Project report

SESSION: 2K20 5th SEMESTER

Group members:

ahsaan sadiq (20-ie-03)

Muhammad hassaan (20-ie-14)

Salman tariq (20-Ie-48)

Subject:

Operations of manufacturing systems

Submitted To:

Dr. Muhammad Sajid

DEPARTMENT OF INDUSTRIAL
ENGINEERINg
1
Table of Contents
1. Abstract:.............................................................................................................................................3
2. Problem description:.........................................................................................................................3
3. Motivation:.........................................................................................................................................4
4. Data Collection:.................................................................................................................................4
4.1. Data Collection:.........................................................................................................................4
4.1.1. Geared Motor:.......................................................................................................................5
4.1.2. Soldering iron:.......................................................................................................................5
4.1.3. Soldering Wire:......................................................................................................................6
4.1.4. Press Switch:..........................................................................................................................7
5. Complete Assembly:..........................................................................................................................7
6. Input Data Analysis and Module Assumptions:..............................................................................7
7. Simulation Program:.........................................................................................................................8
8. Output Statistical Analysis:..............................................................................................................8
9. Conclusion:.........................................................................................................................................8
10. Recommendations:........................................................................................................................9
11. References:.....................................................................................................................................9

Automatic feed solder

2
1. Abstract:
This work is carried out to design and fabricate an innovative product as
Semester Project. The product designed and developed in this regard is automatic feed solder
which feeds the soldering wire automatically. As electronics get smaller and manufacturers come
under greater pressure to improve efficiency and throughput, the traditional soldering method is
no longer up to scratch. The major benefit of automating the soldering process is improving
speed and efficiency. The assembly consists of a basic soldering iron, geared motor, a switch to
control the motor along with a DC supply to power the motor.

2. Problem description:

Manual feed soldering is a soldering technique that involves the operator applying solder to the
component manually using a soldering wire. Although this technique has many advantages, it
also has several disadvantages.

One of the main disadvantages of manual feed soldering is inconsistency. The operator is
controlling the amount and speed of solder application by hand, and there is a greater chance of
inconsistency in the amount of solder applied to each joint. This can result in poor-quality solder
joints and potentially lead to electronic failures. Another disadvantage is that manual feed
soldering requires a high level of skill and experience. Additionally, manual feed soldering can
be slower than automatic feed soldering, particularly for larger-scale production work. This can
result in increased production time and costs.

One of the main advantages of automatic feed soldering is its efficiency. The process can solder
multiple components simultaneously, making it much faster than manual soldering. This allows
for faster production times and greater output, which can translate to cost savings for
manufacturers. Additionally, automatic feed soldering can improve the quality of the soldering
connections. The wave of molten solder ensures that all the metal surfaces are evenly wetted,
which results in a consistent and reliable connection. This reduces the risk of defects, such as
cold joints or insufficient wetting, that can occur with manual soldering.

Another advantage of automatic feed soldering is its ability to handle large volumes of PCBs
with ease. This makes it ideal for high-volume production runs, where manual soldering would
be impractical or time-consuming. Additionally, automatic feed soldering can reduce the risk of
operator fatigue and repetitive strain injuries, which can occur with manual soldering.

Finally, automatic feed soldering can be used to solder a wide range of components, including
those with large and complex shapes. This makes it a versatile solution for electronic
3
manufacturers, who can use the process for a variety of different products and applications.

3. Motivation:
Automatic feed soldering is an efficient, consistent, and versatile process that offers many
advantages over traditional manual soldering. It improves production output and quality,
reduces defects, and improves operator safety. This makes it a valuable tool for electronic
manufacturers looking to optimize their production processes. Automatic feed soldering is
also versatile and can be used to solder a wide range of components, including those with
complex shapes. This makes it a valuable tool for electronic manufacturers who need to
solder various types of components.

Finally, automatic feed soldering improves safety for operators. It reduces the risk of
operator fatigue and repetitive strain injuries associated with manual soldering. It also
minimizes the risk of burns and other injuries associated with handling molten solder.

4. Data Collection:
We collected the required information by using the manual soldering iron ourselves and also
discussed with the individuals using in their everyday routine.

4.1. Data Collection:

The following components comprise the main assembly:

4.1.1. Geared Motor:

Geared motors are used because they offer several advantages, including higher torque
4
output, precise speed control, improved efficiency, space-saving design, and noise reduction.

