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DEVELOPMENT OF MICROCONTROLLER BASED

SOLDERING IRON WORKSTATION

Rex L. Lentija
Al-mojohn Aviles

A designed project presented to the faculty of the Department of Industrial Engineering

and Technology, College of Engineering and Information Technology, Cavite State
University, Indang, Cavite in partial fulfillment of the requirements for the Degree of
Bachelor of Industrial Technology major in Electronics Technology with Contribution
No. ________________. Prepare under the supervision of Ms. Ma. Fatima B. Zuñiga.

INTRODUCTION

Electronics came into human as early civilization exists. Today it’s inconceivable

to think of a society living without the power electronics. Electronics, as an enabling

technology is becoming more and more important and is the basis for many industrial

processes, for the rational use of the energy, for new technologies in individual and mass

transportation, areas that are rapidly growing requiring new concepts in order to fulfill

cost, reliability and miniaturization.

One of the most important processes in creating electronics circuit is soldering.

Soldering involves using a molten filler metal to wet the mating surfaces of a joint, with

or without the aid of a fluxing agent, leading to a formation of metallurgical bonds

between the filler and the respective components. In this processes, the original formation

of the components are eroded by virtue of the reaction occurring between the molten

filler metal and the solid components. The quality of soldered joints depends strongly on
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the combination of filler and component materials, including surface coating that may be

applied to the components, and also on the processing conditions that are used. It is

precisely for the reason that a sound understanding of the metallurgical changes

accompanying the sequence of events that occur in making soldered joints is so vital for

developing reliable joining process.

Soldering iron is invented way back in four thousand years ago by using open

flame or heated charcoal. Since there is no control for its temperature, Weller Company

invented magnastat soldering iron that uses temperature sensitive magnetic tip. Soldering

iron is a powerful weapon in the electronics industry. Soldering technology has generally

evolved in an empirical manner, largely by trial and error. Standard soldering workstation

plays a vital role in achieving a high quality solder and creating a laboratory that is

conducive for safety and health.

Our daily lives are shaped by electronics system. In the home we have myriad of

electronic accessories: radios, televisions, camcorders, CD players, telephone answering

machines, microwave ovens, and personal computers. Not so obvious but just a part of

our lives are sophisticated electronics controls such us microprocessor engine control our

car. We utilize a telephone system that functions with electronic devices to amplify and

transfer telephone signals. Our conversations are carried around the world using a

combination of microwave or fiber-optic links and satellites. For better and at time for

worse, electronics has changed our lives. Although we are in constant touch with what is

happening around the world, we are also at the peril of weapon of unimaginable

destructive power that rely on electronics developments. An understanding of electronics

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is imperative not only for designing and using electronic systems but for directing the

evolution of electronics systems so that they serve to improve the human condition.

Statement of the Problem

Cavite State University offers electronics technology program which aims to

boost its technological advancement to be able to adhere its mission to produce a globally

competitive individuals. Soldering workstation is a core factor to achieve a high

parameter of instructions and favorable approach to students in learning potential

techniques in soldering process.

Electronics laboratory in the Department of Industrial Engineering and

Technology has inadequate of this kind of equipment. Instances happen that using non

regulated soldering iron can damage some component of the circuit. Electronics

component is highly sensitive even an electrostatic discharge from human body can

easily harm the component. Without proper resistance and discharging equipment in the

workstation it can create adverse effect on the process specially during testing.

In addition Excessive exposure to lead oxide fumes can result in lead poisoning.

Symptoms include loss of appetite, indigestion, nausea, vomiting, constipation, headache,

abdominal cramps, nervousness, and insomnia. Lead is absorbed through the mucous

membranes of the lung, stomach, or intestines and then enters the bloodstream.

This made the proponent propose the development of microcontroller based

soldering iron workstation to provide necessary and correct tool to have a quality and

sophisticated output in terms of electronic innovation and projects. In addition, it will

lessen the harmful effect of soldering fumes contributing to the overall health safety of
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the users. It will benefit the present and incoming students who wish to develop their

skills in electronics and keep them safe from hazardous health effect. Providing a better

stage for this kind of activity will immense the productivity of the students in pursuit to

quality learning.

Significance of the Study

The study will be a significant undertaking in creating a health friendly working

environment. These studies also help the students and instructors to achieve a high level

of work quality and accuracy during the phase of constructing different projects.

Considering the needs of the students and interest in quality education, instructor and

student are guaranteed a combative mastery. Furthermore this research can provide

proposition on the benefits of using microcontroller based soldering iron in conformity

with the health regulation.

Moreover this research will be helpful to students who are aiming to become an

electronics technician. It will also serve as future reference for researchers in the field of

electronics technology. And essentially, this research will enlighten every students the

importance of proper working tools and equipment in the workstation.

Objectives of the Study

The fundamental objective of this study is to develop a microcontroller based

soldering iron workstation to create an innovative working space for students and

instructors working on electronic activities such as repairing, troubleshooting and circuit

production of the Department of Industrial Engineering and Technology Electronics

Laboratory.
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Specifically, aims to:

1. Design the microcontroller based soldering iron workstation;

2. Construct the microcontroller based soldering iron workstation;

3. Test the proposed design project; and

4. Evaluate the proposed design project.

Time and Place of the Study

The design project will be develop and constructed at Pob. 2, Indang, Cavite from

November 2015 to January 2016. Final installation, finalization and preliminary testing

of the design project will be held in the Department of Industrial Engineering Electronics

Laboratory.

The final testing and evaluation will be held at the Department of Industrial

Engineering Electronics Laboratory on the first week of February 2016.

Scope and Limitation

This study is limited to the creation, testing and evaluation of microcontroller

based soldering iron workstation intent to improve the students learning and overall

health condition.

A complete workstation equipped with regulated soldering iron and hot air

soldering for integrated circuit and fume filter for direct absorption of soldering iron

fumes. It also consists of improvised printed circuit board holder to mount during

operation for accuracy and stability of the work. Personal Protective Equipment as well

as suit is provided. Furthermore the study constrain to the needs of the students in the

standard and proper tools and equipment.

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The soldering iron control panel will use Atmel ATtiny85V microcontroller for

memory. It is the high-performance, low-power Atmel 8-bit AVR RISC-based

microcontroller combines 8KB ISP flash memory, 512B EEPROM, 6 general purpose

I/O lines, 32 general purpose working registers, one 8-bit timer/counter with compare

modes, one 8-bit high speed timer/counter, programmable watchdog timer with internal

oscillator, three software selectable power saving modes, and debug wire for on-chip

debugging. By executing powerful instructions in a single clock cycle, the device

achieves throughputs approaching 1 MIPS per MHz, balancing power consumption and

processing speed.

To regulate its temperature, LM7805 is a series of three terminal positive

regulators with several fixed output voltages manufactured by Fairchild Semiconductor

Corporation. Each type employs internal current limiting, thermal shut down and safe

operating area protection, making it essentially indestructible. If adequate heat sinking is

provided, they can deliver over 1A output current. Although designed primarily as fixed

voltage regulators, these devices can be used with external components to obtain

adjustable voltages and currents.

The workstation is equipped with anti-static device and grounding system for

proper electro-static discharging. The workstation measures 24 inches high, 36 inches

long and 24 inches wide. The counter top is made of laminated marine plywood with ¾

inch thick. The base composes of rounded aluminum with 1 inch diameter attached to a

1.5 inch diameter size wheel for easy transport. It also includes a cabinet for materials

and accessories storage measuring 20 inches high and 20 inches wide.

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The study involves all students taking up Bachelor of Industrial Technology

major in Electronics of Cavite State University of the academic year 2015-2016. The

researcher will conduct an overall survey to all respondents to ensure that the project

development is conforming to its purpose.

Definition of Terms

Anti-Static Mat. It provides a path to ground for a charge from conductive or

static dissipative items placed on the mat. This are made of single layer homogenous

polymer mix, two layer static dissipative rubber material or vinyl with homogenous

conductive layer material

Anti-Static Wrist Strap. Sometimes refer to ground bracelet is an antistatic

device used to safely ground a person working on very sensitive electronic equipment, to

prevent the buildup of static electricity on their body, which can result in electrostatic

discharge (ESD).

