Anda di halaman 1dari 96

Modification Design of Interlock System of ESPEC PV-212M Oven

A Project Study
Presented to the Faculty of the
College of Engineering and Technical Department
Manuel S. Enverga University Foundation
University Site, Lucena City

In Partial Fulfillment of the Requirement


for the Degree
Bachelor of Science in Electronics Engineering
Expanded Tertiary Education Equivalency and Accreditation Program

by
Alvin Joseph F. Pea
March 2015

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


2

Approval Sheet
This special project entitled:
MODIFICATION DESIGN OF INTERLOCK SYSTEM OF ESPEC PV-212M OVEN
MACHINE
Prepared and submitted by Alvin Joseph F. Pena in partial fulfillment of the requirements for
the degree of Bachelor of Science in Electronics Engineering (ETEEAP Program) has been
presented and passed the Oral Examination.

Engr. Evangeline L. Constantino


Adviser

Approved by the Committee on Oral Examination with a grade of ____ on March 15, 2015

Benilda N. Villenas, PhD


Member
Engr. Erwin Ellazar
Member

Engr. Sherwin Lagrama


Member
Guillermo M. Rago Jr., RCE, Ed.D.
Chairperson

Accepted in partial fulfillment of the requirements for the degree of Bachelor of Science
in Electronics Engineering (ETEEAP Program).

________
Date

Guillermo M. Rago Jr., RCE, Ed.D.


Dean, College of Engineering and Technical Department

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


3

Acknowledgement
First and foremost thanks to our God Almighty for giving me the strength and courage to
accomplish my studies and to everyone who had helped me complete this project study.
I want to thank my loving wife Azeonete, My One and only daughter Audrey, I thank
you for all your support, care, understanding, patience, and love that gave me strength in my
pursuit with this endeavor. To my superior, Rodolfo Tobias for giving me the opportunity to
earned and complete this degree. Furthermore, I would like to thank my mother Felicidad, father
Medardo, siblings Allan, Jason, and Micah for the encouragement and inspiration parted to me as
a source of my strength in fulfilling my dream of finishing my studies.
I also want to thank my project study adviser Engr. Evangeline L. Constantino for the guidance
throughout the various revisions of this research, valued criticism and instructions as well and to
all my classmates in ECE class of 2014-15 on their support and cheerfulness that made this
school electrifying and uncomplicated for each and every one of us.
Lastly I would like to express also my gratitude to those who had given me the
opportunity to complete this project study most especially to our dean Dr. Guillermo Rago, ECE
instructors, Engr. Erwin Ellazar and Engr. Sherwin Lagrama, without your support and advise
these could not be possible.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


4

Dedication

To my ever-beautiful wife, Azeonete,

To my daughter- Audrey,

To my Pena Family.

I dedicate this manuscript to all of you as you have been and always be my inspiration.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


5

Table of Contents
Title Page
Approval Sheet...
Acknowledgement..
Dedication..
Table of Contents...
List of Tables.
List of Figures
Abstract..

1
2
3
4
5
7
8
9

UNIT I INTRODUCTION
Background of the Study ..
Objectives of the Study..
Conceptual Framework..
Significance of the Study...
Scope and Delimitation..
Definition of Terms
Acronyms

10
11
11
13
14
14
17

UNIT II- REVIEW OF RELATED LITERATURE AND STUDIES

18

UNIT III METHODS AND PROCEDURE


Research Design
Research Environment...
Procedures ......
Design Concept.

26
26
27
29

UNIT IV- RESULTS AND DISCUSSION


Data Gathering .
32
System Design Modification...
35
Block Diagram.
38
Circuit Design.
38
Material Selection
38
Schematic Diagram..
39
Circuit Diagram
39
Wiring Diagram
44
PCB Layout.
45
System Integration...
45
Specification Requirements
46
Bill of Materials
48
Prototype Fabrication..
49
Installation..
.
51
User Manual ..
53
Cost Benefits Analysis
54
Testing and Evaluation..
56

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


6

Summary of Findings

59

UNIT V CONCLUSIONS AND RECOMMENDATIONS


Conclusions
Recommendations.