These features make geared motors ideal for a wide range of industrial and commercial
applications.

4.1.2. Soldering iron:

A soldering iron is a hand-held tool that is used to heat and melt solder, which is then
used to join two pieces of metal or electronic components together. Soldering irons
typically consist of a heating element, a metal tip, and a handle. The tip of the soldering
iron is heated to a temperature that is high enough to melt the solder, which is then
applied to the metal surfaces or components that need to be joined.

5
4.1.3. Soldering Wire:

Soldering wire is a thin metal wire that is used to apply solder to a joint or connection.
Soldering wire typically consists of a core of solder alloy, which is surrounded by a flux
coating. The flux coating helps to clean and prepare the surface of the metal to be
soldered, and it also helps the solder to flow and adhere to the metal surface.

4.1.4.
P

ress Switch:

A press switch, also known as a push-button switch, is a type of switch that is used to
control the flow of electricity in an electrical circuit. Press switches typically consist of a
button or plunger that is pushed down to close the contacts of the switch, and released to
open them again.

5. Complete Assembly:

6
6. Input Data Analysis and Module Assumptions:

By analyzing several samples and solving this problem we generate ideas while considering
the operation manufacturing techniques such as capital planning, flexible design, same
transportation cost with more products than the previous. The following steps are taken to
model the product.

1. Find the problem.

2. Search the existing solution if any.
3. Bring the ideas on paper.
4. Choose the optimum design and draw their rough sketches.
5. Convert this drawing into 3D-model by using the solid works software.
8. Also make the assembly of parts in solid works.

7. Simulation Program:

None type of simulation is done during or after the project completion.

8. Output Statistical Analysis:

Overall, automatic feed soldering can improve productivity and consistency in mass
production.
The output of automatic feed soldering can be further improved by regularly monitoring the
equipment, adjusting the soldering parameters, and maintaining the equipment to ensure it is
operating at optimal performance.

7
9. Conclusion:
Automatic feed soldering offers several advantages over traditional soldering methods,
including:

Increased Efficiency: Automatic feed soldering machines can work faster and more
accurately than manual soldering, resulting in increased efficiency and productivity.

Consistency: The use of automated soldering machines ensures consistent results in terms of
solder joint quality, reducing the likelihood of defects and improving the overall reliability of
the electronic assembly.

Improved Worker Safety: Automated soldering machines eliminate the need for manual
soldering, reducing the risk of worker injuries, such as burns or fume inhalation.

Flexibility: Automatic feed soldering machines can be programmed to work with a wide
range of soldering materials and configurations, providing greater flexibility in the
manufacturing process.

Quality Control: Automated soldering machines can incorporate inspection systems that can
detect solder joint defects, helping to ensure the overall quality of the electronic assembly.

Reduced Waste: Automatic feed soldering machines can help to reduce solder waste by
controlling the amount of solder applied to each joint, leading to a more sustainable and cost-
effective manufacturing process.

10.Recommendations:
Although the design provides a suitable way of automatically feeding the wire during soldering, it is
yet not the best. Improvements can be made in the prototype using more advanced materials and
equipments.

11.References:
1. Automatic Soldering Machines. In 2018 IEEE 9th International Conference on Mechanical and
Intelligent Manufacturing Technologies (pp. 199-203). IEEE.

2. Jia, Y., Zhang, J., & Wang, J. (2020). Research on the optimization of automatic soldering
technology based on virtual reality technology. Journal of Physics: Conference Series, 1525(4),
042019.

3. Li, X., Li, H., Wu, D., Liu, Z., & Xiong, Y. (2020). A review of automatic soldering
8
 technologies for electronic assembly. Journal of Materials Science: Materials in Electronics,
31(4), 2805-2819.

4. Maru, R. R., & Thakur, A. (2021). An Overview of the Advancements in Soldering

Technologies. In Advances in Materials Science and Engineering (pp. 1-17). Hindawi.

5. Tang, X., & Li, C. (2021). Automatic Soldering Process Control Based on Multi-Sensor Data
Fusion. Sensors, 21(11), 3926.

6. Yang, H., Li, Y., & Li, X. (2020). A review of automatic soldering technologies for electronic
products. Journal of Manufacturing Processes, 57, 1-16.