Capacitor. It is a passive electronic component that stores energy in the form of

an electrostatic field. In its simplest form, a capacitor consists of two conducting plates

separated by an insulating material called the dielectric. The capacitance is directly

proportional to the surface areas of the plates, and is inversely proportional to the

separation between the plates. Capacitance also depends on the dielectric constant of the

substance separating the plates.

Electrostatic Discharge. Referring to the sudden flow of electricity between two

electrically charged objects caused by contact, an electrical short, or dielectric

breakdown. A buildup of static electricity can be caused by tribocharging or

by electrostatic induction.
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Integrated Circuit. An integrated circuit (IC), sometimes called a chip or

microchip, is a semiconductor wafer on which thousands or millions of tiny resistors,

capacitors, and transistors are fabricated. Its function as a timer, counter, and memory.

Liquid Crystal Display. It is a flat panel display, electronic visual display, that

uses the light modulating properties of liquid crystals. Liquid crystals do not emit light

directly.

Microcontroller. It is a computer present in a single chip that contains the

processor (CPU), non-volatile memory for the program (ROM or flash). Volatile memory

for input and output (RAM), a clock and an input-output unit. It control and regulate the

temperature of the soldering iron.

Personal Protective Equipment. It is commonly known as PPE, proper device

and equipment used by technician during operation to protect from possible serious injury

in case of malfunction.

Printed Circuit Board. A rigid flat board that holds chips and other electronic

components. The board is made of layers typically two to ten that interconnect

components via copper pathways. The design transferred to a copper clad board for

correct and accurate placement of components.

Soldering Iron. It is a hand tool consisting of a handle fixed to a copper tip that is

heated electrically and used to melt and apply solder.

Soldering Lead. It is a kind of metal alloy used to join together metal work

pieces.

Soldering Oxide Fume. Refers to the harmful smoke created by the heated

soldering lead.
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Transistor. It regulates current or voltage flow and acts as a switch or gate for

electronic signals. A transistor consists of three layers of a semiconductor material, each

capable of carrying a current. A semiconductor is a material such as germanium and

silicon that conducts electricity in a "semi-enthusiastic" way.

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REVIEW OF RELATED LITERATURE

The material utilized in this literary review was compost of books, research

papers and internet sources. This is categorized as related literatures and studies, local

and foreign which are closely relevant to the study.

Most of the components in an assembly use the mechanical support of soldered

joints alone to give adequate fixing into assembly. A few isolated component notably

larger and heavier components require additional support, in the form of straps, nuts, and

bolts. On the other hand, all components may use solder as electrical support to form

requires electrical connections. No other method has yet been devised to take the place of

solder in all assemblies to the same level of performance, cost and ease of operation.

Soldering

The science of soldering has been known for many years. It is indeed, a simple process of

bringing parts to be joined together with solder, flux and heat. How to do this and to

achieve a satisfactory result, though, is both a science and art, when each by itself may

vary. Methods and principle used years ago by form a most fascinating subject. (Willis,

2010).According to the article published by the Engineer’s Garage (2010) the soldering

was practiced as far back as five thousand years ago in Egypt. Soldering was widely

performed around four thousand years ago when tin was discovered as soldering metal.

The process of soldering was introduced in Mediterranean region, and was followed in

the Roman Empire, Swiss and Hungaria. Soldering has improved a lot from culture to

culture and generation to generation and in today’s scenario it is the best method for

fabrication and assembly of microelectronics.

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Printing wiring boards are the primary means of interconnecting circuit

components. As such they have contributed greatly to the growth of electronics.

Assembly and connection of printed wiring boards also called printed circuits and etched

wiring involved a sequence of three basic operations. They are the (1) manual or

automatic insertion of electronic components, (2) metallurgical joining of component

leads or terminal to printed conductors, and, usually (3) a cleaning operation to remove

flux and other residual contaminants.

There are a number of requirements for a soldered joint. The main two are:

 It should provide a reliable electrical connection

 It should provide sufficient mechanical strength to hold the component(s) in place
To achieve these aims it is necessary that the joint is made properly. There are four

main points to note when making a joint. If these are correct when the solder joint is

made, it should remain reliable as long as the product is in use. If the soldering is not

carried out correctly, then what is termed a dry joint may result, and these give poor

electrical conductivity, sometimes giving intermittent performance, and also the

mechanical strength will be much less.

The four keys to producing a good joint are:

 Ensure the joint surfaces are clean and free from grease.

 Ensure the temperature of the solder when making the joint is correct.

 Ensure the heat is applied to the joint for the correct amount of time

 Ensure the correct amount of solder is used.

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Each of these keys is important in producing good quality joints. In fact it is

particularly important to ensure that all joints are made to the highest standard because it

only takes one joint to cause problems in a circuit.

In view of the fact that dry joints can cause these problems it is necessary to look for

them as the individual joints are made, examining each one as the solder cools to ensure

it is satisfactory. A good solder joint appears to have a shiny surface to the solder. On the

other hand a dry joint can be identified from the fact that the surface looks dull, having a

"matt" finish. It also does not have the same mechanical strength as a properly made

joint, and provided the wires to the joint are not mechanically would round each other to

provide strength, a dry joint will pull apart more easily than a properly made solder joint.

When any dry solder joint are found the old solder should be removed and the joint

remade.

Types of Soldering

Soldering is classified as shown in the figure below:

Figure 1.Types of soldering

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1.  Soft soldering

It is a process for joining small intricate parts having low melting points which

damages when soldering process is carried out at high temperature. It uses tin-lead alloy

as filler material. The melting point of the filler material should be below 400 oC (752oF).

It uses gas torch as the heat source.

2.  Hard soldering

In this process, hard solder connects two pieces of metals by expanding into the

pores of the work piece opened by high temperature. The filler material possesses high

temperature above 450oC (840oF).

It comprises of two parts namely silver soldering and brazing. 

2.1  Silver soldering

It is a clean process useful for fabricating small fittings, doing odd repairs and

making tools. It uses an alloy containing silver as filler material. Silver provides free

flowing characteristics but silver solder is not good at gap filling hence, different fluxes

are recommended for précised silver solder.

2.2  Brazing

Brazing is a process of joining two pieces of base metals by creating melted metallic

filler that flows by capillary attraction across the joints and cools to form a solid bond

through atomic attraction and diffusion. It creates an extremely strong joint. It uses brass

alloy as filler material.(Engineer’s Garage, 2010).

Dip Soldering

In deep soldering process the assembled board is fluxed then lowered horizontally

into a bath of molten solder. The board is drop into a horizontal position on top of the
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solder. After a suitable period during which the solder achieves wetting over the whole of

the areas to be soldered, one edge of the board lifted (usually the edge which first came

into contact with solder), then the whole board is lifted clear of the bath. Dip soldering

suffers from problems in the flux gases are easily trapped under the board and, as a

consequence, contact times must be quite long to ensure adequate wetting and solder

temperature must be quite high.(Humpston and Jacobson, 2014).

Drag Soldering

By dragging the assembled and fluxed board over the surface of molted solder,

the problem associated with dip soldering can be overcome. Consequent contact times

much shorter.(Humpston and Jacobson, 2014).

Wave Soldering

Wave soldering process use a pump to create a wave of solder over which the

assembled and fluxed board is passed. Contact time is only two to four seconds are usual,

required soldering temperature is lowered.(Humpston and Jacobson, 2014).

Making a solder joint

When soldering, it is necessary to ensure that the right steps are taken to ensure

that the joints will be of a sufficiently high quality. The iron should be set to the correct

temperature. The melting point of most traditional solder containing lead is in the region

of 180oC and in order that sufficient heat can be transferred to the joint the iron tip

temperature should typically be set to the range 330oC – 350oC. However the new lead-

free solders typically require a slightly higher temperature.