61
62

References..
Appendices
A
ESPEC PV-212M Oven Machine
B
PC817 Photocoupler Series..
C
DS1307 Memory.
D
NPN Transistor BC547...
E
MICROCHIP PIC16F87/88 .
F
LM317 Regulator.
G
MICROCHIP 24LC256
H
LCD Pin Diagram
I
Electrical Diagram of Matrix Keypad..
J
1N4007 Rectifier Diode
K
Microprocessor Crystal.
L
Carbon Film Resistor.
M
Tact Switch
N
Respondents Survey Questionnaire.

63

Curriculum Vitae...

89

64
65
66
67
68
69
70
71
72
73
74
75
76
76

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


7

List of Tables
Table No.
1
2
3
4

Title
Likert Scale for Evaluation
Specification Requirements
Bill of Materials
Survey Results

Page
30
46
48
57

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


8

Figure No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26

List of Figures
Title
Conceptual Framework Paradigm
ESPEC PV-212M Oven
Operational process flow ESPEC oven
Existing Schematic Diagram
ESPEC Oven Normal Operation
Upgrading Sequence of Interlock System
Flow Chart of the Source Code of the Microcontroller
Block Diagram of Whole System ESPEC Oven
Electronics Components Used
Schematic Diagram of Interlock System
Circuit Diagram of Interlock System
Input Signal ESPEC Oven
Input Keypad Matrix
Input Power Supply
Transistor drive of a Solenoid Valve
Wiring to ESPEC Oven
Printed and Lay-out Components
Etching Procedure of PCB
Soldering Components
Interlock Circuit for PV-212M
Signal Interconnection for PV-212M
Main System for PV-212M
Solenoid Valve and Cylinder for PV-212M
Project Quotation in O.E.M Pricing
ESPEC Interlock system graph analysis
ESPEC Oven Yield Vs Reject

Page
11
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
50
51
52
52
53
53
55
56
57

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


9

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


10

Abstract
Alvin Joseph Pena., A Modification Design of Interlock System of ESPEC PV-212M
Oven Machine, unpublished Project Study for the degree of Bachelor of Science in Electronics
Engineering. College of Engineering, under the Expanded Tertiary Education Equivalency and
Accreditation Program (ETEEAP), Manuel S. Enverga University Foundation, March 2015

ESPEC Oven machine is one of the most commonly used machines in the semiconductor
industry today, due to its efficiency, versatility and reliability. The machine can cure the mold
compound after processing in mold machine to strengthen the plastic by baking the unit.
In this study the researcher aims to prevent bypassed operation of machine when 175
degree unit inside the chamber can be taken out prematurely since the door can be open all the
time if wanted. In this project study the researcher has shown design flaw in existing interlock
through the implementation of the proposed Modification Design of Interlock System the
researcher to prevent bypassed.
The project features an LED module which shows the parameters set in unlocking the
oven, a matrix keypad for the input of the password set by the user and a microcontroller which
would process the data from the LED matrix and oven and display a corresponding output on the
LED module and do a corresponding action in the solenoid valve.
The feasibility of the study was based on the result on the survey conducted on 10
technical respondents. The survey, which used the Likert Scale, had an overall rating of Strongly
Agree. This result showed that based on effectiveness and functionality, the respondents strongly
agree that the project is effective and functional to its objectives.
Keywords: Curing, ESPEC oven, Interlock, Microcontroller, Semiconductor

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


11

Unit I
Introduction
Background of the Study
Post Bake Oven Chamber is used extensively in baking, heat treatment/drying of mold
unit, device requiring clean air conditions. In addition to the standard instrumentation which
offers two-step programming, Class 100 cleanliness is achieved by employing a HEPA filter and
a back-to-front laminar circulation system. The high-performance of ESPEC Oven provides
stable performance even during heat-up or cooling at high temperatures of 150C (+302F).
Espec oven is a major assembly process flow in NXP Semiconductor. It use for
strengthening the mold compound and test the capability of the unit in heat. This is set-up by 5
hours base on revision of our engineer to full complete curing and heat resistance.
The main issue of this problem many supervisors was disregard the process of machine
due to a long 5 hours curing time of the unit so they stop the machine after placid heating and
others no safety lock door during operation. This means they want more output during their shift
and commitment to customer. After unnecessary using method of process which may affect
quality of unit, the possible anxiety that affect is Crack unit and incomplete test in heating for
reliability. So that why the circuit has been design which called Modification of Interlock
System of ESPEC PV-212M Oven Machine that has a special design sequence to avoid the
process of oven and safety user operation.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


