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.  “LEDdynamics is a custom engineering company specializing in the design and integration of LED technology for end-user and OEM applications.”

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.  Be able to test the LED after completion  Must be faster and more efficient than hand assembly.  System will not need human aid, after initial setup is completed.

Process Description  Drill Metallic Mounting Circuit Board  Prep soldering area with flux  Glue in surface mount LED’s  Solder the LED leads  Test for failed product

Solutions  Build a X table with a set jig for metallic circuit boards.  Make a single press/ dual soldering iron system with wire fed solder.  Test the LEDs inline with solder station.  Allow user to initially select predetermined board size and stores data throughout the run.

Full System Overview  1. Controller  2. Manifold  3. Power Source  4. Wire Feed  5. Push Cylinder  6. Solder Cylinder  7. Solder reels  8. Soldering Tips  9. Guidance Track  10. Soldering Frame

Part Sizes & Tolerances Part Sizes & Tolerances  LED Dimensions Pad Dimension  Both diagrams are drawn with millimeter dimensions  (both diagrams come from Luxeon Emitter,

Pneumatic System Overview  This pneumatic system involves;  Double-acting telescopic cylinder  Double-acting cylinder with double-ended adjustable cushioning  Manifold for air flow control  Start push button

Electrical Concepts Twin motor controllers LCD EStop Stop/Go Switch Selector switch Test unit Solder Heat units Triple solenoid block AC to DC power supply

Project Considerations  What are current systems out there doing? X,Y,Z table fully programmable setup  Cost of these systems? $5,000 plus  How fast is LEDDynamics producing these? 8.3hr

Budget ItemQuantityDescriptionSale Price $Sale Total $ Controller1PLC or Microcontroller UNKNOWN Manifold1UNKNOWN Push Cylinder1 twin-stage, Piston dia. 30/42", double-acting with pneumatic limit position scan UNKNOWN Solder Cylinder1Double-acting cylinder with end position cushioningUNKNOWN Pneumatic Tubing4 ft.Flexeel hose25'/ Wire Feed1 or 2UNKNOWN Solder22 reels Soldering Tips2size: 3/64" (.047", 1.1 mm) Aluminum Stocksee desc.plate stock: 1" x 12" x 18" ASTM B Aluminum Stocksee desc Angle stock: 1/2" x 1/2" x 1/8" x 8' ASTM B Complete Total450++

Schedule Current status

Project Contacts  Oliver Piluski, LED Dynamics  or  John Kidder, Senior Projects Teacher   Andre St. Denis, Senior Projects Teacher 

Acknowledgements  Andre St. Denis  SamCo  John Kidder  Roger Howes  Oliver Piluski

Questions?