of t"e !nit&

6ard:are refers to tangi.le com%onents of com%!ter system s!c" driver .oard(

In%!tGO!t%!t .oard& $"e "ard:are com%onent is !se to store or %rocess res!lts&

Integrated circ!it a miniat!ri>ed electronic circ!it constr!cted of individ!al

semicond!ctor devices( as :ell as %assive com%onents .onded to a s!.strate or circ!it .oard&

Interlock is t"e %rocesses :"en t"e mac"ine reac"es t"e set %oint of1750

Celsi!s it

:ill a!tomatic lock t"e door and it :ill release after "e finis" t"e %rocess&

)ig"t Emitting Diode 8)ED9 is a semicond!ctor device t"at emits inco"erent narro:-

s%ectr!m lig"t :"en electrically .iased in t"e for:ard direction& $"is effect is a form of

electrol!minescence& $"e color of t"e emitted lig"t de%ends on t"e com%osition and condition of

t"e semicond!ctor material !sed( and can .e infrared( visi.le or near-!ltraviolet& )EDS are


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I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3E1F

availa.le in different si>e( s"a%e and color& )EDS may .e in color red( yello:( green( orange(

.l!e and :"ite&

Microcontroller is a com%!ter control system on a single c"i%& It "as many electronic

circ!its .!ilt into it( :"ic" can decode :ritten instr!ctions and convert t"em into electrical

signals &$"e microcontroller :ill t"en ste% t"ro!g" t"ese instr!ctions and e ec!te t"em one .y

one& Microcontroller is no: c"anging electronics design& Instead of "ard :iring a n!m.er of

logic gates toget"er to %erform some f!nction :e no: !se instr!ctions to :ire t"e gates

electronically& $"e list of t"ese instr!ctions given to t"e microcontrollers is called %rogram&

Poka-yoke is a /a%anese term t"at means fail-safing or mistake- %roofing & A %o

yoke is any mec"anism in a lean man!fact!ring %rocess t"at "el%s an e+!i%ment o%erator avoid

mistakes& Its %!r%ose is to eliminate %rod!ct defects .y %reventing( correcting( or dra:in

attention to "!man errors as t"ey occ!r& $"e conce%t :as formalised( and t"e term ado%ted( .y

S"igeo S"ingo as %art of t"e $oyota Prod!ction System& It :as originally descri.ed as .aka-

yoke( .!t as t"is means fool-%roofing t"e name :as c"anged to t"e milder %oka-yoke&

Process #lo:is t"e ill!stration of one %rocess or %roced!re :"ere t"e ste% .y ste% of t"e

%rocess is %ro%erly defined according to t"eir %ro%er se+!ence&

PC? is one of t"e five ,!siness #!lfillment =ro!%s 8,#=9 in 3 P also kno:n as

Po:er de%artment&

Programming )ang!age C is a general-%!r%ose( %roced!ral( im%erative com%!ter

%rogramming lang!age develo%ed in t"e early 1 s .y Dennis *itc"ie for !se on t"e '3I

o%erating system& It "as since s%read to many ot"er o%erating systems( and is no: one of t"e


17/96


most :idely !sed %rogramming lang!ages& C also "as "ad a great infl!ence on many ot"er

%o%!lar lang!ages&

*esistoris a t:o-terminal electrical or electronic com%onent t"at resists an electric c!rrent

.y %rod!cing a voltage dro% .et:een its terminals in accordance :it" O"mNs la:&

$ransistoris a device :"ic" !tili>es a small c"arge in c!rrent to %rod!ce a large c"ange in

voltage( c!rrent or %o:er& It may f!nction also as an am%lifier or an electronic s:itc"&

Varia.le resistor consists of a resistance track :it" connections at .ot" ends and a :i%er

:"ic" moves along t"e track as yo! t!rn t"e s%indle& $"e track may .e made from car.on(cermets 8ceramic and metal mi t!re9 or a coil of :ire 8for lo: resistances9&

A/ro!4+%

3 P - 3e t E %erience

,#= - ,!siness #!lfillment =ro!%s

HA - H!ality Ass!rance

MC' - Micro Controller 'nit

MP)A, - Microc"i% PIC )a.

IDE - Integrated Develo%ment Environment

P#MEA - Process #ail!re Mode and Effect Analysis

PC, - Printed Circ!it ,oard


18/96

I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3E1B

3!$t II

Rev$e) o Relate' L$terat,re a!' St,'$e%

$"is section mentioned t"eories and o%eration of t"e electronic com%onents and materials

needed to modify and creating A!to Interlock of a circ!it( as :ell as ot"er tec"nical information

necessitated to .e disc!ssed for f!rt"er !nderstanding of all t"e target electronic com%onents&

$"e so!rces of information are vario!s electronic .ooks and kno:ledge :e.sites on t"e Internet&

In 3 P Semicond!ctor %artic!larly in Po:er Central Assem.ly t"e %laces :"ere all

%rod!cts "ad .een tested and C!ring t"e molding com%o!nd after :ent in molding mac"ine& $"isis t"e area :"ere t"e researc"ers are also assigned&

E%pe/ PV-212MOve!

According to ESPEC Cor%& 82 F9 Oven !sed e tensively in .aking( "eat

treatmentGdrying of mold !nit( devices re+!iring clean air conditions& In addition to t"e standard

instr!mentation :"ic" offers t:o-ste% %rogramming( Class 1 cleanliness is ac"ieved .y

em%loying a 6EPA filter and a .ack-to-front laminar circ!lation system& $"e "ig"-%erformance

of ESPEC Oven %rovides sta.le %erformance even d!ring "eat-!% or cooling at "ig"

tem%erat!res of 1 KC 8L< 2K#9&

C$r/,$t

According to #loyd 82 1 9 .asically( an electric circ!it consists of a voltage so!rce( a

load( and a %at" for c!rrent .et:een t"e so!rce and t"e load&


19/96


La!",a"e C66

)ovine 82 ?9 noted t"at t"ere are a n!m.er of com%ilers on t"e market t"at allo: !sers

to :rite %rograms 8code9 in different "ig"-level lang!ages& 6ig"-level lang!age frees t"e

%rogrammer from :restling :it" and controlling t"e microcontrollerNs registers :"en :riting

code and accessing t"e different as%ects of t"e microcontrollerNs feat!res and memory&

