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 opiluski@LEDdynamics.comopiluski@LEDdynamics.com or or

www.LEDdynamics.comwww.LEDdynamics.com

John Kidder, Senior Projects TeacherJohn Kidder, Senior Projects Teacher jkidder@vtc.edujkidder@vtc.edu

Andre St. Denis, Senior Projects TeacherAndre St. Denis, Senior Projects Teacher ajs05110@vtc.eduajs05110@vtc.edu

Acknowledgements Acknowledgements

Andre St. DenisAndre St. Denis SamCoSamCo John KidderJohn Kidder Roger Howes Roger Howes Oliver Piluski Oliver Piluski

Questions?Questions?