Hardware and software design of micro energy-saving automatic dip soldering machine based on Atmel AVR
I. Project Overview
1.1 Introduction
At present, soldered plug-in boards generally use wave soldering methods and dip soldering methods. Although the wave soldering machine has high welding speed and high welding quality, it is especially suitable for large-scale factories in assembly line because of its high price, large volume and complicated maintenance. Dip welding machine has the characteristics of simple structure, small volume, good welding quality, low cost and strong visibility. It is used in small batch production, especially suitable for small and medium-sized enterprises, various scientific research units and teaching places. However, the dip welders that exist in the current market still have serious energy waste.
Based on the analysis and comparison of various dip welders on the market, this design has the disadvantages of large energy consumption and inflexibility of the dip welder in the current market. From the perspective of energy saving and environmental protection, through the adoption of Atmel (Atmel) company AVR 8-bit microcontroller (ATXMEGA64A3) designed a miniature energy-saving automatic dip soldering machine. The dip soldering machine has the characteristics of environmental protection, energy saving, small size, simple operation, high automation, good welding quality, low cost, strong visibility and high cost performance, and is suitable for application in teaching, scientific research units and small batch circuit board production and processing. The factory has strong market competitiveness and good social and economic benefits.
1.2 Project Background / Motivation
Since the reform and opening up, China's economy has developed by leaps and bounds, and electronic products have become an indispensable part of people's lives. The development of electronic products is inseparable from the welding of printed circuit boards. Currently, plug-in boards generally use wave soldering and dip soldering. Wave soldering machines are only suitable for large-scale plants in assembly lines because of their high price, large size and complicated maintenance. Dip welding machine has the characteristics of simple structure, good welding quality and low cost. It is widely used in small batch production, especially suitable for small and medium-sized enterprises. It has a wide application range and strong market potential.
Through the investigation of the current welding machine market, it is found that there are many types of dip welding machines on the market, but they all have the disadvantages of large volume, inflexibility and excessive energy consumption. There is no small dip welder that is suitable for teaching and research units. The teaching equipment for the electronic circuit board welding process is still blank. There is no demonstration teaching equipment for teaching and research.
Therefore, a micro energy-saving automatic dip soldering machine with low energy consumption and miniaturization suitable for application in teaching and research units and small batch circuit boards has been developed and developed with good market prospects.
The following table shows the main types of dip welders on the market today:
Dip welder type
main feature
Bench dip welder
The welding quality is high, the structure is simple, the speed is fast, the method of using the air pump to drive the inert gas to realize the flux and the solder foaming method, the immersion, the preheating of the circuit board by the oven, and the manual placement into the circuit board, but each The waiting time between work cycles is too long and the operation is complicated.
Vertical flat dip welding machine
The welding quality is high, the structure is simple, the closed working environment, the cost is low, the speed is slow, and the working mode of clamping the circuit board by the clamping plate is used to soak the flux and the solder, the volume is large, and the welding preparation time is long.
Combined dip welder
The utility model has the advantages of large volume, simple structure, high speed, low cost, simultaneous welding of a plurality of circuit boards, simple preheating device, manual insertion into a circuit board, non-automatic operation, and long welding preparation time.
Hand push dip welder
It is mainly operated by hand, simple in structure, slow in speed, low in efficiency and relatively dangerous. It has been basically eliminated.
The existing dip welder product research found that the dip welder currently on the market has the characteristics of simple structure and low cost, and also finds the existing defects of the current product:
1. Large size and inflexible;
2. The production preparation time is too long, and it takes nearly two hours to heat the solder and the flux into a liquid state;
3. Lack of a very intuitive digital display section;
4. Most of the use of the rail sliding device for the board welding operation, the stability of the board in the operation of the entire welding process is not enough;
5. The dip soldering machine on the market adopts a closed operating environment, which is not convenient for students to understand the actual welding process, and is not suitable for e-learning places.
Therefore, a micro energy-saving automatic dip welder with low energy consumption, miniaturization, simple operation, good welding quality, low cost and strong visibility is suitable for application in teaching and research units and small batch circuit boards. Good market prospects and strong market competitiveness, and good social and economic benefits.
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