12

Objectives of the Study


The main objective of this study is to enable the researcher to come up with a working
prototype of Auto Interlock circuit. This module shall act as a triggering component on the part
of the ESPEC Oven Machine whenever the machine is used.
The following are the specific objectives:
1. To modify the design of interlock system of ESPEC Oven.
2. To designa circuit of modified design Interlock System.
3. To fabricate a prototype of the designed circuit.
4. To evaluate the prototype in terms of effectiveness, and functionality.

Conceptual Framework of the Study

Figure 1: Conceptual Framework Paradigm

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


13

The researcher chose this framework for the reader to easily understand all the possible
resources that the researcher may use to complete this project, Most of the resources are clearly
stated in this illustration.
The researchers included all the possible materials in creating the project. These were the
basic electronics component used in the circuit like diode, resistor, capacitor, transistor and
Relay. The researcher also needs to focus on some of the advance component which is the
EEPROM and Micro Controller Unit, with the help of a third party who is more familiar in
programming language.
Significance of the Study
The technicians especially the process line sustainance will benefit from this study by
preventing the incomplete process of the machine and quality of the unit. Through this action, it
will be a lesser amount of crack component due to incomplete curing and safety operation.
The study is also beneficial to NXP as a whole. The savings that will be realized in
creating in-house fabrication of the project will have a big impact in the departments cost
savings program. By preventing incomplete curing of unit, the customer will give a high
reputation to the company.
This study would serve as a guide or reference in the conduct of other similar application
that might be needed by technical people or student in their line of work or career, particularly in
manufacturing industries.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


14

By practicing this study, the researcher would be able to refresh his knowledge about
electronic circuits and components, enhance the skills in the applied aspect of electronics, and
develop the structural approach of creating a technical paper.
Scope and delimitations of the Study
This study deals with the creation of a Modification of Interlock system Circuit wherein
the ESPEC Oven machine will perform when the temperature 150 degree Celsius was stable the
interlock will activate close and after finish 5 hours curing the door will open. If when the
machines stop within the incomplete curing time, the state of interlock close will always activate
only process can access to release the lock by input the password code.
This is the first time that researcher attempt to create a design with micro-controller units
specially in command a ESPEC Oven machine performed a task using a separate circuit board.
In this circuit design the microcontroller unit will use as the main part of the circuit which will be
the controller of all the input signals to perform another design task.
Thus this study is limited for ESPEC Oven Machine which is located on Central
Assembly department at the post mold cure area where the researcher is currently assigned. The
project study will be limited for one unit ESPEC Oven equipment only and after simulation and
evaluation, it will fan out to other existing same equipment that needed to perform the AutoInterlock system.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


15

Definition of Terms
Buy-off is the process of inspecting a new equipment to be purchased according to the
required specifications prior to the delivery of the equipment to the site of the purchaser.
Capacitor is an electrical device that can store energy in the electric field between a pair
of closely spaced conductors called plates. When voltage is applied to the capacitor, electric
charges of equal magnitude but opposite polarity build up on each plate.
Connector is an electrical connector is a device for joining electrical circuits together. In
computing it can also be known as a physical interface.
Espec PV-212M Oven Machine is the temperature chamber that cures the molding
compound and its also test the capabilities on heat resistance of the unit.
Hardware refers to tangible components of computer system such driver board,
Input/Output board. The hardware component is use to store or process results.
Integrated circuit a miniaturized electronic circuit constructed of individual
semiconductor devices, as well as passive components bonded to a substrate or circuit board.
Interlock is the processes when the machine reaches the set point of

175

Celsius it

will automatic lock the door and it will release after he finish the process.
Light Emitting Diode (LED)

is a semiconductor device that emits incoherent narrow-

spectrum light when electrically biased in the forward direction. This effect is a form of
electroluminescence. The color of the emitted light depends on the composition and condition of
the semiconductor material used, and can be infrared, visible or near-ultraviolet. LEDS are