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One of the major requirements to ensure that a joint is made well is to ensure that

everything is properly clean. The soldering iron bit should be cleaned. Many soldering

iron stands have a holder for a damp sponge. This should be moistened and the bit for the

soldering iron wiped over it, and any residue removed. A small amount of solder can then

be melted onto the iron bit so that it is suitably "tinned".

With the items tinned as required, the soldered joints can be made. The

components should be secured in position. When leads are being soldered to tags, some

like to wind the leads around the tag to give increased mechanical strength. If this is done

then it is considerably more difficult to unsolder if there is a problem later. With the

surfaces to be soldered brought together the soldering iron should be applied. The solder

should then be brought to the joint and solder melted over the area to be soldered. One of

the keys to making a good joint is to use the correct amount of solder. Experience tells

how much should be used in a given situation, but it should be sufficient to cover the area

to be soldered. The contour of the solder should be slightly concave.

It is important not to hold the iron on the joint for too long. It should be retained

there long enough for the solder to flow freely onto the joint and then removed. If it is

held on the joint for too long then the flux will burn off and the solder will oxidize and a

dry joint will be formed. Although certain guidance can be set down to summarize the

best methods for soldering, it is a skill that is learned by actually doing it. Fortunately

soldering is not difficult to master and with the right equipment and tools it is quickly

possible to make reliable joints with little chance of error.(Poole, 2013)

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Soldering iron

A soldering iron is a hand tool used in soldering. It supplies heat to melt solder so

that it can flow into the joint between two work pieces. A soldering iron is composed of a

heated metal tip and an insulated handle. Heating is often achieved electrically, by

passing an electric current (supplied through an electrical cord or battery cables) through

a resistive heating element. Cordless irons can be heated by combustion of gas stored in a

small tank, often using a catalytic heater rather than a flame. Simple irons less commonly

used than in the past were simply a large copper bit on a handle, heated in a flame.

Soldering irons are most often used for installation, repairs, and limited production work

in electronics assembly. High-volume production lines use other soldering

methods. Large irons may be used for soldering joints in sheet metal objects. Less

common uses include pyrography (burning designs into wood) and plastic welding.

  This is obviously the key piece of equipment and it is essential that it is right for

the job. For commercial work, temperature controlled soldering irons are essential to

ensure that that good solder joints can be made reliably.

The much cheaper non-temperature controlled soldering irons may be suitable for

occasional home construction work. However they are not ideal because their

temperature regulation results simply from the cooling of the bit, and when being used

for soldering heat will be extracted and the temperature will fall. Additionally the

temperature of the soldering iron will rise and fall dependent upon a variety of other

factors ranging from the location, the temperature of the day, whether the iron is in a

draught, etc. Thus their temperature will only be approximately in the right region for

soldering.
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Soldering irons come in a variety of sizes and shapes. A continuously tinned

surface must be maintained on the soldering iron tip's working surface to ensure proper

heat transfer and to avoid transfer of impurities to the solder connection. Fully

temperature controlled soldering irons have a thermostat to control the temperature. This

is also adjustable and enables the soldering iron temperature to be set and maintained at

the correct value.(Poole, 2013)

Types of Soldering Iron

1. Simple Iron

For electrical and electronics work, a low-power iron, a power rating

between 15 and 35 watts, is used. Some irons are temperature-controlled, running

at a fixed temperature in the same way as a soldering station, with higher power

available for joints with large heat capacity. Simple irons run at an uncontrolled

temperature determined by thermal; when heating something large their

temperature drops a little, possibly too much to melt solder.

2. Cordless Iron

Small irons heated by a battery, or by combustion of a gas such

as butane in a small self-contained tank, can be used when electricity is

unavailable or cordless operation is required. The operating temperature of these

irons is not regulated directly; gas irons may change power by adjusting gas flow.

Gas-powered irons may have interchangeable tips including different size

soldering tips, hot knife for cutting plastics, miniature blow-torch with a hot

flame, and small hot air blower for such applications as shrinking heat

shrink tubing.
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3. Temperature-Controlled Soldering Iron

Simple irons reach a temperature determined by thermal equilibrium,

dependent upon power input and cooling by the environment and the materials it

comes into contact with. The iron temperature will drop when in contact with a

large mass of metal such as a chassis; a small iron will lose too much temperature

to solder a large connection. More advanced irons for use in electronics have a

mechanism with a temperature sensor and method of temperature control to keep

the tip temperature steady; more power is available if a connection is large.

Temperature-controlled irons may be free-standing, or may comprise a head with

heating element and tip, controlled by a base called a soldering station, with

control circuitry and temperature adjustment and sometimes display.

A variety of means are used to control temperature. The simplest of these

is a variable power control, much like a light dimmer, which changes the

equilibrium temperature of the iron without automatically measuring or regulating

the temperature. Another type of system uses a thermostat, often inside the iron's

tip, which automatically switches power on and off to the element. A thermal

sensor such as a thermocouple may be used in conjunction with circuitry to

monitor the temperature of the tip and adjust power delivered to the heating

element to maintain a desired temperature.

Another approach is to use magnetized soldering tips which lose their

magnetic properties at a specific temperature, the Curie point. As long as the tip is

magnetic, it closes a switch to supply power to the heating element. When it

exceeds the design temperature it opens the contacts, cooling until the temperature
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drops enough to restore magnetization. More complex Curie-point irons circulate

a high-frequency AC current through the tip, using magnetic physics to direct

heating only where the surface of the tip drops below the Curie point. (Humpston

and Jacobson,2014).

Soldering Iron Characteristics

Although tip temperature is not the key element in soldering you should always

start at the lowest temperature possible. A good rule of thumb is to set the soldering iron

tip temperature at 260 C - 500 F and increase the temperature as needed to obtain the

desired result. Controlling soldering iron tip temperature is not the key element in

soldering. The key element is controlling the heat cycle of the work. How fast the work

gets hot, how hot it gets, and how long it stays hot is the element to control for reliable

solder connections. The first factor that needs to be considered when soldering is the

relative thermal mass of the joint to be soldered. This mass may vary over a wide range.

Each joint, has its own particular thermal mass, and how this combined mass compares

with the mass of the iron tip determines the time and temperature rise of the work.

A second factor of importance when soldering is the surface condition. If there are any

oxides or other contaminants covering the pads or leads, there will be a barrier to the flow

of heat. Even though the iron tip is the right size and temperature, it may not be able to

supply enough heat to the joint to melt the solder. A third factor to consider is thermal

linkage. This is the area of contact between the iron tip and the work. The tip is also in

contact with both the pad and component further improving the thermal linkage. This

solder bridge provides thermal linkage and assures the rapid transfer of heat into the

work.(Humpston and Jacobson, 2014).

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Voltage

Most irons run from the mains at 240V. However, low voltage types (e.g. 12V or

24V) generally form part of a "soldering station" and are designed to be used with a

special controller made by the same manufacturer. (Winstanley Alan,2010).

Wattage

Typically, they may have a power rating of between 15-25 watts or so, which is

fine for most work. A higher wattage does not mean that the iron runs hotter - it simply

means that there is more power in reserve for coping with larger joints. This also depends

partly on the design of the "bit" (the tip of the iron). Consider a higher wattage iron

simply as being more "unstoppable" when it comes to heavier-duty work, because it

won't cool down so quickly. (Winstanley Alan,2010).

Temperature Control

The simplest and cheapest types don't have any form of temperature regulation.

Simply plug them in and switch them on. Thermal regulation is "designed in", they may

be described as "thermally balanced" so that they have some degree of temperature

"matching" but their output will otherwise not be controlled. Unregulated irons form an

ideal general purpose iron for most users, and they generally cope well with printed

circuit board soldering and general interwiring. Most of these "miniature" types of iron

will be of little use when attempting to solder large joints (e.g. very large terminals or

very thick wires) because the component being soldered will "sink" heat away from the

tip of the iron, cooling it down too much. (This is where a higher wattage comes in

useful.) A proper temperature-controlled iron will be quite a lot more expensive - and

will have some form of built-in thermostatic control, to ensure that the temperature of the
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bit (the tip of the iron) is maintained at a fixed level (within limits). This is desirable

especially during more frequent use, since it helps to ensure that the temperature does not

"overshoot" in between times, and also guarantees that the output will be relatively stable.