MPLA& IDE

According to microc"i% 82


20/96


%ort can .e config!red as eit"er


21/96


D$o'e1N:;;1

According to datas"eet&com 82 B9 t"e 13? 1 series 8or 13? series9 is a family of

%o%!lar 1& am% general %!r%ose silicon rectifier diodes commonly !sed in AC ada%ters forcommon "o!se"old a%%liances& ,locking voltage varies from to 1 volts& $"is diode is

made in an a ial-lead DO-?1 %lastic %ackage&

$"ese are fairly lo:-s%eed rectifier diodes( .eing inefficient for s+!are :aves of more

t"an 1 k6>& $"e series :as second so!rced .y many man!fact!rers& $"e 13? series :ere in

t"e Motorola Silicon *ectifier 6and.ook in 1 FF( as re%lacements for 132F t"ro!g" 132F1 &

$"e 13 ? series :ere anno!nced in Electrical Design 3e:s in 1 FB( along :it" t"e no:

lesser kno:n 1& -am%ere 13 < 1 series& $"ese devices are :idely !sed and recommended&

Capa/$tor

#rom t"e statement of #loyd 82 1 9 a ca%acitor is an electrical device t"at stores

electrical c"arge and is constr!cted of t:o %arallel cond!ctive %lates se%arated .y an ins!lating

material called t"e dielectric&

Cera+$/

Ale ander 82 ?9 said t"at t"e ceramic is a c"i% of altering layers of metal and ceramic(

de%ending on t"eir dielectric( :"et"er Class 1 or Class 2( t"eir degree of tem%erat!reGca%acity

de%endence varies& $"ey often "ave 8es%ecially t"e class 29 "ig" dissi%ation factor( "ig"fre+!ency coefficient of dissi%ation( t"eir ca%acity de%ends on a%%lied voltage( and t"eir ca%ac

c"anges :it" aging& 6o:ever t"ey find massive !se in common lo:-%recision co!%ling and

filtering a%%lications&


22/96


Re%$%tor

Ale ander 82 ?9 released t"e statement t"at resistor is a t:o-terminal electronic

com%onent designed to o%%ose an electric c!rrent .y %rod!cing a voltage dro% .et:een itsterminals in %ro%ortion to t"e c!rrent( t"at is( in accordance :it"O"mQs la:7 V U I*&

Practical resistors can .e made of resistive :ire( and vario!s com%o!nds and films( and t"ey can

.e integrated into"y.rid and %rinted circ!its& Si>e( and %osition of leads are relevant to

e+!i%ment designers resistors m!st .e %"ysically large eno!g" not to over"eat :"en dissi%ating

t"eir %o:er&

#o!r-.and identification is t"e most commonly !sed color-coding sc"eme on all resistors&

It consists of fo!r colored .ands t"at are %ainted aro!nd t"e .ody of t"e resistor& $"e first t:o

.ands encode t"e first t:o significant digits of t"e resistance val!e( t"e t"ird is a %o:er-of-ten

m!lti%lier or n!m.er-of->eroes( and t"e fo!rt" is t"etolerance acc!racy( or acce%ta.le error( of

t"e val!e& Sometimes a fift" .and identifies t"e t"ermal coefficient( .!t t"is m!st .e

disting!is"ed from t"e tr!e -color system( :it" < significant digits&

PC& P$!%

According to ans:ers&com t"is are t"e electronic interconnects devices for %rinted circ!it

.oards& It "as a .etter signal integrity for "ig" relia.ility a%%lication across a :ide range of

ind!stries& *egardless t"e ty%e and design of a PC .oard( e ternal signal and %o:er connections

m!st .e made& Printed circ!it .oards( as :ell as ot"er electronic com%onents( in many instances

are electronically oined t"ro!g" connectors& $"e com%onents are ty%ically interconnected to

define a given f!nction&

http://en.wikipedia.org/wiki/Terminal_(electronics)http://en.wikipedia.org/wiki/Electronic_componenthttp://en.wikipedia.org/wiki/Electronic_componenthttp://en.wikipedia.org/wiki/Electronic_componenthttp://en.wikipedia.org/wiki/Electric_currenthttp://en.wikipedia.org/wiki/Electric_currenthttp://en.wikipedia.org/wiki/Ohm's_lawhttp://en.wikipedia.org/wiki/Hybrid_circuithttp://en.wikipedia.org/wiki/Hybrid_circuithttp://en.wikipedia.org/wiki/Printed_circuit_boardhttp://en.wikipedia.org/wiki/Engineering_tolerancehttp://en.wikipedia.org/wiki/Electronic_componenthttp://en.wikipedia.org/wiki/Electronic_componenthttp://en.wikipedia.org/wiki/Electric_currenthttp://en.wikipedia.org/wiki/Ohm's_lawhttp://en.wikipedia.org/wiki/Hybrid_circuithttp://en.wikipedia.org/wiki/Printed_circuit_boardhttp://en.wikipedia.org/wiki/Engineering_tolerancehttp://en.wikipedia.org/wiki/Terminal_(electronics)


23/96

I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3E2<

L$"ht E+$tt$!" D$o'e

,ase on Ale ander 82 ?9 a lig"t-emitting diode 8)ED9 as s"o:n in is a semicond!ctor

device t"at emits inco"erent narro:-s%ectr!m lig"t :"en electrically .iased in t"e for:ard

direction& $"is effect is a form of electrol!minescence& )EDs are small e tended so!rces :it"

e tra o%tics added to t"e c"i%( :"ic" emit a com%le intensity s%atial distri.!tion& $"e color of

t"e emitted lig"t de%ends on t"e com%osition and condition of t"e semicond!cting material !sed(

and can .e infrared( visi.le or near-!ltraviolet& *!.in ,ra!nstein of t"e *adio Cor%oration of

America first re%orted on infrared emission from galli!m arsenide 8=aAs9 and ot"er

semicond!ctor alloys in 1 & E %erimenters at $e as Instr!ments( ,o. ,iard and =ary Pittman(

fo!nd in 1 F1 t"at galli!m arsenide gave off infrared 8invisi.le9 lig"t :"en electric c!rrent :as

a%%lied& ,iard and Pittman :ere a.le to esta.lis" t"e %riority of t"eir :ork and received t"e