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


16

available in different size, shape and color. LEDS may be in color red, yellow, green, orange,
blue and white.
Microcontroller is a computer control system on a single chip. It has many electronic
circuits built into it, which can decode written instructions and convert them into electrical
signals .The microcontroller will then step through these instructions and execute them one by
one. Microcontroller is now changing electronics design. Instead of hard wiring a number of
logic gates together to perform some function we now use instructions to wire the gates
electronically. The list of these instructions given to the microcontrollers is called program.
Poka-yoke is a Japanese term that means "fail-safing" or "mistake- proofing". A pokayoke is any mechanism in a lean manufacturing process that helps an equipment operator avoid
mistakes. Its purpose is to eliminate product defects by preventing, correcting, or drawing
attention to human errors as they occur. The concept was formalised, and the term adopted, by
Shigeo Shingo as part of the Toyota Production System. It was originally described as bakayoke, but as this means "fool-proofing" the name was changed to the milder poka-yoke.
Process Flowis the illustration of one process or procedure where the step by step of the
process is properly defined according to their proper sequence.
PC40 is one of the five Business Fulfillment Groups (BFG) in NXP; also known as
Power department.
Programming Language C is a general-purpose, procedural, imperative computer
programming language developed in the early 1970s by Dennis Ritchie for use on the UNIX
operating system. It has since spread to many other operating systems, and is now one of the

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


17

most widely used programming languages. C also has had a great influence on many other
popular languages.
Resistoris a two-terminal electrical or electronic component that resists an electric current
by producing a voltage drop between its terminals in accordance with Ohms law.
Transistoris a device which utilizes a small charge in current to produce a large change in
voltage, current or power. It may function also as an amplifier or an electronic switch.
Variable resistor consists of a resistance track with connections at both ends and a wiper
which moves along the track as you turn the spindle. The track may be made from carbon,
cermets (ceramic and metal mixture) or a coil of wire (for low resistances).

Acronyms
NXP

Next Experience

BFG

Business Fulfillment Groups

QA

Quality Assurance

MCU

Micro Controller Unit

MPLAB

Microchip PIC Lab

IDE

Integrated Development Environment

PFMEA

Process Failure Mode and Effect Analysis

PCB

Printed Circuit Board

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


18

Unit II
Review of Related Literature and Studies
This section mentioned theories and operation of the electronic components and materials
needed to modify and creating Auto Interlock of a circuit, as well as other technical information
necessitated to be discussed for further understanding of all the target electronic components.
The sources of information are various electronic books and knowledge websites on the Internet.
In NXP Semiconductor particularly in Power Central Assembly the places where all
products had been tested and Curing the molding compound after went in molding machine. This
is the area where the researchers are also assigned.
Espec PV-212MOven
According to ESPEC Corp. (2006) Oven used extensively in baking, heat
treatment/drying of mold unit, devices requiring clean air conditions. In addition to the standard
instrumentation which offers two-step programming, Class 100 cleanliness is achieved by
employing a HEPA filter and a back-to-front laminar circulation system. The high-performance
of ESPEC Oven provides stable performance even during heat-up or cooling at high
temperatures of 150C (+302F).
Circuit
According to Floyd (2010) basically, an electric circuit consists of a voltage source, a
load, and a path for current between the source and the load.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