Some irons have a bimetallic strip thermostat built into the handle which gives an audible

"click" in use: other types use all-electronic controllers, and some may be adjustable

using a screwdriver. Some versions might have built-in digital temperature readout, and

will have a control knob to enable you to vary the setting. The temperature could be

boosted for soldering larger joints, for example, or for using higher melting-point solders

(e.g. silver solder). These are designed for the most discerning users, or for continuous

production line/ professional use. The best stations have irons which are well balanced,

with comfort-grip handles which remain cool all day. A thermocouple will be built into

the tip or shaft, which monitors temperature.(Winstanley Alan,2010).

Anti-static Protection

If you're interested in soldering a lot of static-sensitive parts (e.g. CMOS chips or

MOSFET transistors), more advanced and expensive soldering iron stations use static-

dissipative materials in their construction to ensure that static does not build up on the

iron itself. The cheapest irons won't necessarily be ESD-safe but never the less will still

probably perform perfectly well in most hobby or educational applications, if you take

the usual anti-static precautions when handling the components. The tip would need to be

well earthed (grounded) in these circumstances.(Winstanley Alan,2010).

Bits

It's useful to have a small selection of manufacturer's bits (soldering iron tips)

available with different diameters or shapes, which can be changed depending on the type
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of work in hand. You'll probably find that you become accustomed to, and work best

with, a particular shape of tip. Often, tips are iron-coated to preserve their life, or they

may be bright-plated instead. Copper tips are seldom seen these days.(Winstanley,2010).

Safety

Soldering of electronic assemblies, indeed the whole assembly process, is a

potentially dangerous procedure. Equipment in electronics assembly is often used with

solvents which maybe poisonous or explosive. In many assembly processes, particularly

soldering itself, heat is hazard when combined with these solvent and materials. Safety is

a vital concern to all person involved in soldering process. Considering specific safety

aspects, describing hazards and possible effects, suggesting ways to avoid them, and

detailing first aid which may be required within the varied aspects in soldering. (CVSU

Library)

According to Occupational Health and Safety Administration (OSHA) (2010),

lead is used in soldering process in the form of lead/silver filler metal. When heated, lead

oxide fumes are formed. Excessive exposure to lead oxide fumes can result in lead

poisoning. Symptoms include loss of appetite, indigestion, nausea, vomiting,

constipation, headache, abdominal cramps, nervousness, and insomnia. Lead is absorbed

through the mucous membranes of the lung, stomach, or intestines and then enters the

bloodstream.

As stated by the Restriction of Hazardous Substance’s ( RoHS, 2002), only

<10000ppm is the acceptable level to be used in the electrical and electronics industry in

solder, lead acid batteries, electronic components and in the glass of cathode ray tube.
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Microcontroller

A microcontroller already contains all components which allow it to operate

standalone, and it has been designed in particular for monitoring and/or control tasks. In

consequence, in addition to the processor it includes memory, various interface,

controllers, one or more timers, an interrupt controller, and last but definitely not least

general purpose I/O pins which allow it to directly interface to its environment.

Microcontrollers also include bit operations which allow you to change one bit within a

byte without touching the other bits.

Even at a time when Intel presented the first microprocessor with the 4004 there

was already a demand for microcontrollers: The contemporary TMS1802 from Texas

Instruments, designed for usage in calculators, was by the end of 1971 advertised for

applications in cash registers, watches and measuring instruments. The TMS 1000, which

was introduced in 1974, already included RAM, ROM, and I/O on-chip and can be seen

as one of the first microcontrollers, even though it was called a microcomputer.

The first controllers to gain really widespread use were the Intel 8048, which was

integrated into PC keyboards, and its successor, the Intel 8051, as well as the 68HCxx

series of microcontrollers from Motorola. Today, microcontroller production counts are

in the billions per year, and the controllers are integrated into many appliances we have

grown used to, like household appliances, telecommunication, automotive industry,

aerospace industry and industrial automation.(Gridding and Weiss, 2007).

Microcontroller Processor Core

The processor core (CPU) is the main part of any microcontroller. It is often taken from

an existing processor, e.g. the MC68306 microcontroller from Motorola contains a 68000
 24

CPU. At the core of the CPU is the arithmetic logic unit (ALU), which is used to perform

computations(AND, ADD, INC, . . . ). Several control lines select which operation the

ALU should perform on the input data. The ALU takes two inputs and returns the result

of the operation as its output.(Gridding and Weiss, 2007).

.
 25

Figure 2. Basic CPU architecture of microcontroller

A basic CPU architecture depicted in Figure 2. It is consist of data path, which executes

instruction, and of control unit, which basically tells data path what to do.

Microcontroller Module

The basic internal designs of microcontrollers are pretty similar. Figure 3 shows the block

diagram of a typical microcontroller. All components are connected via an internal bus

and are all integrated on one chip. The modules are connected to the outside world via

I/O pins.

Figure 3. Basic

layout of microcontroller

Processor Core: The CPU of the controller. It contains the arithmetic logic unit, the

control unit, and the registers (stack pointer, program counter, accumulator register,

register file,
 26

Memory: The memory is sometimes split into program memory and data memory. In

larger controllers, a DMA controller handles data transfers between peripheral

components and the memory.

Interrupt Controller: Interrupts are useful for interrupting the normal program flow in

case of (important)external or internal events. In conjunction with sleep modes, they help

to conserve power.

Timer/Counter: Most controllers have at least one and more likely 2-3 Timer/Counters,

which can be used to timestamp events, measure intervals, or count events.

Many controllers also contain PWM (pulse width modulation) outputs, which can be used

to drive motors or for safe breaking (antilock brake system, ABS). Furthermore the PWM

output can, in conjunction with an external filter, be used to realize a cheap digital/analog

converter.

Digital I/O: Parallel digital I/O ports are one of the main features of microcontrollers. The

number of I/O pins varies from 3-4 to over 90, depending on the controller family and the

controller type.(Gridding and Weiss 2007).

Microcontroller Programming

Many relative electronic based courses prefer to use microcontroller because it is

relatively small and occupies less space in the system compared to personal computer,

performing not so complicated task that is impractical to use. The engineers can easily

reprogram the microcontroller whenever there is a change or innovation on the whole

system. Programming a microntroller is like programming a microprocessor. Many

manufactures of this chips like Intel, Motorola, National Semiconductor, Microchip,

Zilog, Atmel, and Texas Instrument. Some manufacturers provide only the hardware in
 27

which the programmer could use many popular programming language like C compiler

and even the Basic Language. (Coronacion, Sante, and Paniterce 2013)

MATERIALS AND METHODS

This chapter provides information on the project methods and materials used in

developing the project design. The conceptual framework, planning, construction,

fabrication as well as testing and evaluation to ensure the one hundred percent

performance and it acceptability in terms of user-machine interactions.

Materials

The materials used in constructing the microcontroller based soldering iron and

hot air soldering is indicated in Tables 1 to 2. Table 3 representing the materials used in

making the workstation. Workstation peripherals and construction materials were

presented in Table 4. Table 5 represents the other miscellaneous materials used while
 28

making the design project. Tools and equipment used in the phase of production is also

presented in Table6.

