LED Solder Press Final Presentation Final Presentation Senior Projects 2 Senior Projects 2 By Ryan...

LED Solder PressLED Solder Press

Final Presentation Final Presentation Senior Projects 2Senior Projects 2

By Ryan Bigl &By Ryan Bigl & Kyle LevesqueKyle Levesque

Background InfoBackground Info

This project is for a small business This project is for a small business called LEDDynamics, located in called LEDDynamics, located in Randolph, Vermont.Randolph, Vermont.

““LEDDynamics is a custom LEDDynamics is a custom engineering company specializing in engineering company specializing in the design and integration of LED the design and integration of LED technology for end-user and OEM technology for end-user and OEM applications.” applications.” (From there website: http://www.leddynamics.com)(From there website: http://www.leddynamics.com)

Problem statementProblem statement

Design an automated miniature solder press Design an automated miniature solder press that will…that will…

Be able to solder pre-glued surface mount Be able to solder pre-glued surface mount LED emitters to a metallic circuit board LED emitters to a metallic circuit board (MCPCB).(MCPCB).

Be able to test the LED after completion. Be able to test the LED after completion. Must produce better efficiency yield, in Must produce better efficiency yield, in

comparison to current hand assembly.comparison to current hand assembly. System with basic human aid will System with basic human aid will

consistently step through the soldering consistently step through the soldering process.process.

SolutionsSolutions Build a (human controlled) X table with Build a (human controlled) X table with

a set jigs for different sized metallic a set jigs for different sized metallic circuit boards.circuit boards.

Make a single press/ dual soldering Make a single press/ dual soldering iron system.iron system.

Test the LEDs inline with solder station.Test the LEDs inline with solder station.

Basic user controls to start and stop Basic user controls to start and stop the soldering process.the soldering process.

LED SizingLED Sizing

LED Sizing Table

LED Bulb height Bulb Dia Base Radius Base Width Base thickness Pad Width Pad Length DFTOBTEC Overall height

1 .087 in. .213 in. .316 in. .286 in. 0.106 in. .06 in. .073 in. .038 in. .197 in.

0.106 in. .06 in. .073 in. .038 in.

2 .089 in. .213 in. .316 in. .286 in. .104 in. .06 in. .070 in. .036 in. .196 in.

.1045 in. .06 in. .075 in. .036 in.

3 .09 in. .211 in. .315 in. .286 in. .102 in. .059 in. .073 in. .036 in. .193 in.

.102 in. .058 in. .072 in. .04 in.

Ave .089 in. .212 in. .316 in. .286 in. .104 in. .06 in. .073 in. .037 in. .195 in.

Light Strip Base SizesLight Strip Base Sizes Soldering 2 different Soldering 2 different

strip sizesstrip sizes

Soldering 3 different Soldering 3 different strip stylesstrip styles

Large Base Small Base

12.75" x .535" x .062"

.985" x .985" x .071"

System OverviewSystem Overview

Automated Process Automated Process DescriptionDescription

1.1. Solder iron will come down until LED holder is Solder iron will come down until LED holder is pressing down on the LED. Heat irons are at set pressing down on the LED. Heat irons are at set heat point (627 degrees F). heat point (627 degrees F).

2.2. Solder iron will then come down and press fully Solder iron will then come down and press fully (40newtons) onto the board and leads for 1.5sec. (40newtons) onto the board and leads for 1.5sec. It will then lift back up to the LED holding position. It will then lift back up to the LED holding position.

3.3. The microcontroller will then test LED across the The microcontroller will then test LED across the LED holders to see if the soldering process was a LED holders to see if the soldering process was a success.. success..

4.4. Iron then lifts up full distance to rest position. Iron then lifts up full distance to rest position. Microcontroller signals user end of soldering step. Microcontroller signals user end of soldering step. If LED was bad Red light will blink. If LED was bad Red light will blink.

Full System Overview Full System Overview

User Interface

3way Valve

MCU& ElectronicsAir lines

Regulator and oil trap

Air c

ylin

der

120VAC

PWM

Data lines

12v D

C

Jig System

Fixture System overviewFixture System overview

(2) pull pins(2) pull pins (2) springs(2) springs Adjustable slide Adjustable slide

supportsupport (2) rail / receivers(2) rail / receivers Base plateBase plate Front support plateFront support plate (6) 6-32” x ¾”(6) 6-32” x ¾”

Pneumatics System Pneumatics System OverviewOverview

Building air usedBuilding air used Next fed into Oil Trap and Next fed into Oil Trap and

Regulator unitRegulator unit Regulator is set to desired Regulator is set to desired

PSIPSI(~65PSI)(~65PSI) Regulated air is then Regulated air is then

controlled by the MCU in a controlled by the MCU in a 12v three way valve unit.12v three way valve unit.

Air from valve is ran into a Air from valve is ran into a flow control valve and then flow control valve and then into the cylinder.into the cylinder.

The cylinder is a 9/16” 3” The cylinder is a 9/16” 3” throw spring returned throw spring returned cylinder with a magnetic cylinder with a magnetic piston.piston.

