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LED Solder Press

LED Solder Press. Status Report Presentation Senior Projects I By Ryan Bigl & Kyle Levesque. Background Info. This project is for a small business called LEDDynamics, located in Randolph, Vermont.

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LED Solder Press

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  1. LED Solder Press • Status Report Presentation • Senior Projects I • By Ryan Bigl & • Kyle Levesque

  2. Background Info • This project is for a small business called LEDDynamics, located in Randolph, Vermont. • “LEDDynamics is a custom engineering company specializing in the design and integration of LED technology for end-user and OEM applications.” (From there website: http://www.leddynamics.com)

  3. Problem statement Design an automated miniature solder press that will… • Be able to solder pre-glued surface mount LED emitters to a metallic circuit board (MCPCB). • Be able to test the LED after completion. • Must produce better yield in comparison to current hand assembly. • System with basic human aid will consistently step through the soldering process.

  4. Solutions • Build a (human controlled) X table with a set jigs for different sized metallic circuit boards. • Make a single press/ dual soldering iron system. • Test the LEDs inline with solder station. • Basic user controls to start and stop the soldering process.

  5. Full System Overview 120VAC Data lines Air cylinder MCU& Electronics Air lines 12v DC Regulator and oil trap PWM 3way Valve User Interface Jig System

  6. Process Description(Covered by the system) • Solder iron will come down until LED holder is pressing down on the LED. Heat irons to full heat potential (430 degrees c). • Solder iron will then come down and press fully (40newtons) onto the board and leads for 1.5sec. It will then lift back up to the LED holding position. (Irons will be allowed to cool to standby temperature, 100 degrees c). • Irons will then travel full distance down to touch board (one quarter of a second) and microcontroller will then test LED and record. • Iron then lifts up full distance to rest position. Microcontroller signals user end of soldering step. If LED was bad Red light will blink. 

  7. Process Diagram??

  8. Full System Overview 120VAC Data lines Air cylinder MCU& Electronics Air lines 12v DC Regulator and oil trap PWM 3way Valve User Interface Jig System

  9. Full System Overview 120VAC Data lines Air cylinder MCU& Electronics Air lines 12v DC Regulator and oil trap PWM 3way Valve User Interface Jig System

  10. Full System Overview 120VAC Data lines Air cylinder MCU& Electronics Air lines 12v DC Regulator and oil trap PWM 3way Valve User Interface Jig System

  11. Mechanical System Design Milestones • Pneumatic system working • Mechanical design finalized • IDW files 85% complete

  12. Power and Signal Overview 120VAC P.W.M Heater AC power supply Iron heat sensor Microcontroller AC to DC power supply Red Light Test lead Stop/Go Switch Green Light EStop Triple solenoid block Users control box Cylinder position sensors

  13. Electrical Schematic

  14. Programming State Diagram?

  15. Budget

  16. Schedule Current status

  17. Summary • Heating— The soldering head and press system has been designed. • Mechanical—The fixture and alignment pin system has been designed. • Pneumatic—The pneumatic system has been designed, purchased, and tested. • Software—The state diagram is finished.

  18. Questions? Slides created by Kyle Levesque

  19. Project Contacts • Oliver Piluski, LED Dynamics • opiluski@LEDdynamics.com or www.LEDDynamics.com • John Kidder, Senior Projects Teacher • jkidder@vtc.edu • Andre St. Denis, Senior Projects Teacher • ajs05110@vtc.edu

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