Table 1. Materials to be use in microcontroller based soldering iron workstation

Qty Unit Description/Specification Item

Microcontroller based soldering iron

10 pc 100 ohms ¼ watt resistor Resistor

2 pc 2.7K ohms ¼ watt resistor Resistor

1 pc 300 ohms 2 watts resistor Resistor

2 pc 10K ohms ¼ watt resistor Resistor

3 pc 470 ohms ¼ watt resistor Resistor

1 pc 2K ohms ¼ watt resistor Resistor

1 pc 200K ohms ¼ watt resistor Resistor

2 pc 100K ohms ¼ watt resistor Resistor

Table 1 continued…

1 pc 1.2K ohms ¼ watt resistor Resistor

3 pc 220 micro farad 16V capacitor Capacitor

1 pc 104 capacitor Capacitor

1 pc 100 micro farad 16V capacitor Capacitor

1 pc 4.7 micro farad 50V capacitor Capacitor

1 pc F2AL 250V fuse Fuse

1 pc 100K variable resistor Variable Resistor

1 pc 250V AC 5A switch Switch

2 pc IN4007 diode Diode

1 pc 4735 zener diode Diode

1 pc 78L05 transistor Transistor

 29

1 pc BT1036 600E transistor Transistor

1 pc LM358P regulator integrated circuit Integrated Circuit

1 pc S3C954B microcontroller Microcontroller

1 pc Red LED 1.5mm LED

1 pc 3 terminal variable resistor 202 Variable Resistor

1 pc SM310401 LED Display

1 pc 5 pins jack Connector

1 pc 2A Transformer Transformer

1 pc Hakko 907 Soldering Iron Soldering Iron

Table 2. Materials used in hot air soldering

Qty Unit Description/Specification Item

Digital Hot Air Soldering

5 pc 10K ohms ¼ watt resistor Resistor

2 pc 470 ohms ¼ watt resistor Resistor

3 pc 5.1K ohms ¼ watt resistor Resistor

1 pc 33K ohms ¼ watt resistor Resistor

9 pc 100 ohms ¼ watt resistor Resistor

1 pc 110K ohms ¼ watt resistor Resistor

1 pc 15K ohms ¼ watt resistor Resistor

1 pc 150 ohms ¼ watt resistor Resistor

1 pc 1000 micro farad 16V capacitor Capacitor

 30

8 pc 104 capacitor Capacitor

2 pc 220 micro farad capacitor Capacitor

1 pc L54 (474) capacitor Capacitor

1 pc 22 micro farad Capacitor

1 pc 47 micro farad Capacitor

1 pc CBB2104J400V capacitor Capacitor

2 pc 3904 transistor Transistor

1 pc 220A transformer Transformer

1 pc F2AL 250V fuse Fuse

1 pc 1N4140 Diode

6 pc 1N4007 Diode

1 pc HS31040 LED Display LED Display

1 pc 3362 variable resistor Variable Resistor

Table 2 continued…

1 pc B10K variable resistor Variable Resistor

1 pc MOC3041 integrated circuit Integrated Circuit

1 pc HA17358 integrated circuit Integrated Circuit

1 pc ATMEGA8 microcontroller Microcontroller

Table 3.Materials to be use in constructing the workstation

Qty Unit Description/Specification Item
Workstation
1 pc 21" x 11 x ¾” Laminated wood Wood
1 pc 14” x 6” ¼” acrylic glass Plastic
20 meter 1 1/2” square tube Metal
1 liter pure white quick drying enamel Paint
 31

1 bottle white glossy spray paint paint

- - Assorted screws Screws

Tool Cabinet with Casters

- - Assorted screws Screws
4 pcs 10” x 11” 1/2” plywood Wood
4 pcs 2” Caster Wheels

Table 4. Workstation Peripherals

Qty Unit Description/Specification Item
Working Table Peripherals
4 pc 220v AC SPST switch switch
1 pc PCB holder Holder
Table 4 continued…
1 pc 220v Exhaust fan Fan
2 pc 12v DC fan Fan
1 pc Antistatic wrist strap Antistatic Device
10 pc mask mask
1 pc long nose Tools
1 pc side cutting pliers Tools
1 pc blade cutter Tools
1 pc desoldering pump Tools
3 pc tweezer Tools
3 pc nozzle Tools
3 pc Antistatic Mat 15x34 inches Antistatic Device
 32

Table 5. Miscellaneous supply materials

Qty Unit Description/Specification Item
2 btl Ferric chloride Solution
2 pcs 10” x 5” copper boards Boards
2 roll 1” wide masking tape Tapes
1 roll Soldering lead Lead
- m stranded wire Wire
- - Assorted screws Screws
2 pcs Soldering tips Tips
8 pcs Sand papers Sand Paper
3 blt Varnish paint Paint
2 pcs soldering sponges Sponges
1 btl Wood glue Glue

Table 6. Tools and equipment to be use in developing the workstation

Qty Unit Description/Specification Item
Tools
2 pcs Soldering irons Irons
1 pc Desoldering pump Pump
1 s Hand drill Drill
2 pcs Soldering stand Stands
2 s Flat and screw drivers Drivers
1 s Multipurpose convertible saw Saw
2 pcs Hammer Hammers
1 s Set of pliers Pliers
1 s Precision screw drivers Drivers
1 pc Glue gun Glue Gun
2 pcs Multitester Tester
 33

Methods

The general methods and procedures followed in developing this soldering iron

workstation were the following:

1. Conceptualizing the framework of the design project.

2. Formulate a system flow process in developing the soldering iron workstation.

3. Canvassing and estimate of component prices.

4. Layout and design the workstation

5. Designing the PCB layout and the circuitry

6. Installing the soldering iron and hot air soldering

7. Construction of the workstation

8. Installation of the workstation peripherals

9. Pre-testing of the components

 34

10. Evaluation of the workstation

11. Revision

12. Final Testing

Conceptualizing the Microcontroller Based Soldering Iron Workstation

The conceptual framework of Microcontroller Based Soldering Iron Workstation

is based in the educational knowledge of the author coupled with the integration of

technology which is essentials in achieving a high quality of output. Figure 4 shows the

conceptual framework develops to set as reference from the input to output process.

INPUTS PROCESS OUTPUT

Knowledge Requirements
Electronics Shop Practice
Electronics Technology
Basic Soldering Iron Techniques
Design
Programming Mobilization
Microcontroller and Digital Technology Construction A
Fabrication Microcontroller
Google Sketch
Installation Based Soldering
Carpentry Assembly Iron
CADD Testing Workstation
Modification

Material Requirements
Electronic Components, LCD Display,
Microcontroller Module, Power Supplies,
Switching Device, Soldering Iron Heat
Elements, Wires, Grounding System, Anti-
static Mat, Soldering Kit, and others.
 35

Evaluation

Figure 4.Conceptual framework of the microcontroller based soldering iron workstation.

The conceptual framework presented in the Figure 4 was considered as the

general guide to attain the objectives of the design project. The notion and thought were

formulated to let the researchers be abreast with how the design project will be

constructed. The input act as a strong core and basis for corrective layout of the

workstation. Electronics shop practice; basic soldering techniques, microcontroller and

digital technology were subjects being passed by the researchers in their previous years in

the university. The learning’s amass by the researchers in those topics made them adept

of doing so the design project. From conceptualizing, mobilization of the required items

and components, construction, fabrication, assembly, installation, testing and

troubleshooting of the design project. Basic metal fabrication is essential for the

researchers for creating the base frame of the workstation. Overall, the knowledge to the
 36

the right tools and equipment as well as the components to be used by the researcher to

materialized the design project prevails.

Acquisition of Materials Needed in Developing the Design Project.

The researcher aims to save time and money without compromising the quality of

the design project. Overall aesthetic is also considered in choosing right materials to be

used in constructing the workstation to established strong and durable foundation that

will last. Listing all materials with estimated cost and quantity as well as specification

and description is furnished. The components and devices are purchased according to its

importance and use during the development of the project. Soldering iron parts, hot air

gun, magnifying lamp, fume extractor, watt and volt meter and the tool cabinet comprises

the workstation. Some of the component bought online. The researchers went to Raon

Electronics Center, in Recto, Manila and Tanza, Cavite to purchase electronics parts.