19

Language C++
Lovine (2004) noted that there are a number of compilers on the market that allow users
to write programs (code) in different high-level languages. High-level language frees the
programmer from wrestling with and controlling the microcontrollers registers when writing
code and accessing the different aspects of the microcontrollers features and memory.
MPLAB IDE
According to microchip (2003) MPLAB Integrated Development Environment is a free,
integrated toolset for the development of embedded applications employing Microchip's PIC
and PIC microcontrollers. MPLAB IDE runs as a 32-bit application on MS Windows. Is easy
to use and includes a host of free software components for fast application development and
super-charged debugging. MPLAB IDE also serves as a single, unified graphical user interface
for additional Microchip and third party software and hardware development tools. Between
tools is a snap, and upgrading from the free software simulator to hardware debug and
programming tools is done in a flash because MPLAB IDE has the same user interface for all
tools.
PIC16F876A
Microchip (2007) stated that this powerful (200 nanosecond instruction execution) yet
easy-to-program (only 35 single word instructions) CMOS FLASH-based 8-bit microcontroller
packs Microchip's powerful PIC architecture into an 28-pin package and is upwards compatible
with the PIC16C5X, PIC12CXXX and PIC16C7X devices. The PIC16F876A features 256 bytes
of EEPROM data memory, self-programming, an ICD, 2 Comparators, 5 channels of 10-bit
Analog-to-Digital (A/D) converter, 2 capture/compare/PWM functions, the synchronous serial

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


20

port can be configured as either 3-wire Serial Peripheral Interface (SPI) or the 2-wire InterIntegrated Circuit (IC) bus and a Universal Asynchronous Receiver Transmitter (USART). All
of these features make it ideal for more advanced level A/D applications in automotive,
industrial, appliances and consumer applications.
Transistor
The general purpose transistor NPN type and to understand the overall operation of the
transistor amplifier, you must only consider the current in and out of the transistor and through
the various components in the circuit. Therefore, from this point on, only the schematic symbol
for the transistor will be used in the illustrations, and rather than thinking about majority and
minority carriers, we will now start thinking in terms of emitter, base, and collector current.
Before going into the basic transistor amplifier, there are two terms you should be
familiar with: AMPLIFICATION and AMPLIFIER. Amplification is the process of increasing
the strength of a SIGNAL. A signal is just a general term used to refer to any particular current,
voltage, or power in a circuit. An amplifier is the device that provides amplification (the increase
in current, voltage, or power of a signal) without appreciably altering the original signal.
Transistors are frequently used as amplifiers. Some transistor circuits are CURRENT amplifiers,
with a small load resistance; other circuits are designed for VOLTAGE amplification and have a
high load resistance; others amplify POWER.
By inserting one or more resistors in a circuit, different methods of biasing may be
achieved and the emitter-base battery eliminated. In addition to eliminating the battery, some of
these biasing methods compensate for slight variations in transistor characteristics and changes
in transistor conduction resulting from temperature irregularities. (www.tpub.com/electronics,
2005)

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


21

Diode1N4001
According to datasheet.com (2008) the 1N4001 series (or 1N4000 series) is a family of
popular 1.0 amp general purpose silicon rectifier diodes commonly used in AC adapters for
common household appliances. Blocking voltage varies from 50 to 1000 volts. This diode is
made in an axial-lead DO-41 plastic package.
These are fairly low-speed rectifier diodes, being inefficient for square waves of more
than 15 kHz. The series was second sourced by many manufacturers. The 1N4000 series were in
the Motorola Silicon Rectifier Handbook in 1966, as replacements for 1N2609 through 1N2617.
The 1N5400 series were announced in Electrical Design News in 1968, along with the now
lesser known 1.5-ampere 1N5391 series. These devices are widely used and recommended.
Capacitor
From the statement of Floyd (2010) a capacitor is an electrical device that stores
electrical charge and is constructed of two parallel conductive plates separated by an insulating
material called the dielectric.
Ceramic
Alexander (2004) said that the ceramic is a chip of altering layers of metal and ceramic,
depending on their dielectric, whether Class 1 or Class 2, their degree of temperature/capacity
dependence varies. They often have (especially the class 2) high dissipation factor, high
frequency coefficient of dissipation, their capacity depends on applied voltage, and their capacity
changes with aging. However they find massive use in common low-precision coupling and
filtering applications.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