%atent for t"e infrared lig"t-emitting diode& 3ick 6olonyak /r& of t"e =eneral Electric Com%any

develo%ed t"e first %ractical visi.le-s%ectr!m )ED in 1 F2&

$"e researc"er !ses t"e a.ove literat!re to !nderstand t"e %ro.lems system of interlock

ESPEC oven mac"ine and "o: does it :ork in different :ays& $"is :ill also .e needed to

!nderstand t"e c"aracteristic and .e"avior of t"e devices t"at c"osen on t"e circ!it( t"e %ossi.le

%ro.lem and circ!it conflict may arise :"en t"en researc"er constr!cting it&

M$/ro/o!troller

A st!dy .y C"eng( et Al& 82 ?9 mac"ine vision set !% !sing t:o cameras as "!man eyesand a micro-controller as a "!man .rain to recogni>e t"e o. ect& Moreover( :it" t"e aid of

artificial intelligence( t"e mac"ine acted like a reg!lar %erson and identifies o. ects& $"is

mac"ine vision %ro ect :as im%lemented on t"e *o.oco% ro.ot& In ot"er :ords( t"ese researc"es


24/96

I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3E2?

create an eyes for t"e *o.oco% ro.ot t"at %romoted t"e st!dy of ro.otics and artificial

intelligence 8AI9 researc"es for t"e O"io State 'niversity& $"e st!dy is related to t"e researc"erNs

%ro%osed st!dy in s!c" a :ay t"at it is dealing :it" t"e !se a micro controller c"i% as t"e core

com%onent in t"e circ!it&

$an( et Al& 82 B9 re%laced a mec"anical clock :it" a m!c" relia.le( acc!rate(

maintenance free and %orta.le service& $"ey !sed a microcontroller .ased digital clock !sing PIC

1F#B A and soft:are :ritten in C lang!age& $"e controller control all t"e feat!res and t"e in%!t

fre+!ency taken from a 6 clock fre+!ency circ!it &$o s"o: t"e time seven segment )ED(

fo!r )EDs :ere !sed&

$"is can .e considered as related to t"e researc"erNs %ro%osed st!dy in s!c" a :ay t"at

t"e Microcontroller .ased Digital also !ses a PIC microcontroller !sing C lang!age )CD dis%lay

as t"e core com%onent in t"e circ!it&

$"e gro!% of Amon( et&al( 8MSE'#( Marc" 2 9 also designed a control system

consisting of several sensors :it" different o. ectives :it" =SM mod!le& Eac" sensor is aimed at

detecting some kind of sec!rity .reac"& Most im%ortantly( t"e entire system !sed a

microcontroller t"at %laced in t"e device to control( to "ook !%( to %o:er and store information&

$"e o. ective is to detect t"ree kinds of sec!rity .reac"es t"at is lig"t detection( o%ening a door

and movements& Once any of t"e sensors is triggered( t"e =SM mod!le sends SMS message to

t"e o:ner of t"e "o!se or esta.lis"ment& $"is a!t"ori>ed %erson !sed PI3 n!m.er to control t"e

system& $"e related to t"e researc" is !tili>ed t"e same medi!m :"ic" is t"e micro controller in

form!lating a circ!it&

In a st!dy made .y ,aronia( et& al( 8MSE'#( Marc" 2 9 entitled A Microcontroller

.ased A!tomated Door )ock SystemJ( "e designed a control system consisting of a


25/96


microcontroller c"i% t"at controls t"e doors of classrooms and la.oratories& $"e %ro%osal :as to

install a circ!it and a key%ad to control t"e o%ening and closing of t"e door& $"e a!t"ori>ed

%ersonnel t"at "ave t"e %ass:ord or n!m.er com.ination t"at :ill .e encoded into t"e key%ad

can only do t"is& $"e st!dy can .e related to t"e researc"erNs %ro%osed st!dy in s!c" a :ay t"at

t"e A!tomated Door )ock System also !ses a microcontroller c"i% as t"e core com%onent in t"e

circ!it&

#rom t"e st!dy of Al.!ero and *eganit of Polytec"nic 'niversity of t"e P"ili%%ines

8Marc" 2 ?9 t"ey designed an a%artment digital electric s!. metering system !sing a

microcontroller PIC1F#B and a )i+!id Crystal Dis%lay t"at :as !sed in t"e System& 'sing as!. metering system( t"e cons!mers com%rising of t"e lessee of commercial !nit or t"e %erson

renting a%artment :ill .e availing t"e electricity service .y means of %aying t"e o:ner a certain

amo!nt in advance& $"e electricity :ill .e availa.le as long as t"e %re%aid load is not e+!al to t"e

.ase rate %rovided .y t"e electricity s!%%lier& $"e transaction for t"e electric cons!m%tion :ill .e

in a %re%ayment format& $"e digital electric meter dis%lay kilo:att "o!r electricity cons!m%tion(

remaining %re%aid .alance and cost %er kilo:att "o!r on its )i+!id Crystal Dis%lay& $"eirs

st!dies is also related to t"e researc"erNs %ro%osed st!dy in s!c" a :ay t"at t"e a%artment digital

electric s!. metering system also !ses a PIC microcontroller and )CD dis%lay as t"e core

com%onent in t"e circ!it&

$"e a.ove st!dies :ere c"osen .y t"e researc"er to em%"asi>e t"e im%ortant

%artici%ation of Microcontroller in every design in t"e modern years& $"e ca%a.ility to sim%lify

t"e circ!it in creating effective sol!tion .y means of t"is small c"i% can .e %ossi.le&


26/96

I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3E2F

3!$t III

Metho'% a!' Pro/e',re%<

$"is !nit disc!ssed t"e different met"ods and %roced!re t"at t"e researc"er :ill .e !sing to

reali>e t"e st!dy& It consists of researc" met"od( researc" design( researc" environment and

%roced!re&

Re%ear/h De%$"!