Layout and Design of Workstation

 37

Figure 5. Workstation top view

Figure 6. Workstation side view

Figure 7. Workstation front view

 38

Figure 8. Workstation
isometric view

Layout of the workstation shown in Figure 5 to 8 is provided by the researchers

conforming to the standard working tables. Cabinet for components and tools safekeeping

are shown in Figure 9 to 12

Cabinet Caster Layout

 39

Figure 9. Cabinet top view

Figure
10. Cabinet side view

Figure
11.

Cabinet front view

 40

Figure 12. Cabinet

isometric view

Designing and Construction the Printed Circuit Board and the Circuitry

Constructing the internal circuitry is conforming to the specification of the

components to fully maximize its usage. Figures 13 to 14 showing the design of

magnifying lamp circuit design. Procedures of constructing these boards are as follows:

a. Materials and components were prepared according to its usage;

b. Testing of electronics components to ensure that it is in good working condition;

c. Review diagram and design for possible error;

d. Print design to acetate sheet for exposure;

e. Cut pre-sensitized board to the actual sized needed in the circuit;

f. Put the printed acetate sheet to the pre-sensitized board for light exposure;

g. After exposure dip the pre-sensitized board to a solution and shake occasionally;
 41

h. Make the board dry ; and

i. Test.

Figure 13. Pre-sensitized board

 42

Figure 14. Printed presensitized board

Construction of Workstation

Creation of the soldering workstation needs a professional carpentry skill to

deliver a quality and durable output. The researchers seek help for the construction of

soldering workstation. The following procedures were being observed while constructing

the workstation:

a. Purchase the metals, wood and other materials needed in constructing the

workstation.

b. Cut the metal and wood according to its size stated in the plan.

c. Used sand paper to soften the surface of the countertop.

d. Paint the control box as well as the workstation.

e. Bore hole in the control box for different control knob and switches.

f. Assemble countertop to its base frame by screws.

g. Spray paint for glossy finish.

 43

Figure 15. Using drill to put holes for knobs and control

Figure 16. Assembling countertop and base frame

 44

Figure

17. Spray paint for finishing touch

Installation of Soldering Iron and Hot Air Soldering

Electronics Technology subjects are the tools of the researchers to do the

following procedures:

a. Unboxing the items to checked the different items specified in the list;

b. Read and understand the manuals of each item;

c. Modify the circuit board to fit in the workstation control panel;

d. Re-wiring is required to connect the circuit to its power supply;

e. Cut the acrylic to be used as the display and circuit holder;

f. Bore hole to acrylic for temperature and air control

g. Connect wires from the circuit board to power supply;

h. Soldering iron and hot air soldering is being connected;

 45

i. Plug-in power supply and turn on the device.

 46

Figure 18. Acrylic cutting for temperature control display

 47

Figure 19. Acrylic drilling for different control

 48

Figure 20. Circuit board attachment to the acrylic and control box

Wiring and Installation of Workstation Peripherals

Wiring and installation and putting workstation peripherals are the last major

steps to achieve the goals of the design project. The researchers ensure that the materials

used in the workstation are conformed to the standard set by the industry. Connection

between the circuit board and power supply needs extra length or assembly and repair

purposes. The connection is being extended through a connecting wire with the same size

and specification. The transformer lies beneath the circuit board or easy location of the

connection. The power supply of soldering iron and hot air gun is passing through the

digital watt and voltmeter to monitor the energy consumption of the device.
 49

Figure 21. Power supply wiring

 50

Figure 22. Connecting wires to different equipment’s

Pre-testing of the Components

Pre testing of the components and other workstation peripherals is essential to

ensure the effectiveness and workability of the workstation. Pre –testing includes

soldering iron, hot air soldering, control box exhaust, digital watt and voltmeter,

magnifying lamp and the outlet. The researchers test the soldering iron from its

minimum temperature to determine how long it could reach the standard heating

temperature that can melt the solder. From two hundred degrees Celsius it can easily

reach three hundred fifty degrees Celsius. Hot air soldering is on sleep mode when you

turn the switch on. When the hot air is on work mode it will heat up to the minimum

temperature set in last use. Also being test is the air pressure knob from minimum to

maximum. While the two devices are on the digital watt and voltmeter is measuring its

wattage use as well the voltage entered into the device power supply.
 51

Figure 23. Temperature display of soldering iron and hot air soldering.

Evaluation of Workstation

An evaluation instrument was formulated to determine acceptability and

functionality of the design project by having the following criteria; (a) functionality, (b)

aesthetics, (c) workability, (d) durability, (e) economy, and (f) safety. Functionality focus

on the ease of operation, comfort and convenience and user friendliness. Physical

attributes, style and design and appropriateness of the colors and structure comprises the

aesthetics ‘criteria. Materials, expertise and tools and machine availability is under the

workability criteria. In durability section it is measured by its quality of materials,

craftsmanship and the design of the prototype. Economy stated the ease of acquiring the

materials needed , time and labor spent and machine required to developed the designed

project. Safety includes the absence of toxic and hazardous materials, absence of sharp

edges and the provision of the prototype devices.

 52

Figure 23. Workstation demonstration

The researchers requested instructors from the Department of Industrial Engineering and

Technology, electrical technology and electronics technology students to evaluate the

design project. As stated the objectives, this workstation will be used as trainers in the

laboratory for electrical and electronics doing different activities. This student evaluators

focus on the workability of the workstation, material availability and general safety. The

researcher’s conducted demonstration to test its function and to show the proper use of

the components present in the workstation (see Figure ). In addition , the details and the

specifics of the workstation is being discussed by the researchers and answer question

from the respondents. After the researchers demonstrate and discuss the features of the

workstation , the respondents give their appropriate rating, remarks and suggestions. At

last the researchers collected and tabulated the result to determine the result of the

evaluation.
 53

Figure 24. Faculty demonstration

Figure 25. Faculty evaluation

The legend used for giving a numerical value rating was presented in Table.

While the legend used or giving a descriptive rating equivalent of every numerical

average mean score was presented in Table

Table 7. Grading system and its equivalent

______________________________________________________
Numerical Rating Equivalent
_______________________________________________________________________
5 Excellent
4 Very Good
3 Good
2 Fair
 54

1 Poor

______________________________________________________
Table 8. Descriptive rating equivalents

Numerical Mean Average Descriptive Rating

_______________________________________________________________________
4.51 - 5.00 - Excellent

3.51 - 4.50 - Very Good

2.51 - 3.50 - Good

1.51 - 2.50 - Fair

1.00 - 1.50 - Poor

______________________________________________________

Replacement of Anti-Static Mat to Formica Board

As per evaluators request the, the countertop should be replace with formica board

due to the following reasons:

a. Anti-static mat is only available in 16x20 inches size which requires three pieces

to fit in the countertop.

b. Its cutting is visible on the top.

c. It uses screws to fasten the mat.

d. It is not pleasant to the eye.

 55

Figure 26. Workstation with anti-static mat countertop

Figure 26. Workstation with formica board countertop

 56

RESULTS AND DISCUSSION

Project Description

This soldering workstation is expected to be utilized by both the instructors and

students studying electronics technology at the Electronics Laboratory of Department of

Industrial Engineering and Technology of Cavite State University and also may be used

in trainings and actual demonstration. It will be a big help to the students and individuals

who wish to hone their skills in practical electronics especially techniques in soldering.

The design project was developed to alleviate the workstation status of the

laboratory by using controlled components. Incorporating digital iron and digital hot air

soldering to bring quality output and to prevent damage to the component as it is mitigate

the oversupply of heat to the circuit board. Furthermore, the researcher developed the

design project to lessen the implication brought up by unprotected and non-conducive

workstation. The study attained its goal to build a user friendly, and enhance the

controlled element of the workstation.