22

Resistor
Alexander (2004) released the statement that resistor is a two-terminal electronic
component designed to oppose an electric current by producing a voltage drop between its
terminals in proportion to the current, that is, in accordance with Ohm's law: V = IR.
Practical resistors can be made of resistive wire, and various compounds and films, and they can
be integrated into hybrid and printed circuits. Size, and position of leads are relevant to
equipment designers; resistors must be physically large enough not to overheat when dissipating
their power.
Four-band identification is the most commonly used color-coding scheme on all resistors.
It consists of four colored bands that are painted around the body of the resistor. The first two
bands encode the first two significant digits of the resistance value, the third is a power-of-ten
multiplier or number-of-zeroes, and the fourth is the tolerance accuracy, or acceptable error, of
the value. Sometimes a fifth band identifies the thermal coefficient, but this must be
distinguished from the true 5-color system, with 3 significant digits.
PCB Pins
According to answers.com this are the electronic interconnects devices for printed circuit
boards. It has a better signal integrity for high reliability application across a wide range of
industries. Regardless the type and design of a PC board, external signal and power connections
must be made. Printed circuit boards, as well as other electronic components, in many instances
are electronically joined through connectors. The components are typically interconnected to
define a given function.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


23

Light Emitting Diode


Base on Alexander (2004) a light-emitting diode (LED) as shown in is a semiconductor
device that emits incoherent narrow-spectrum light when electrically biased in the forward
direction. This effect is a form of electroluminescence. LEDs are small extended sources with
extra optics added to the chip, which emit a complex intensity spatial distribution. The color of
the emitted light depends on the composition and condition of the semiconducting material used,
and can be infrared, visible or near-ultraviolet. Rubin Braunstein of the Radio Corporation of
America first reported on infrared emission from gallium arsenide (GaAs) and other
semiconductor alloys in 1955. Experimenters at Texas Instruments, Bob Biard and Gary Pittman,
found in 1961 that gallium arsenide gave off infrared (invisible) light when electric current was
applied. Biard and Pittman were able to establish the priority of their work and received the
patent for the infrared light-emitting diode. Nick Holonyak Jr. of the General Electric Company
developed the first practical visible-spectrum LED in 1962.
The researcher uses the above literature to understand the problems system of interlock
ESPEC oven machine and how does it work in different ways. This will also be needed to
understand the characteristic and behavior of the devices that chosen on the circuit, the possible
problem and circuit conflict may arise when then researcher constructing it.
Microcontroller
A study by Cheng, et Al. (2004) machine vision set up using two cameras as human eyes
and a micro-controller as a human brain to recognize the object. Moreover, with the aid of
artificial intelligence, the machine acted like a regular person and identifies objects. This
machine vision project was implemented on the Robocop robot. In other words, these researches

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


24

create an "eyes" for the Robocop robot that promoted the study of robotics and artificial
intelligence (AI) researches for the Ohio State University. The study is related to the researchers
proposed study in such a way that it is dealing with the use a micro controller chip as the core
component in the circuit.
Tan, et Al. (2008) replaced a mechanical clock with a much reliable, accurate,
maintenance free and portable service. They used a microcontroller based digital clock using PIC
16F877A and software written in C language. The controller control all the features and the input
frequency taken from a 50HZ clock frequency circuit .To show the time seven segment LED,
four LEDs were used.
This can be considered as related to the researchers proposed study in such a way that
the Microcontroller based Digital also uses a PIC microcontroller using C language LCD display
as the core component in the circuit.
The group of Amon, et.al, (MSEUF, March 2005) also designed a control system
consisting of several sensors with different objectives with GSM module. Each sensor is aimed at
detecting some kind of security breach. Most importantly, the entire system used a
microcontroller that placed in the device to control, to hook up, to power and store information.
The objective is to detect three kinds of security breaches that is light detection, opening a door
and movements. Once any of the sensors is triggered, the GSM module sends SMS message to
the owner of the house or establishment. This authorized person used PIN number to control the
system. The related to the research is utilized the same medium which is the micro controller in
formulating a circuit.
In a study made by Baronia, et. al, (MSEUF, March 2005) entitled A Microcontroller
based Automated Door Lock System, he designed a control system consisting of a