$"e foc!s of t"e st!dy is to develo% a %rototy%e a!to-interlock circ!it :"erein t"e

*esearc" and Develo%ment met"od :as a%%lied to esta.lis" t"e %ositive res!lt& $"e %rototy%ing

is t"e engineering term commonly !sed for trial and error "o:ever t"e desired o!t%!t are

vis!ali>ed and calc!lated& $"is :as done .y t"e researc"er to see t"e %ossi.le :eakness of t"e

design( d!ring t"e %rocess of trial t"e researc"er "as t"e c"ance to contin!o!sly develo% a circ!it(

correct t"e %ossi.le mistake and to develo% t"e %ossi.le im%rovement .y adding e tra feat!res in

t"e system&

$"e %rototy%ing met"od :as a%%lied to t"e %ro ect to %rod!ce t"e .est res!lts :it"

regards to t"e o. ective of t"e st!dy& "ile contin!o!sly designing and im%roving t"e system to

fit t"e o. ective( a trial and error test :as cond!cted every time& $"is ens!res t"at t"e circ!it

design im%roves every time a trial :as made&

Re%ear/h Lo/ale

$"e researc"er foc!s for t"e sol!tion on %rocess of t"e mac"ine and safety of !ser :"ere

t"e c!rrently "a%%ening on 3 P semicond!ctor es%ecially on Po:er De%artment& $"is is t"e

de%artment :"ere t"e researc"er c!rrently assigned& All of t"e data gat"ered from t"e com%any

starting from t"e data :"ere t"e .y%ass of t"e mac"ine and some %ro.lem "ad .een seen( like


27/96


MPM# 8Mac"ine Prod!ct Monitoring #orm9( Vis!al Ins%ection )og s"eet( HA log s"eet and t"e

daily HA PPM re%orting :"ere all t"e non conformance .een indicated&

$"e entire st!dy :as cond!cted at 3 P Semicond!ctor facility( and at sc"ool :"ere t"e

researc"er c!rrently st!dying at Man!el S& Enverga 'niversity&

Re%po!'e!t% o the Re%ear/h

$"e researc"er gat"ered res%ondents to com%lete t"e st!dy& $"ey are t"e %eo%le :"o :ill

"el% t"e researc"er to make t"is .ig %ro ect %ossi.le& $"e line engineer is t"e one :"ose e %ert

on t"e e+!i%ment :ill give t"e feed.ack on t"e risk and t"e im%act of t"e feasi.ility st!dy& $"esoft:are engineer is t"e one :"o :ill do t"e %rogramming in t"e Micro-controller !nit& $"e line

s!%ervisor :ill make sc"ed!le regarding t"e availa.ility of t"e mac"ines needed on t"is %ro ect&

$"e o%erator and HA %ersonnel :ill validate t"e effect of t"e %ro ect once it is im%lemented&

Pro/e',re%

$"e researc"er s"all !ndertake t"e systematic activities in order to com%lete t"is researc" st!dy&

Data Gather$!"# $o contin!e t"is st!dy t"e researc"er :ill refer to t"e tec"nical man!als

of t"e Es%ec PV-212M Oven Mac"ine& $"is :ill also needed a cons!ltation to e+!i%ment

engineering to "ave additional ideas t"at is not covered .y t"e tec"nical man!als&

$"e researc"er :ill also gat"er relevant information in t"e electronic engineering .ooks

and in t"e tec"nical Internet sites needed in ac"ieving t"e o. ectives of t"is st!dy&

$"ese tools :ill "el% a lot to researc"er to dee%ly !nderstand t"e %ro ect t"at :ill going

t"ro!g"&


28/96

I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3E2B

S4%te+ De%$"! Mo'$ $/at$o!# $"e researc"er :ill create a design modification for t"e

%ro ect .ased on e isting design %ro.lem identification( design com%!tation( creating circ!it(

installation( and testing t"e o!t%!t of t"e %ro ect&

$"e system :o!ld .e modified .y attac"ing a key%ad matri and an )CD screen to

%revent !na!t"ori>ed !nlocking of t"e Oven& $"e data coming in from t"e oven and t"e key%ad

matri :o!ld .e %rocessed .y t"e microcontroller for acc!rate and f!nctional res!lt&

C$r/,$t De%$"!# In designing a circ!it t"is :ill need a corres%onding kno:ledge in .asic

electronics and t"e .asic %rinci%le of eac" com%onent& 1&9 'nderstand .asic f!nction of t"e

mac"ine and "o: f!nction of interlock& 2&9 Develo% an electronic circ!it design .ased on t"e

learningNs ac+!ired from t"e researc" %rocess&


29/96


$"e eval!ation :ill foc!s on t"e criteria of effectiveness and f!nctionality& In %roving its

effectiveness and f!nctionality( data :ill .e gat"ered t"ro!g" a s!rvey :"ic" :as analy>ed

t"ro!g" a modified )ikert Scale&

$"e H!estions :ill .e follo:s

Effectiveness

1&9 Is t"e mac"ine %erforming a!to-interlock :"en t"e mac"ine sta.le at 1 degree&

2&9 Celsi!sW Is t"ere any occ!rrence of after t"e installation of t"e circ!itW

#!nctionality

1&9 3o mac"ine "ang-!%s or .reakdo:n related to a!to interlock&2&9 3o mac"ine do:ntime d!ring starting !% oven&

$"e format of a ty%ical five-level )ikert item is7

1& Strongly Disagree

2& Disagree


30/96


>M ? @SA B= 6 @A := 6 @3 = 6 @D 2= 6 @SD 1=

.................................

TNR

>here<

>M ? >e$"hte' Mea!

TNR ? Total N,+ er o Re%po!'e!t%

$a.le 1

Likert Scale for Evaluation

Rat$!" Rate S/ale

SA U Strongly agree ?&21 &

A U Agree ?


31/96

I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3Eing t"e affectivity( efficiency and safety and t"is

:ill .e ans:ered .y t"e stake"olders via s!rvey&


32/96



33/96

I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3Eation of t"is %ro ect

st!dy& It also %rovides t"e %resentation and inter%retation of t"e data gat"ered on "o: t"e

researc"er cond!cted "er met"od( design modification( analysis( %roced!re and t"e o!tcome of

t"e modified design of interlock system of ESPEC PV-212M Oven mac"ine&

Data Gather$!"