Project Structure

The design project compose of one workstation as shown in Figure 27 , equipped

with one soldering iron, one hot air for rework, a magnifying lamp, printed circuit board

holder, fume extractor and 3 slot universal outlet. The total surface area of the

workstation is 24 inches x 36 inches. It stands 30 inches. The central control unit is place

in 8x36x6 confine box for safety and tidy arrangement of wires and components. The
 57

workstation base and frame is made of steel for reliability and longevity. The entire

surface and the control box is made of ½ inches coated marine plywood painted with

Figure 27. Soldering Iron workstation

 58

super white glossy paint. The control panel attached to an acrylic sheet for the proper

visibility of the temperature display. The countertop is covered with formica board for

smooth and tidy finish. The main power supply is 220V from the outlet and pass through

the transformer for regulation and converting AC to DC to supply the circuit to its needed

voltage. Both soldering iron and hot air is being controlled by HTR46R23 from the series

of 8-bit high performance RISC architecture microcontrollers, designed especially for

applications that interface directly to analog signals, such as those from sensors. All

devices include an integrated multi-channel Analog to Digital Converter in addition to

one or more Pulse Width Modulation outputs. Device flexibility is enhanced with the

usual features of the other microcontroller range such as HALT and wake-up functions,

oscillator options, and programmable frequency divider.

These features combine to ensure applications require a minimum of external

components and therefore reduce overall product costs. Having the benefits of integrated

analog/digital and PWM functions, in addition to the advantages of low power

consumption, high performance, input/output flexibility, as well as low cost, these

devices have the versatility to suit a wide range of application possibilities such a sensor

signal processing, motor driving, industrial control, consumer products, and subsystem

controllers. The workstation also comes with a rolling four drawer cabinet for

safekeeping of different components, tools, safety tools and manuals. A waste bin is also

provided for proper disposal of toxic waste while and after the laboratory.

A. Workstation Physical Structure

 59

Figure28. Front view of physical structure of soldering iron workstation

Figure 29. Side view of workstation physical structure

 60

Figure 30. Tool cabinet front view physical structure

Based on the Figure 28 to 30 the workstation consists of several division. Parts and

control panel were also presented. Stationary equipment’s in the workstation countertop

was being featured.

Project Capabilities and Limitation

1. Soldering Iron

The soldering iron circuit board is equipped with S3C9545B Microcontroller to

control the temperature as well as save program to command the operation. A 12-bit

address bus supports program memory operations. A separate 8-bit register bus carries

addresses and data between the CPU and the internal register file. The S3C9454B have 2-

Kbytes or 4-Kbytes of mask-programmable on-chip program memory: which is

configured as the Internal ROM mode, all of the 4-Kbyte internal program memory is
 61

used. The S3C9454B microcontroller has 208 general-purpose registers in its internal

register file. Twenty-six bytes in the register file are mapped for system and peripheral

control functions. The S3C9454B microcontroller has two kinds of address space: (a)

internal program memory (ROM), (b) internal register file. Operating temperature range

from 40°C to + 85°C, operating voltage range is 2.0 V (LVR Level) to 5.5 V. Initial

temperature start with 100 degrees Celsius up to four hundred eighty degrees Celsius

maximum. Upon reaching the set temperature the heat sensing element will pass the

signal to the MCU to neutralize and balance the heat being supplied to the iron tip. It is

also important to remember that the temperature should not be always set to its maximum

temperature setting to prevent early damage of iron tip as well as overheating of the

components.
 62

Figure 31. S3C9545B microcontroller block diagram

 63

Figure 32. S3C9545B microcontroller pin assignment diagram

An external RC oscillation source provides a typical 4 MHz clock for S3C9545B

microcontroller. An internal capacitor supports the RC oscillator circuit. An external

crystal or ceramic oscillation source provides a maximum 10 MHz clock. The XIN and

XOUT pins connect the oscillation source to the on-chip clock circuit. When you use

external oscillator, P1.0, P1.1 must be set to output port to prevent current consumption.

The two power-down modes, Stop mode and Idle mode, affect clock oscillation as

follows: — In Stop mode, the main oscillator "freezes", halting the CPU and peripherals.

The contents of the register file and current system register values are retained. Stop
 64

mode is released, and the oscillator started, by a reset operation or by an external

interrupt with RC-delay noise filter (for KS86C4502/C4504, INT0-INT1). — In Idle

mode, the internal clock signal is gated off to the CPU, but not to interrupt control and

the timer. The current CPU status is preserved, including stack pointer, program counter,

and flags. Data in the register file is retained. Idle mode is released by a reset or by an

interrupt (external or internally-generated).

Table 9 . Pin Description

 65

The soldering is detachable for easy replacement of the tip and to prolong the life

of the internal circuitry. It has a minimum temperature value of one hundred (100)

degrees Celsius up to four hundred eighty (480) degrees. Tip to ground resistance

normally varies from two to four ohms which is safe for the electro-static discharge.

Avoid setting the maximum temperature of the soldering to lengthen the life of the tip.

2. Hot Air Soldering

Hot air soldering comes with the automatic sleep sensor for energy conservation. It

uses Atmega8, a twenty pins, eight bit microcontroller. The Atmel core combines a rich

instruction set with 32 general purpose working registers. All the 32 registers are directly

connected to the Arithmetic Logic Unit (ALU), allowing two independent registers to be

accessed in one single instruction executed in one clock cycle. The resulting architecture

is more code efficient while achieving throughputs up to ten times faster than

conventional CISC microcontrollers.

The ATmega8 provides the following features: 8 Kbytes of In-System Programmable

Flash with Read-While-Write capabilities, 512 bytes of EEPROM, 1 Kbyte of SRAM, 23

general purpose I/O lines, 32 general purpose working registers, three flexible

Timer/Counters with compare modes, internal and external interrupts, a serial

programmable USART, a byte oriented Twowire Serial Interface, a 6-channel ADC

(eight channels in TQFP and QFN/MLF packages) with 10-bit accuracy, a programmable

Watchdog Timer with Internal Oscillator, an SPI serial port, and five software selectable

power saving modes. The Idle mode stops the CPU while allowing the SRAM,

Timer/Counters, SPI port, and interrupt system to continue functioning. The Power down
 66

mode saves the register contents but freezes the Oscillator, disabling all other chip

functions until the next Interrupt or Hardware Reset. In Power-save mode, the

asynchronous timer continues to run, allowing the user to maintain a timer base while the

rest of the device is sleeping. The ADC Noise Reduction mode stops the CPU and all I/O

modules except asynchronous timer and ADC, to minimize switching noise during ADC

conversions. In standby mode, the crystal/resonator Oscillator is running while the rest of

the device is sleeping. This allows very fast start-up combined with low-power

consumption.

Figure 33. Atmega8(L) block diagram of the AVR microcontroller architecture

 67

In order to maximize performance and parallelism, the AVR uses a Harvard

architecture with separate memories and buses for program and data. Instructions in the

Program memory are executed with a single level pipelining. While one instruction is

being executed, the next instruction is pre-fetched from the Program memory. This

concept enables instructions to be executed in every clock cycle. The Program memory is

In-System Reprogrammable Flash memory. The fast-access Register File contains 32 ×

8-bit general purpose working registers with a single. Minimum temperature of the hot air

is 200 degress Celsius up to 50 degrees Celsius. Sleep mode will be activated

immediately after the nozzle is being placed in its holder.

Testing and Evaluation of Project

Testing and evaluation of the design project takes place at the display room of the

Department of Industrial Engineering and Technology on March 1 to 2 2016. The

researchers conducted several dry run and demonstration to finalize and ensure that all

equipment’s and workstation peripherals are working. Some minor issues have been

fixed like improper wiring, and labeling.

The evaluators of the design project is divided into three groups from the

Department of Industrial Engineering and Technology of the Cavite State University,

breakdown as follows; five instructors, twenty electronics technology students and

twenty electrical technology students. The total of forty five respondents accomplished

the evaluation of the design project.

 68

After accomplishing the by the group of evaluators, the data were brought

together, the mean per criterion and the over-all mean was computed to determine

whether the workstation was acceptable and working. Included in the evaluation form is

the comments and suggestion section which gives the evaluators a chance to suggest any

idea that can enhance or improve the design project before it will be finalize. The results

were tabulated and presented in the Table to Table . The summary of mean per

criterion and ranking is presented to table

1. Evaluation by Instructors

For the detailed computed mean based of the result of evaluation by the Cavite

State University, Department of Industrial Engineering and Technology, please refer to

Appendix Table 1.

