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

7/21/2019 A Modification Design of Interlock System of ESPEC PV-212M Oven Rev 9_updated.docx

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

A Proect 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" 21


2/96


3/96

I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3Eeonete(

$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&


5/96

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

Tale o Co!te!t%

$itle Page@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@ 1A%%roval S"eet@@@@@@@@@@@@@@@@@@@@@@@@@@&&&@ 2Ackno:ledgement@@@@@@@@@@@@@@@@@@@@@@@@@@&& ed in

creating in-"o!se fa.rication of t"e %roect :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&


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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

%roect 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 eisting same e+!i%ment t"at needed to %erform t"e A!to-

Interlock system&


15/96

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

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 of 1750

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 eec!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 %oka-

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:ing

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 3P 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 1s .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


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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 mit!re9 or a coil of :ire 8for lo: resistances9&

A/ro!4+%

3P - 3et 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 3P 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& $"is

is t"e area :"ere t"e researc"ers are also assigned&

E%pe/ PV-212MOve!

According to ESPEC Cor%& 82F9 Oven !sed etensively 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 1KC 8L


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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


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


21/96


D$o'e1N:;;1

According to datas"eet&com 82B9 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 aial-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 1FF( as re%lacements for 132F t"ro!g" 132F1&

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

lesser kno:n 1&-am%ere 13


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Re%$%tor

Aleander 82?9 released t"e statement t"at resistor is a t:o-terminalelectronic

com%onentdesigned to o%%ose anelectric 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.ridand%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"e tolerance 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( eternal 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 MAC6I3E2ed

%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 a

s!. 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&


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

3!$t III

Metho'% a!' Pro/e',re%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 etra feat!res in

t"e system&

$"e %rototy%ing met"od :as a%%lied to t"e %roect 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 3P 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 3P 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 %roect %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& $"e

soft: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 %roect&

$"e o%erator and HA %ersonnel :ill validate t"e effect of t"e %roect 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 %roect 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

%roect .ased on eisting design %ro.lem identification( design com%!tation( creating circ!it(

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

$"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

I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3EM ? @SAB= 6 @A:= 6 @3= 6 @D2= 6 @SD1=

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

TNR

>hereM ? >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 ?


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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&


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

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 %roect 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 TempStabilization of temp 175 Start 5hrs

Door will Lock5hrs ndDoor will unlocknd Mode

!perational "omplete



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Start Mode Rising up TempStabilization of temp 175Start 5hrs

Door will Lock5hrs ndDoor will unlocknd Mode

!perational "omplete

Door Lock Steadil&

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



38/96

Start

Machine#

Temp#"ount

(s

Machine !k

(s

Temp 175

Lock Solenoid

!pen Solenoid

(s

"ount

(s the Machine Turn !)*

nter 'assword

(s 'assword "orrect*

"ount + "ount ,1

Dela&+1----ms

.D

/

/

.o

.o

0es

0es

.o.o

0es

.o

0es



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



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

Mater$al Sele/t$o!# D!ring t"e circ!it develo%ment of t"is %roect 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 %roect

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

$ransistor ,C? 13? DiodeI

C Socket P"otoco!%ler

)ED mm )M


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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 %roect&


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

Figure 11:Circ!it Diagram of Interlock System


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I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3E?ER S3PPLY

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

$"e )M


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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 FmA

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 ICG "#EU &1 A G ? U &2

R17( R19U 8VPO*$ V,E9 G I,U 8?&2 &9 G &2 U 1 O"m( !se BK1 Oh+resistor

PU 8VPO*$ V,E9 I,U 8?&2 &9 &2 U & :att( !se ;#2B >attresistor


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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 Stale 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 eisting 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 %roect

st!dy( "ave also searc" at *S catalog!e and Alean 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

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

$a.le 27

S$ecification %e&uire'ents


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Com%onent S%ecific *e+!irement Model *e+!ired ,rand

PCB1

#or:ard c!rrent I# mA

Collector-emitter voltage V CEO $"ro!g" 6ole Micro -tal

*elay voltsG2am% contact PC, Mo!nt 3ais

)M ed ,oard Prototy%e ,oard PC, Alean

$act S:itc" SPS$-3O ma [ 12Vdc S:itc" Al%s


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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& Proect %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 %roect %artners t"at can s!%%ort t"ese re+!irements :ill .e

created d!ring t"e definition stage of t"e %roect& 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 %roect

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 %roects cost in Po:er de%artment&

$a.le


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I3$E*)OC4 S5S$EM O# ESPEC PV-212M OVE3 MAC6I3Eed

1 Alean 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, net

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

Figure "":Main System for PV-212M

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


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trigger t"e 1stcondition 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 Quotation

Cost!!!!

US $ 14,838 per unit

or Php 771,576

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

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: Proect 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

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

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 Farication

Costof '4' 166%-8 S

"##%#'4' 771957


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Te%t$!" a!' Eval,at$o!

On fig!re 2 s"o:s after installing :it" t"e ne: modified interlock system t"e se+!ence

im%rove&

Figure "#: ESPEC Interlock system gra%" analysis

#ig!re 2 s"o:s t"e rise of %rocess "eating& $"e door interlock :ill not activate !ntil t"e

set %oint of tem%erat!re "as .een not sta.le& After sta.le at 1 degree Celsi!s and c!ring time is

in %rocess t"e door activate close once t"e "rs ela%se t"e door :ill o%en& $"e researc"er s"o:

t"e modified interlock :as effectively and f!nctionality .ase on t"e design circ!it&


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1 3 : 5

-%--

1-----%--

3-----%--

:-----%--

-----%--

5-----%--

-----%--

0ield per Month

Re;ect 'er Month

Figure "6: ESPEC Oven 5ield Vs *eect

!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(

&

)ot

a*

+eihte

- %ean

Ee/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 %17

ed !nlock in t"e oven&

1

1

1 - - 13 %817

F,!/t$o!al$t4

1& 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 %roect& ,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 3P 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 eisting 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 reect 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 MAC6I3EFation 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 %roect 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

%roect&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 %roect( t"e researc"er

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

Reere!/e%

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

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