$"e data gat"ered :as f!lly st!died to identify t"e so!rces of o%%ort!nities& #acts

o.tained "ad to .e form!lated to determine t"e .aseline %ros%ect of t"is %ro ect st!dy&

ESPEC PV-212M ove! +a/h$!e #$"e researc"er gat"ered t"e follo:ing data s"o:n in

#ig!re 2 and :as f!lly st!died to identify t"e so!rce of o%%ort!nity& ,elo: fig!res s"o:s t"e

act!al mac"ine and electrical lay-o!t of ESPEC Oven PV-212M :"ere t"e researc"er foc!s t"e

interlock system to im%rove t"e safety of t"e !ser :"en !sing t"e mac"ine&

Figure 27 ESPEC PV-212M Oven Mac"ineE $%t$!" pro/e%% lo) /hart# In #ig!re < ill!strate t"e %rocess flo: c"art of ESPEC PV-

212M Oven&


34/96

Start Mode Rising up Temp Stabilization of temp 175 Start 5hrs

Door will Lock5hrs ndDoor will unlocknd Mode

!perational "omplete



35/96


Figure 4 7 E isting Sc"ematic Diagram

Data in fig!re s"o:s t"at t"e most critical c!ring of t"e !nit sta.le in 1 degree

Celsi!s !nit inside t"e c"am.er can .e take o!t %remat!rely( since door can .e o%en all times if

:anted .eca!se of t"e !nnecessary %roced!re so :"y t"e line %rocess tec"nician didnNt kno: if

t"e cycle :as done&


36/96



37/96

Start Mode Rising up Temp Stabilization of temp 175 Start 5hrs

Door will Lock5hrs ndDoor will unlocknd Mode

!perational "omplete

Door Lock Steadil&

nter 'asswordDoor will unlocknd Mode!nl& 'rocess Tech can access


Figure 6: '%grading Se+!ence of Interlock System

It e %lains t"e additional flo: system to %revent .y%ass s"o:s in no& 1& A ne: se+!ence

a%%ear once t"ereNs an error enco!ntered& $"e door :ill .e locked and only t"e %rocess

tec"nician :"o "as access to t"e door :o!ld .e a.le to !nlock and investigate t"e error "a%%ened

:it" t"is t"e researc"er comes !% an idea .y !sing a microcontroller to im%rove t"e se+!ence of

interlock system and also added feat!res to t"e mac"ine&

S4%te+ Flo) Chart & On #ig!re t"e flo: c"art %rocess of microcontroller :"ere t"eresearc"er created a %rogram on "o: :ill e ec!te t"e system of interlock& $"e researc"er also

!sed MP)A, soft:are to create a %rogram to im%rove t"e se+!ence of t"e interlock system&

1


38/96

Start

Machine#

Temp#"ount

(sMachine !k

(s Temp 175

Lock Solenoid

!pen Solenoid

(s"ount

(s the Machine Turn !)*

nter 'assword

(s 'assword "orrect*

"ount + "ount ,1Dela&+1----ms

.D

/

/

.o

.o

0es

0es

.o.o

0es

.o

0es



39/96

'ower Suppl& S' " ! . Modi2cation (nterlock S&stem (nterlock


Figure 7: #lo: C"art of t"e So!rce Code of t"e Microcontroller

&lo/0 D$a"ra+# As ill!strated in #ig!re B( t"e first section is t"e %o:er s!%%ly& An in%!t

signal of 22 volts AC is a%%lied to t"e %o:er s!%%ly :"ic" :ill give so!rce across t"e system of

ESPEC PV-212M Oven& $"e ESPEC Oven section is t"e main .ody c"am.er :"eret"ey %rocess

t"e !nit carried o!t accordingly 8e&g& tem%erat!re and time9 and also for test relia.ility of "eating

t"e !nit&

Figure 8: ,lock Diagram of "ole System ESPEC Oven

In t"is section :"ere t"e researc"er foc!sed on t"e Modification Interlock System .y

interfacing t"e signal to t"e ESPEC oven mac"ine and take control of microcontroller& $"e #inal

section Interlock( a ty%e of electromec"anical !sed .y a G2 :ay valve solenoid and %iston

cylinder t"at %erform to .e lock and !nlock t"e door&

C$r/,$t De%$"!

$"e develo%ment of %ro%osed %ro ect st!dy covers t"e "ard:are and :iring connection of

t"e modified design&


40/96


Mater$al Sele/t$o!# D!ring t"e circ!it develo%ment of t"is %ro ect st!dy( incl!ded :ere

t"e selection of t"e %recise com%onent and materials s"o:n in fig!re :"ic" are electronic

standard and are readily availa.le in t"e market& $"ese materials are t"e essence of t"is %ro ect

st!dy since it :ill define "o: relia.le and efficient t"is %ro ect :o!ld .e&

$ransistor ,C ? 13? DiodeI

C Socket P"otoco!%ler

)ED mm )M


41/96

I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3E?1

Figure : Electronics Com%onents 'sed

S/he+at$/ D$a"ra+# #ig!re 1 ill!strates t"e %rototy%e circ!it :"ic" :ere s%ecially

designed for ESPEC Oven to create a systematically se+!ence of interlock door .y !sing a

%rogramma.le circ!it :"ic" called microcontroller&

Figure 1!: Sc"ematic Diagram of Interlock System

C$r/,$t D$a"ra+# $"e circ!it diagrams .elo: s"o:s t"e com%!tation %er %arts of t"e

sc"ematic diagram( .ased on t"e in%!t( o!t%!t and %rocessing of t"e %ro ect&


42/96

I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3E?2

Figure 11: Circ!it Diagram of Interlock System


43/96

I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3E?<

I!p,t< ESPEC OVEN

Figure 1": In%!t Signal ESPEC Oven

In%!t Sectiont"e internal infrared )ED :it" 1 mA( :e co!ld ass!re t"at t"e

%"ototransistor :ill .e in t"e sat!rate state 8O39( .eca!se t"e minim!m c!rrent to make t"e

%"ototransistor on is a.o!t 1 mA& $"e follo:ing circ!it is !se o%toco!%ler to interfacing t"e

Idiode U 1 mA 8 & 1 A9( V)ED U 2 Volt to interfacing t"e microcontroller in IGO s"o:n in #ig!re

12&

*1 U 8Vcc V)ED9 G I, U 82? 29 G & 1 U 1?FF&FF O"m( !se1#80 Oh+ resistor

P U 8Vcc V)ED9 I, U 82? 29 & 1 U &att resistor


44/96

I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3E??

And t"e o!t%!t of o%toco!%ler in collector "ave a resistor of1;0 oh+% %!ll-!% to sta.le t"e

signal gave to microcontroller %ort&

INP3T< KEYPAD MATRI

Figure 13: In%!t 4ey%ad Matri

Keypad Pin Connects to Arduino Pin...