Table 10 . Computed mean based from the result of evaluation by the CVSU DIET

instructors

Panel of CVSU Descriptive

Criteria DIET Instructors Rating
Functionality 4.60 Excellent

Aesthetics 4.20 Very Good

Workability 4.80 Excellent

Durability 4.33 Very Good

Economy 4.53 Excellent

Safety 4.73 Excellent

Average Mean 4.53 Excellent

 69

Table 10 shows that the workstation is highly accepted by the instructors. The overall

mean average is 4.53 with the descriptive rating of excellent. Among the six criteria, four

got the excellent rating and the workability gets the highest points followed by

functionality which means the instructors is considering the use of the workstation. It will

be a big help to the instructors to do a demonstration and activities regarding component

soldering. In the other side the set of evaluators noticed that the cabinet for tool and

components safekeeping has no label. They suggest that it should be labeled for proper

handling of materials and components. Also suggest that countertop must be made of

formica board instead of anti-static mat. Also suggest that there should be and

instructional manual for each equipment for reference in the future use.

2. Evaluation by Electronics Technology Students

For the detailed computed mean based on the result of the evaluation Bachelor of

Industrial Technology major in Electronics students, please refer to the Appendix Table 2

Table 11. Computed mean based from the result of evaluation by the Bachelors of

Industrial Technology major in Electronics Students

Panel of BIT Descriptive

Criteria Electronics Students Rating
Functionality 4.87 Excellent

Aesthetics 4.72 Excellent

Workability 4.88 Excellent

Durability 4.80 Excellent

Economy 4.80 Excellent

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Safety 4.77 Excellent

Average Mean 4.81 Excellent

In Table 11, electronics technology student compliments the design project as

they gave 4.81 average mean. All the criteria garnered an excellent status, that conclude

that the workstation is highly acceptable to the electronics technology students. Among

the six criteria workability and functionality got the highest point. This turnout indicate

that the reliability of the function of the design project meet the standard of a laboratory

workstation. Further improvement of the workstation like the availability of the PCB drill

and integrated circuit components has been suggested.

3. Evaluation by Electrical Technology Students

For the detailed computed mean based on the result of the evaluation Bachelor of

Industrial Technology major in Electronics students, please refer to the Appendix Table 2

Table 12 . Computed mean based from the result of evaluation by the Bachelors of

Industrial Technology major in Electronics Students

Panel of BIT Descriptive

Criteria Electronics Students Rating
Functionality 4.82 Excellent

Aesthetics 4.78 Excellent

Workability 4.88 Excellent

Durability 4.73 Excellent

Economy 4.77 Excellent

Safety 4.75 Excellent

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Average Mean 4.79 Excellent

Table 12 shows the result of evaluation conducted to the electrical technology

students. The six criteria’s gathered an excellent descriptive rating. Safety got the lowest

point as the evaluators concerned about the fume being released by the burned solder.

Although the researchers make a precautionary step to provide safety and health friendly

workstation by creating a fume filter, there is some instances that the fume still explode

to the air and scattered around the laboratory. This suggest that for further improvement

the students states that it should be a large fume extractor that can thoroughly absorbed

all the smoke when soldering takes place. However the overall rating says that the design

project is highly recommendable to use as the laboratory workstation.

4. Combined Computed Mean Based of the Result

Table 13. Combined computed mean based from the result of the evaluators

Descriptive
Criteria Mean/Criteria Rating
Functionality 4.76 Excellent

Aesthetics 4.57 Excellent

Workability 4.86 Excellent

Durability 4.62 Excellent

Economy 4.70 Excellent

Safety 4.75 Excellent

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Average Mean 4.71 Excellent

Table 13 shows the overall mean average of the design project. The computed

mean average of the combined results of the different evaluators is 4.71 with the

descriptive rating of excellent. The acceptability of the design project is based on the

workability and functionality of the workstation. It signifies the usefulness for both

the students and instructors dealing with electronics subjects. Electronics students

gave the highest average mean of 4.81, followed by electrical technology students

that gave 4.79 and college instructors gave the least average mean of 4.53.

5. Evaluation by Descriptive Rating

Table 14. Evaluation by descriptive rating

Descriptive
Criteria Mean/Criteria Rating
Workability 4.86 Excellent

Functionality 4.76 Excellent

Safety 4.75 Excellent

Economy 4.70 Excellent

Durability 4.62 Excellent

Aesthetics 4.57 Excellent

Average Mean 4.71 Excellent

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Table 14 presents the descriptive rating of the results of evaluation by different

respondents. All the criteria earned an excellent rating.

6. Evaluation by Ranking Criteria

Table 15. Evaluation by ranking criteria

Descriptive
Criteria Mean/Criteria Rating
Workability 4.86 1

Functionality 4.76 2

Safety 4.75 3

Economy 4.70 4

Durability 4.62 5

Aesthetics 4.57 6

Table 15 shows the ranking of each criterion after the series of evaluation has

been conducted. Workability secure the top spot garnering 4.86 points, it implies that the

availability of materials, tool and machine as well as the expertise showed by the

researcher during demonstration help to alleviate the status of workability criteria.

Functionality comes next as it address the ease of operation, provision for comfort and

convenience. Safety is concerned with the absence of toxic materials, sharp edges and the

provision of the prototype devices. Economy refers to how the design project is being

developed, the materials used, time and labor spent as well as the machine required to

develop the prototype. Durability is the second from the lowest attained points gathered

during the evaluation. Its parameter includes the quality of materials used, craftsmanship
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and design of the prototype . Aesthetics got the lowest score pertaining to the physical

attributes of the design project as well as the style and design.

7. Overall Mean of the Design Project

Table 14. Computed overall mean based from the result of evaluation by all panels

Descriptive
Number Panel Average Mean/Panel Rating
1 Electronics Technology Students 4.81 Excellent

2 Electrical Technology Students 4.79 Excellent

3 College Instructors 4.53 Excellent

Average Mean 4.71 Excellent

The overall mean from all respondents was 4.71 with a descriptive rating of

excellent. It is a manifestation the design project was highly acceptable by both in the

academe and students. Workability of the workstation is highly regarded.

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SUMMARY, CONCLUSION AND RECOMMENDATIONS

Summary

The of a soldering iron workstation was proposed and developed to set standards

in electronics laboratory development incorporating digital soldering and hot air gun for

properly control tools and equipment’s. Using a set of specialized microcontroller, the

tools give and maintain exact amount of heat needed according to the specification of the

components. It lessens the adverse effect of uncontrolled soldering that can damage any

integral part of the circuit. The study attained its objectives such as designing the

microcontroller based soldering iron, construction, test and evaluation of the design

project.

The researcher also includes a set of activities to be done by the future users to

test the ability of the workstation. Also available in the workstation is the instructional

manual of every tools present in the workstation. It will properly guide the future users

how to operate, maintain and troubleshoot the workstation. Proper tip cleaning and tip

replacement guide has also been stated.

Favorable output were attained during the during the evaluation period with the

Department of Industrial Engineering and Technology instructors, Bachelor of Industrial

Technology major in Electronics and Electrical Students. Demonstration and actual

operation of the workstation is being conducted to the evaluators. A comprehensive

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instruction is being detailed to give the user an overview of the functions and different

setting of the tools and equipment’s in the workstation.

Conclusion

The microcontroller based soldering iron workstation was developed as stated in

the design and specification has found its usefulness in the quality of output produce by

students using the workstation. The design project is established to be very useful for

both instructors and student. The workstation is tested and evaluated with an overall

descriptive rating of excellent, a manifestation that the design project was highly

acceptable.

Recommendation

To further enhance the soldering workstation, the following recommendation

were made;

1. Modification of the size of the workstation to a bigger one;

2. Improvement of the used magnifying lamp;

3. Providing additional line of components; and

4. Increase the power capacity of fume extractor.