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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.”

  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. • 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.

  4. 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

  5. Light Strip Base Sizes • Soldering 2 different strip sizes • Soldering 3 different strip styles

  6. Jig Assembly • 2 pull pins • 2 springs • Adjustable slide support • 2 rail / receivers • Base plate • Front support plate

  7. LED Sizing

  8. 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.

  9. 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. Solder-Testing Frame • 11. User Interface Board • 12. Data Bus • 13. Test Cylinder • 14. Soldering Power Supply • 15. Test Lead

  10. Part Sizes & Tolerances • LED Dimensions Pad Dimension • Both diagrams are drawn with millimeter dimensions • (both diagrams come from Luxeon Emitter, http://www.lumileds.com/pdfs/AB10.PDF

  11. 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

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

  13. 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

  14. Budget

  15. Schedule Current status

  16. 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

  17. Questions?

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