1 D9

2 D8

3 D7

4 D6

5 D5

6 D4

7 D3

8 D2

$"e matrices are act!ally an interface tec"ni+!e& It can .e !sed to interface in%!ts like

t"e PC key.oard keys( .!t also to control m!lti%le o!t%!ts like )EDs& According to t"is

tec"ni+!e( t"e IGO are divided into t:o sections7 t"e col!mns and t"e ro:s&


45/96


INP3T< PO>ER S3PPLY

Figure 14: In%!t Po:er S!%%ly

$"e )M


46/96

I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3E?F

O!t%!t Section .y !sing Volt %o:er s!%%ly and solenoid coil :it" 2? Volt and F mA

o%erating c!rrent s"o:n in #ig!re 1 &

O3TP3T< ESPEC OVEN

Figure 1#: $ransistor drive of a Solenoid Valve

*C U O"m can .e directly drive to coil

I& U IC G "#E U &1 A G ? U & 2

R17( R19 U 8VPO*$ V,E 9 G I, U 8?&2 & 9 G & 2 U 1 O"m( !seBK1 Oh+ resistor

P U 8VPO*$ V,E 9 I, U 8?&2 & 9 & 2 U & :att( !se;#2B >att resistor


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>$r$!" D$a"ra+# On fig!re 1F s"o:s on "o: to .e connect t"e :iring from t"e mac"ine

of ESPEC Oven to Modification Design of system interlock circ!it&


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(nput Signal

!utput Signal

I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3E?B


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3 condition signal


Figure 16: iring to ESPEC Oven

$"e :iring diagram s"o:s t"e connections of t"e %rototy%e to t"e ESPEC Oven& $"e first

connection esta.lis"ed :as t"at of t"e microcontroller and t"e oven& $"at :as t"e first in%!t& $"e

second :as t"at of t"e key%ad matri :"ic" is t"en connected to t"e microcontroller and "as an

o!t%!t in t"e )CD mod!le& $"is set !% :ill control t"e solenoid valve :"ic" acts as t"e main

s:itc" to t"e oven door&

PC& La4o,t# $"is s"o:s t"e layo!t of t"e com%onents on t"e %resentesi>ed PC,& $"e

task :as done !sing CAD soft:are for com%onent layo!t called EA=)E soft:are& $"is :as to

ens!re t"at all t"e :irings are done and t"at %ro%er s%acing for eac" com%onent is made&

Figure 17: Printed and )ay-o!t Com%onents

S4%te+ I!te"rat$o!# Interfacing system s"o:( t"ereNs a t:o condition signal .efore t"e

interlock m!st .e f!nctionone is Ma/h$!e Operat$o! and t:o is Sta le 19B 'e"ree Cel%$,%

once t"e signal are satisfy& $"e microcontroller :"o take action to lock t"e door .ase on t"e

%rogram in IC :"ile in %rod!ction r!nning t"e )CD dis%lay s"o: t"e time and ot"er minor

activities if t"ere any error enco!nter into door lock& $"e matri key%ad :ill access to !nlock t"e


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door if t"ere errors enco!nter and only %rocess tec"nician :"o "ave access door to investigate

:"at "a%%en and :"y t"e %rocess sto%s&

Spe/$ $/at$o! Re ,$re+e!t%

$"e list of s%ecific re+!irement of eac" electronics com%onent "as .een searc"ed t"ro!g"

t"e internet and ot"er e isting items !sed in t"e line .!t t"e researc"er e "a!st all aven!es at

arriving t"e correct s%ecification of materials to .e !sed in attaining s!ccess on t"ese %ro ect

st!dy( "ave also searc" at *S catalog!e and Ale an to o.tain t"e "ig" end %rod!ct commonly

!sed in t"e ind!stry today& $"e list is com%osed of t"e main com%onents !sed in t"e %ro%osed

%ro ect st!dy as s"o:n in ta.le 2&

$a.le 27

S$ecification %e&uire'ents


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&$ll o Mater$al%

En!merated in $a.le < are t"e materials costing ta.le for A!to Interlock system of

ESPEC Oven& Pro ect %rototy%e and develo%ment cannot .e com%leted :it"o!t t"e total cost on

all items t"at :ill .e !sed and m!st .e a%%roved .y t"e %rod!ct team& A list of reso!rce

*e+!irements and t"ose %ro ect %artners t"at can s!%%ort t"ese re+!irements :ill .e

created d!ring t"e definition stage of t"e %ro ect& Any additional f!nding re+!irements :ill .e

identified as soon as %ossi.le and :ill re+!ire a%%roval from M$Ns .efore .ecoming availa.le&

After generating P* at SPEED system t"e total inc!rred amo!nt is t"e total cost of t"e %ro ect

and is e+!ivalent to 1(FBB&? %esos& $"is fig!re denotes t"e initial investment cost for t"e

%rototy%e circ!it and :ill .e c"arged to s%ecial %ro ects cost in Po:er de%artment&

$a.le


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F - F IC Socket < *S P6P 1 &

PC,Presensiti>ed 1 Ale an P6P 1B &

F2


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In #ig!re 1B s"o:n( After making a design of t"e circ!it in eagle soft:are t"e researc"er

%re%are a etc"ing PC, :"ere t"e design :ill .e a%%ear a form of circ!it to t"e PC, ,oard& $"e

first ste% :ill .e e %ose t"e fl!orescent lam% .y B min!tes to marked t"e design to t"e PC, ne t

is t"e develo%er sol!tion :"ere t"e PC, :ill dissolve t"e rendering area of PC, and a%%ear t"e

desire circ!it and last is t"e ferric c"loride dissolved t"e co%%er and a%%ear a last form of circ!it

PC, after E %os!re and Etc"ing t"e .oard ne t ste% is soldering t"e com%onents :"ere t"e

researc"er assem.lies one .y one to com%lete t"e com%onents s"o:n in #ig!re 1 &

Figure 1 : Soldering Com%onents

After a long %roced!re t"e .oard "as .een finali>e :"ic" :ill !se for installation of

Interlock system PV-212M Oven for im%rove ca%a.ility of t"e mac"ine s"o:n #ig!re 2 &

Figure "!: Interlock Circ!it for PV-212M


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I!%tallat$o!# $"is section s"o:ed t"e installation of t"e %rototy%e into t"e PV-212 oven

.y defining t"e connection of eac" in%!t and ill!strating t"e %rocess of eac" connection& #ig!re