Solder head System Solder head System OverviewOverview

Single solder iron Single solder iron Heater controlled Heater controlled by MCUby MCU

LED holders double LED holders double as Testing leads as Testing leads

Luxeon specified Luxeon specified solder iron tip sizesolder iron tip size



LED holders double LED holders double as Testing leadsas Testing leads




LED holders double LED holders double as Testing leads as Testing leads


Power and Signal OverviewPower and Signal Overview

EStop

Stop/Go Switch

Test lead

P.W.M Heater

Triple solenoid block

AC to DC power supply

AC power supply

Cylinder position sensors

Iron heat sensor

Green Light

Red Light

Users control box

Microcontroller

120VAC

Electrical SchematicElectrical Schematic

State Diagram ConceptState Diagram Concept

Power On

Heater control

Cylinder Control

LED Test


Power On

Heater control

Cylinder Control

LED Test

Power On

Temp check

Cylinder Control

Turn Heater OFFTurn Heater ON<625oF

<625oF And >630oF

>630oF


Power On

Heater control

Cylinder Control

LED Test

Is the Cylinder Extended

Delay 1.5 Sec

Extend Cylinder

Yes

No

Has the start been Pressed?

Jump to Heat Control

Flash Green light .25 SecTurn Green light on solid

Lift up Part way .5 Sec

LED Test


Power On

Heater control

Cylinder Control

LED Test

Is it good?(.7v drop)

Lift up Cylinder

Lift up cylinder

No (2x)

Yes Turn on Red lightTurn off green light

Test LED

No (1x)

Flash Red lightTurn off green light

Jump to Heat

Control

BudgetBudget

system Description Quantity Unit Price Total

Computer control Microcontroller and Board (HC08 or HC12) 1 $38.00 $38.00

hot bar unit

12l14 Ultra-machine-able low carbon steel for piston mount and head assembly (~cost) 1 $75.00 $75.00

we-1237s 33 Watt Solder Iron tips 1/4" thread on tip (http://www.action-electronics.com/unpl.htm#Heater) 2 $24.90 $49.80

WE-PL155 Chisel tip plated irons 0.07" x 0.66" (same as above) 2 $6.65 $13.30

E-0875N01-03C-03 single acting, return spring, magnetic, cylinder ( aircylinders.com) 1 $54.59 $54.59

12v three way valve 1 $0.00 $0.00

4910K81 A series air regulator, trap and gauge unit 8.16" x 1.97" (mcmastercarr.com) 1 $52.38 $52.38

air regulator mounting bracket 1 $3.00 $3.00

Magnetic sensors strap units 2 $32.00 $64.00

tension spring 1 $2.00 $2.00

Jig unit

4" * 2.5" *1.25" low carbon steel 2 $32.00 $64.00

Pull springs 2 $1.50 $3.00

36" * 36" *.25" low carbon steel 2 $30.00 $60.00

4" *14" *.5" low carbon steel 1 $20.00 $20.00

.25” x 1.5” x 18” low carbon steel $30.95 $30.95

.25” x .75” x 18” low carbon steel $20.32 $20.32

Total $550.34

Schedule Schedule

Current status

SummarySummary Heating— The soldering head and press system Heating— The soldering head and press system

has been designed and still needs to be machined.has been designed and still needs to be machined.

Mechanical—The fixture and alignment pin system Mechanical—The fixture and alignment pin system has been designed and built.has been designed and built.

Pneumatic—The pneumatic system has been Pneumatic—The pneumatic system has been designed, purchased, and tested. designed, purchased, and tested.

Software—The software has been completed, but Software—The software has been completed, but still needs wiring.still needs wiring.

Project ContactsProject Contacts

Oliver Piluski, LED DynamicsOliver Piluski, LED Dynamics [email protected]@LEDdynamics.com or or

www.LEDDynamics.comwww.LEDDynamics.com

John Kidder, Senior Projects TeacherJohn Kidder, Senior Projects Teacher [email protected]@vtc.edu

Andre St. Denis, Senior Projects TeacherAndre St. Denis, Senior Projects Teacher [email protected]@vtc.edu

Roger HowesRoger Howes [email protected]@vtc.edu

mailto:[email protected]

http://www.leddynamics.com/




Questions?Questions?

For further information you can For further information you can access all project web pages at access all project web pages at http://web.vtc.edu/ELM/projects/projehttp://web.vtc.edu/ELM/projects/projects_and_teams.htmcts_and_teams.htm, ,

or directly link to our website at or directly link to our website at http://www.vtc.edu/elm/projects/200http://www.vtc.edu/elm/projects/2005-2006/LEDSolderingSystem/WebSite5-2006/LEDSolderingSystem/WebSite//

http://web.vtc.edu/ELM/projects/projects_and_teams.htm

http://web.vtc.edu/ELM/projects/projects_and_teams.htm

http://www.vtc.edu/elm/projects/2005-2006/LEDSolderingSystem/WebSite/



LED Solder Press Final Presentation Final Presentation Senior Projects 2 Senior Projects 2 By Ryan...

Documents

Transcript of LED Solder Press Final Presentation Final Presentation Senior Projects 2 Senior Projects 2 By Ryan...