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LED Solder PressLED Solder Press
Status Report Presentation Status Report Presentation Senior Projects ISenior Projects I 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, called LEDdynamics, located in Randolph, Vermont.located in 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.”
Problem statementProblem statement
Design an automated miniature Design an automated miniature solder press that will…solder press that will…
Be able to solder pre-glued surface Be able to solder pre-glued surface mount LED emitters to a metallic mount LED emitters to a metallic circuit board.circuit board.
Be able to test the LED after Be able to test the LED after completion completion
Must be faster and more efficient Must be faster and more efficient than hand assembly.than hand assembly.
System will not need human aid, System will not need human aid, after initial setup is completed.after initial setup is completed.
Process DescriptionProcess Description
Drill Metallic Mounting Circuit BoardDrill Metallic Mounting Circuit Board Prep soldering area with fluxPrep soldering area with flux Glue in surface mount LED’sGlue in surface mount LED’s Solder the LED leads Solder the LED leads Test for failed productTest for failed product
SolutionsSolutions
Build a X table with a set jig for Build a X table with a set jig for metallic circuit boards.metallic circuit boards.
Make a single press/ dual soldering Make a single press/ dual soldering iron system with wire fed solder.iron system with wire fed solder.
Test the LEDs inline with solder station.Test the LEDs inline with solder station.
Allow user to initially select Allow user to initially select predetermined board size and stores predetermined board size and stores data throughout the run.data throughout the run.
Full System Overview Full System Overview 1. Controller1. Controller 2. Manifold2. Manifold 3. Power Source3. Power Source 4. Wire Feed4. Wire Feed 5. Push Cylinder5. Push Cylinder 6. Solder Cylinder6. Solder Cylinder 7. Solder reels7. Solder reels 8. Soldering Tips8. Soldering Tips 9. Guidance Track9. Guidance Track
10. Soldering Frame10. Soldering Frame
Part Sizes & Tolerances Part Sizes & Tolerances
LED Dimensions Pad DimensionLED Dimensions Pad Dimension Both diagrams are drawn with millimeter Both diagrams are drawn with millimeter
dimensionsdimensions (both diagrams come from Luxeon Emitter, (both diagrams come from Luxeon Emitter,
http://www.lumileds.com/pdfs/AB10.PDF http://www.lumileds.com/pdfs/AB10.PDF
Pneumatic System OverviewPneumatic System Overview This pneumatic system This pneumatic system
involves;involves;
Double-acting Double-acting telescopic cylindertelescopic cylinder
Double-acting cylinder Double-acting cylinder with double-ended with double-ended adjustable cushioningadjustable cushioning
Manifold for air flow Manifold for air flow controlcontrol
Start push button Start push button
Electrical ConceptsElectrical Concepts
Twin motor controllers
LCD
EStopStop/Go Switch
Selector switch
Test unit
Solder Heat units
Triple solenoid block
AC to DC power supply
Project ConsiderationsProject Considerations
What are current systems out there What are current systems out there doing? doing? X,Y,Z table fully programmable setupX,Y,Z table fully programmable setup
Cost of these systems?Cost of these systems? $5,000 plus$5,000 plus
How fast is LEDDynamics producing How fast is LEDDynamics producing these? these? 8.3hr8.3hr
BudgetBudget
Item Quantity Description Sale Price $ Sale Total $
Controller 1 PLC or Microcontroller 35.00 - 195.00 UNKNOWN
Manifold 1 UNKNOWN UNKNOWN UNKNOWN
Push Cylinder 1twin-stage, Piston dia. 30/42", double-acting with
pneumatic limit position scanUNKNOWN UNKNOWN
Solder Cylinder 1 Double-acting cylinder with end position cushioning UNKNOWN UNKNOWN
Pneumatic Tubing 4 ft. Flexeel hose 25'/ 17.92 2.87
Wire Feed 1 or 2 UNKNOWN UNKNOWN UNKNOWN
Solder 2 2 reels 5.95 11.9
Soldering Tips 2 size: 3/64" (.047", 1.1 mm) 4.79 9.58
Aluminum Stock see desc. plate stock: 1" x 12" x 18" ASTM B209 300.97 300.97
Aluminum Stock see desc. 900 Angle stock: 1/2" x 1/2" x 1/8" x 8' ASTM B221 7.71 7.71
Complete Total 450++
Schedule Schedule Current status
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
Acknowledgements Acknowledgements
Andre St. DenisAndre St. Denis SamCoSamCo John KidderJohn Kidder Roger Howes Roger Howes Oliver Piluski Oliver Piluski
Questions?Questions?