21 s"o:s t"e main signal connection from t"e oven& $"a data coming from t"is connection is t"e

tem%erat!reand t"e stat!s of .eing locked or !nlocked&

Figure "1: Signal Interconnection for PV-212M

#ig!re 22 s"o:ed t"e main system( :"erein t"e relays !sed to !nlock and lock t"e oven

are located& A connection from t"e o!t%!t of t"e %rototy%e( :"ic" is like a %!lse( s:itc"es t"e

relay on or off& $"is :as t"e main foc!s of t"e %rototy%e t"at is to %revent any !na!t"ori>ed

!nlock of t"e relays&


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Figure "": Main System for PV-212M

$"e main lock latc"( s"o:ed in #ig!re 2


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trigger t"e 1st condition of t"e signal goes to microcontroller& 8$"e setting :as already

set-!% .ase of revision of o!r engineering %rocess&9


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Project QuotationCost!!!!US $ 14,838 per unitor Php 771,576


Co%t &e!e $t A!al4%$%&

On fig!re 2? s"o:n t"e act!al %rice +!otation from t"e O&E&M :ay to e %ensive vers!s

to t"e in "o!se fa.rication of %rototy%e&

Figure "4: Pro ect H!otation in O&E&M %ricing&

,ase of t"e %ricing of O&E&M vs& in "o!se fa.rication it %rove a .ig dissimilar val!e of

%ro ect cost& $"is %ro ect :ill add to cost saving %rogram of 3 P Semicond!ctor& $"e researc"

is confident eno!g" on t"e ca%a.ility of "is circ!it design and its contri.!tion& It may .ring :"en

it :ill .e fanned o!t to all ESPEC Oven in APP Ca.!yao&

In house Fa ricationCost of '4' 1 66% -8 S"# #%# '4' 771957


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1 3 : 5-%--

1-----%--

3-----%--

:-----%--

-----%--

5-----%--

-----%--

0ield per MonthRe;ect 'er Month

Figure "6: ESPEC Oven 5ield Vs *e ect

!ct


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I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3EF1

$a.le ?

Survey %esults

A,to I!terlo/0 PV-212M Ove!S,rve4 H,e%t$o!!a$re

S&

& ' (&

S(&

)ota*

+ei hte- %ean

E e/t$ve!e%%1& $"e mac"ine is %erforming a!tomaticinterlock every time t"e mac"ine is ino%eration&

7 5 - - 13 %56::::

2& A!to interlock didnNt sto% :"ile in o%eration 5 1 - - 13 % 1 7ed !nlock in t"e oven&

11

1 - - 13 %81 7

F,!/t$o!al$t41& 3o mac"ine "!ng-!%s or .reakdo:n relatedto a!to interlock&

8 1 3 - - 13 %56::::

2& 3o mac"ine do:ntime d!ring sta.ili>ation of "eating&

6 3 3 - - 13 %5


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I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3EF2

Interlock circ!it and safety on "o: to address t"e res%ondents sec!rity concerns :it" regards to

t"e %ro ect& ,y giving t"eir %ositive res%onses on t"e s!rvey( t"e researc"er is confident eno!g"

on t"e ca%a.ility of "is circ!it design and its contri.!tion to 3 P in terms of efficiency(

maintaina.ility( safety and cost savings it may .ring :"en it :ill .e fanned o!t to all ESPEC

Oven in APP Ca.!yao&

S,++ar4 o F$!'$!"%

After t"e im%lementation of t"e Modified Design of Interlock System of ESPEC PV-

212M oven several im%rovements :ere reali>ed&

1& ,ased on t"e modification of t"e e isting design( t"e %rototy%e im%roved t"e Oven

o%erations .y %ro"i.iting !na!t"ori>ed !nlock once it reac"es 1 degrees Celsi!s&

2& $"e circ!it design( :"ic" involved designing of t"e sc"ematic diagram and :iring

diagram( feat!red t"e %arts needed for t"e system to .e effective and to f!nction :ell& $"is

im%rovement :as reali>ed t"ro!g" t"e res%ondentNs s!rvey res!lt& $"is res!lt :as analy>ed after

a .rief demonstration to t"e res%ondents on t"e o%eration of t"e system& $"e main im%rovement

reali>ed in t"e system :as t"e decrease in t"e re ect yield as soon as t"e circ!it design of t"e

%rototy%e :as im%lemented&


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I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3EF<

?& Eval!ation of t"e finis"ed %ro ect gave t"e average res!lts of Strongly Agree on t"e

)ikert +!estions as to "o: effective and f!nctional t"e system is&

D!ring testing of t"e modified interlock system to attain t"e se+!ence of interlock t"eresearc"er cond!ct test trial in line %rod!ction as many as do if t"e design circ!it :ill .e %ro.lem

.ase on res!lt t"e circ!it "as meet t"e condition se+!ence& /!dgment criteria "ave .een set and

t"e standardi>ation of t"is %roced!re is ongoing and :ill .e deli.erated .y Central )ine

%rod!ction :"ere t"e ESPEC Oven lay&


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I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3EF?

3!$t V

Co!/l,%$o!% a!' Re/o++e!'at$o!%

Co!/l,%$o!%

$"e main goal of t"e %ro ect st!dy is to %rod!ce safe +!ality of t"e %rod!ct and also to t"e

!ser t"ro!g" t"e installation of Modification of Interlock system on ESPEC PV-212M Oven

:"ic" :ill activate d!ring sta.ili>ation of "eating %rocess& $"e researc"er learned many t"ings

along t"e :ay d!ring t"e creation of "is design and concl!ded t"e follo:ing o.servations

1& $"e original design of t"e interlock system of ESPEC oven :as modified

effectively to %revent !na!t"ori>ed !nlocking&

2& A circ!it :as designed for t"e main o. ective :"ic" is to create a modified

interlock system of an ESPEC oven& $"is design allo:ed t"e .est o!tcome from

t"e %rototy%e as it :as designed s%ecifically for t"e oven&

ed !nlocking of t"e system&

?& $"ro!g" a s!rvey t"at :as cond!cted to a gro!% of res%ondents t"at :itnessed t"e

o%eration of t"e %rototy%e( t"e effectiveness and f!nctionality :as rated and

eval!ated& $"e res!lts of t"e eval!ation :ere t"at t"e %rototy%e :as effective and

f!nctional in avoiding !na!t"ori>ed !nlocking&


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Re/o++e!'at$o!%

After validating all t"e findings and concl!sion and meas!red system st!dy t"e researc"er

recommended t"e follo:ing7

1& In t"e modification of t"e design circ!it t"e researc"er "ig"ly recommend cond!cting

series of st!dies( gat"ering information and do not "esitate to ask t"e e %erts& it" t"is

information yo! :ill .e a.le to design a circ!it .ased on t"e a.ility to %revent

!na!t"ori>ed !nlocking&2& In t"e develo%ment of circ!it design( t"e researc"ers recommends t"e !se of EA=)E F&

soft:are .eca!se of friendly !se and dra: a sc"ematic and %rinted circ!it .oard of a

