A RESEARCH PROJECT
BY
NNAEMEKA ORIOHA
EE/2017/167
SUBMITTED TO
DEPARTMENT OF ELECTRICAL ELECTRONIC ENGINEERING FACULTY OF ENGINEERING CARITAS UNIVERSITY, AMORJI-NIKE, ENUGU.
IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE AWARD OF BACHELOR OF ENGINEERING (B.ENG)
AUGUST 2017
APPROVAL PAGE
This project has been read and approved by the undersigned as with the requirement at the department of Electrical Electronic Engineering of Caritas University Amorji Nike Enugu for the award of Bachelor of Engineering (B.Eng.) in Electrical Electronic Engineering.
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Engr. Ejimorfor Date
(Project supervisor)
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Engr. Ejimofor Date
(Head of Department)
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External Supervisor
DECLARATION
I declare that this project material is an original work done by me under the supervision of Engr. Ejimorfor, department of electrical electronic engineering faculty of engineering caritas university, amorji-nike, enugu
DEDICATION
This project is dedicated to Almighty God and to my parents Engr. & Mrs. Chukwu A. Orioha and to my beloved brothers and sisters whose ever loving kindness and support has seen me through my years of studies.
ACKNOWLEDGEMENT
I wish to express my immense gratitude to God Almighty for his mercy, guidance and protection towards me for seeing me through the rigors of this work. I am greatly indebted to my supervisor Engr. Ejimofor for his kind gesture and whose critics lead to the achievement of this work. I also will remain grateful to the tremendous contribution of my lecturers Engr. Ojobor (the Dean of Engineering Faculty), Engr. Ejimofor (Head of Electrical Electronic Engineering Department), Engr. Mbah, Engr. Ochi, and all the staff of Electrical Electronic Engineering both academic and non academic staff for their intellectual upbringing. My special appreciation goes to my loving parents Engr. & Mrs. Chukwu A. Orioha, my grandparent, my uncles and aunties, my brothers and sisters whose moral and financial support cannot be over emphasized. Also my sincere gratitude and special regards to my friends too many to mention whose encouragement also lead to the success of this work.
Soldering in electronics is analogous to fixing of a component using glue. It is actually a general phenomenon in the field of electronics which involves fixing of electronic components into a special board called PCB with the help of instruments like soldering iron and electrical solder commonly called as ‘Solder wire’.While soldering we all face problem of toxic fumes. These fumes are of lead solder wire and flux. Combinedly, these fumes are highly toxic if excess amount is inhaled. In order to solve this problem, here we had designed a simple circuit called solder fume extractor using an op-amp IC which removes fumes from the soldering area. The work is of automatic type which runs exhaust fan during soldering and stops exhaust fan when soldering iron is kept on soldering stand.
CHAPTER ONE
1.1 INTRODUCTION
Electronics production is heavily concerned with soldering components on to printed circuit boards (PCBs). A small part of the operation is automated, using wave soldering machines, with the majority being manual as operators add individual components using hand soldering irons. Further hand soldering and desoldering is frequently used in rework stations to carry out repairs and upgrades.
All of this soldering activity generates fumes which can cause long term, serious harm to operators if inhaled. Employers may face expensive compensation claims as a result. Most countries recognise this and enforce legislation to ensure that employers protect their employees from these harmful effects. Even in regions without such legislation employers have an ethical duty to provide such protection.
Fume Extraction Systems are designed for electronics soldering applications that generate fume comprising; resin acid particulate and gaseous organic compounds within the Electronics sector. Solutions are available for manual and automated processes including: wave solder, reflow, selective solder and conformal coating applications. T1, TVT2 and T15 offer tip extraction for lead free soldering applications. These are high volume units that are designed to extract and filter the fumes and debris.
This device designed to extract and fumes and debris through small bore hoses and attachments. Ideal for soldering iron tip fume extraction. Due to high concentration of debris generated from up to 100 operators, these systems have been designed to keep the unit compact, but still utilize a comprehensive filter system. With this in mind, the units incorporate a facility for retaining a high concentration of particulate within the filter enclosure. These systems have a built in silencer that has a collar to allow for redirection or external venting of filtered air if required.
The fume extraction units have been designed primarily to extract the fumes generated during hand soldering in the electronics industry. These portable systems come complete with extraction arms and installation kit that contain everything required to set up one or two operators with ease. Minimal installation allows the units to be moved with the work bench when factory layouts need changing due to production challenges. The low noise levels and fully comprehensive filtration units are ideal for factories with changing production demands.
1.2 AIM OF THE PROJECT
The aim of this work is to construct a solder fume extractor using an op-amp IC which removes fumes from the soldering area. The work is of automatic type which runs exhaust fan during soldering and stops exhaust fan when soldering iron is kept on soldering stand.
1.3 OBJECTIVE OF THE PROJECT
At the end of this work, students involved will
- be able construct a device which removes fumes from the soldering area using an op-amp IC
- able to know the effect of fumes on human health
- operating principle of solder fume extractor
- principle, design and connection of an op-amp.
1.4 APPLICATION OF THE PROJECT
The systems are ideally suited for soldering iron tip extraction, vac pens, flexi fume arms and any other number of applications that requires close proximity micro extraction.
1.5 PROBLEMS AND LIMITATION OF THE PROJECT
Solder Fume Extractor can be expensive and cause disruption. This device when using on work area, it need to move the extractor system to the job.
1.6 SCOPE OF THE PROJECT
This solder fume extractor was built using an op-amp IC which removes fumes from the soldering area. The work is of automatic type which runs exhaust fan during soldering and stops exhaust fan when soldering iron is kept on soldering stand.
Apart from the op-amp CA3130 used, two NPN transistors and few other passive component were also used. For fumes removing we had used a small 12V DC exhaust fan.
For automation of the projects solder fumes extractor we have used a sensor called piezo sensor (PZ1). The sensor PZ1 generate voltage when heat is detected (heat generates stress in it). Thus, we had attached a heat sink with piezo sensor PZ1. The PZ1 is connected to two inputs (inverting and non-inverting) of IC1 as shown in figure 1.
1.7 EFFECT OF FUMES ON WORKERS
During hand soldering, fume without effective control will rise vertically, probably entering the breathing zone of the solderer. Fume may drift and accumulate in the workroom, especially if the soldering work is widespread and intense, and general background ventilation is poor. Other people in the area who are not soldering can therefore be put at risk, as can staff maintaining and cleaning soldering plant, equipment and control systems.
Solder fume, comprises 99.5% particles and 0.5% gases. It is one of the top causes of occupational asthma in the workplace because, when breathed in, it can trigger an irreversible allergenic reaction in the respiratory system. Once this sensitisation reaction has taken place, further exposure to the substance, even the tiniest trace, will produce symptoms. These can become increasingly severe, with continued exposure possibly causing permanent lung damage. Sufferers are often unable to return to soldering work ever again.
Other medical conditions can also occur; these include skin and eye irritation, allergenic conditions, bronchitis, sionasal cancer and carcinogenic heart/lung diseases.
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