%ro ect&ed

.oard( a modern ty%e %roced!re t"at can easily to design t"e circ!it fast&?& In eval!ating t"e effectiveness and f!nctionality of t"e %ro ect( t"e researc"er

recommends t"at t"e modified of interlock system a%%lied to t"e 3 P Semicond!ctor

Ca.!yao )ag!na :"ere t"e address iss!e in Central Area Station&


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I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3EFF

Re ere!/e%<

Ale ander( C& 4& 82 ?9& Funda'entals of Electric *ircuit+ Mc=ra:-6ill Inc&

,oylestad( *& )&( \ 3as"elsky( )& 82 29& Electronic ,evice and *ircuit -.eory 8?t" ed&9&

8%%& 1? -21F9

#loyd( $& )& 82 1 9& /rinci$les of Electric *ircuits 8 t" ed&9+ 8 %% ? 2- ?B 9

=i.ilisco( S& 82 F9 Electricity and Electronics0 Second Edition & Singa%ore7 Mc=ra: 6ill

,ook Com%any&

=ro.( ,& 82 9& (asic Electronics+ 8 %age 9 Sc"!lt> 6ill Inc&

/o"n( )& 82 ?9& / * %o2otics a (eginner s uide to %o2otics /ro5ects sing t.e / * )icro &

8 %% 2 -21 9 $"e Mc=ra:-6ill Com%anies&

)o ek( ,& 82 F9& istory of se'iconductor engineering (

8 %%& 212 21 9 S%ringer&

!( #& 82 ?9& -.eory of resistor networks: -.e two $oint resistance &


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Appe!'$/e%

Appe!'$ A

ESPEC PV-212M Ove!


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I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3EFB

Appe!'$ &

PC819 Ser$e%


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Appe!'$ C

DS1 ;9


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Appe!'$ D

&CB:9


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Appe!'$ E

PIC17F9 88


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Appe!'$ F

LM 19 Re",lator


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Appe!'$

LCD D$%pla4


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Appe!'$ I

Matr$ Ke4 oar'


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Appe!'$

1N:;;9


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Appe!'$ K

Cr4%tal O%/$llator


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Appe!'$ L

Car o! F$l+ Re%$%tor


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Appe!'$ M

Ta/t S)$t/h


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Appe!'$ N


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I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3EB1


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I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3EB2


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I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3EB?


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I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3EBB


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C,rr$/,l,+ V$tae

A)VI3 /OSEP6 #)O*ES PE]A? 1 San #ernando Malvar ,atangas City

Cell no7 1 FBB12 G F 1??? B

CA*EE* AIM I am t"erefore looking for a %osition( one t"at :ill .!ild on myskills and e %eriences in Electronics and related fields and allo:me sco%e for !%:ard movements&

ED'CA$IO3College $ec"nological 'niversity of t"e P"ili%%ines 2 2-2

Ayala ,o!levard( Ermita( ManilaCo!rse7 Electronics Engineering $ec"nology

Secondary )as Pi0as 3ational 6ig" Sc"ool( )PC& 1 B-2 2

>ORKING E PERIENCE

Oct& 1 ( 2 ? - Mar& 2 ( 2AM4O* $EC63O)O=5 P6I)IPPI3ES Pine and etc&&&)og every set-!% and tro!.le s"oot of t"e mac"ine&Monitoring do:ntime mac"ines&Installed =ASO 'nits to 43S B 2F ire.onder mac"ines&

A!g& 1


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6andle PM Doc!mentation 8PM Master%lan( PM Data.ase etc@9ESD =ro!nd installation and monitoringMonitoring do:ntime mac"ineS!%%orting to t"e P*O/EC$ 8A!to S"!t off Press!re( 'V C!ring :G P)C 3AIS Control(ACS@9S!%%orting line s!staining activities s%ecialties in EA=)E F ire.onder@

Oct& 1ed .oard8A)E A39

INTEREST SKILL4no:ledge in P)C Programming 8Omron( 4V .!ilder 4eyence94no:ledge in Electro%ne!maticsElectronics Circ!it Design 8EA=)E G )ive:ire Soft:are9Digital Electronics $ec"ni+!esInd!strial and Process Control Cali.ration and Maintenance Instr!ments&


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TRAININGS ATTENDED<

ELECTROPNE3MATICS CONTROLCond!cted7 Oct& ?( ( 2 \ 21( 2Place7 P"ili%s Semicond!ctors Ca.!yaoInstr!ctor7 Ar:in #& 6a.a0aCE*$I#ICA$E .y7 D'A)$EC6 CE3$E*

ASM EAGLE 7; >IRE&ONDER Cond!cted7 /!ly 21( 22( 2Place7 ASM Agency 8Ala.ang Madrigal ,!siness Park9Instr!ctor7 Sir *o+!e

CE*$I#ICA$E .y7 ASM 8A!tomation Assem.ly Mac"ine9PRESENTATION SKILLSCond!cted7 Oct& 11( 2Place7 P"ili%s Semicond!ctor Ca.!yaoInstr!ctor7 Connie #& 4a"ana%CE*$I#ICA$E .y7 P"ili%s Semicond!ctor

SENSOR STEPPER MOTOR Cond!cted7 Se%& 2F( 2 ( 2Place7 P"ili%s Semicond!ctors P"ili%%ines

Instr!ctor7 Sir& P"ili% DemaganteH3ANT3M FCH-Fl$p Ch$p H,a!t,+ @Pro"ra++$!"=Cond!cted7 Se%& 21-2oneInstr!ctor7 Mem.er of ESD Committee


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A Modification Design of Interlock System of ESPEC PV-212M Oven Rev 9_updated

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Transcript of A Modification Design of Interlock System of ESPEC PV-212M Oven Rev 9_updated