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


25

microcontroller chip that controls the doors of classrooms and laboratories. The proposal was to
install a circuit and a keypad to control the opening and closing of the door. The authorized
personnel that have the password or number combination that will be encoded into the keypad
can only do this. The study can be related to the researchers proposed study in such a way that
the Automated Door Lock System also uses a microcontroller chip as the core component in the
circuit.
From the study of Albuero and Reganit of Polytechnic University of the Philippines
(March 2004) they designed an apartment digital electric sub metering system using a
microcontroller PIC16F877 and a Liquid Crystal Display that was used in the System. Using a
sub metering system, the consumers comprising of the lessee of commercial unit or the person
renting apartment will be availing the electricity service by means of paying the owner a certain
amount in advance. The electricity will be available as long as the prepaid load is not equal to the
base rate provided by the electricity supplier. The transaction for the electric consumption will be
in a prepayment format. The digital electric meter display kilowatt hour electricity consumption,
remaining prepaid balance and cost per kilowatt hour on its Liquid Crystal Display. Theirs
studies is also related to the researchers proposed study in such a way that the apartment digital
electric sub metering system also uses a PIC microcontroller and LCD display as the core
component in the circuit.
The above studies were chosen by the researcher to emphasize the important
participation of Microcontroller in every design in the modern years. The capability to simplify
the circuit in creating effective solution by means of this small chip can be possible.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


26

Unit III
Methods and Procedures:
This unit discussed the different methods and procedure that the researcher will be using to
realize the study. It consists of research method, research design, research environment and
procedure.
Research Design
The focus of the study is to develop a prototype auto-interlock circuit wherein the
Research and Development method was applied to establish the positive result. The prototyping
is the engineering term commonly used for trial and error; however the desired output are
visualized and calculated. This was done by the researcher to see the possible weakness of the
design, during the process of trial the researcher has the chance to continuously develop a circuit,
correct the possible mistake and to develop the possible improvement by adding extra features in
the system.
The prototyping method was applied to the project to produce the best results with
regards to the objective of the study. While continuously designing and improving the system to
fit the objective, a trial and error test was conducted every time. This ensures that the circuit
design improves every time a trial was made.
Research Locale
The researcher focus for the solution on process of the machine and safety of user where
the currently happening on NXP semiconductor especially on Power Department. This is the
department where the researcher currently assigned. All of the data gathered from the company
starting from the data where the bypass of the machine and some problem had been seen, like

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


27

MPMF (Machine Product Monitoring Form), Visual Inspection Log sheet, QA log sheet and the
daily QA PPM reporting where all the non conformance been indicated.
The entire study was conducted at NXP Semiconductor facility, and at school where the
researcher currently studying at Manuel S. Enverga University.
Respondents of the Research
The researcher gathered respondents to complete the study. They are the people who will
help the researcher to make this big project possible. The line engineer is the one whose expert
on the equipment will give the feedback on the risk and the impact of the feasibility study. The
software engineer is the one who will do the programming in the Micro-controller unit. The line
supervisor will make schedule regarding the availability of the machines needed on this project.
The operator and QA personnel will validate the effect of the project once it is implemented.
Procedures
The researcher shall undertake the systematic activities in order to complete this research study.
Data Gathering. To continue this study the researcher will refer to the technical manuals
of the Espec PV-212M Oven Machine. This will also needed a consultation to equipment
engineering to have additional ideas that is not covered by the technical manuals.
The researcher will also gather relevant information in the electronic engineering books
and in the technical Internet sites needed in achieving the objectives of this study.
These tools will help a lot to researcher to deeply understand the project that will going
through.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


28

System Design Modification. The researcher will create a design modification for the
project based on existing design problem identification, design computation, creating circuit,
installation, and testing the output of the project.
The system would be modified by attaching a keypad matrix and an LCD screen to
prevent unauthorized unlocking of the Oven. The data coming in from the oven and the keypad
matrix would be processed by the microcontroller for accurate and functional result.
Circuit Design. In designing a circuit this will need a corresponding knowledge in basic
electronics and the basic principle of each component. 1.) Understand basic function of the
machine and how function of interlock. 2.) Develop an electronic circuit design based on the
learnings acquired from the research process.3.) The advantage and disadvantage of the project
and its cost.4.) Create a prototype of the electronic circuit that emulates the Espec PV-212M
Oven Machine.
Prototype Fabrication. In this activity, the researcher will create a design circuit by
using EAGLE software and etching solutions used for the fabrication of board by preparing a
developer solution and ferric chloride for etching PCB design.
Evaluation. This activity is the time for the researcher to test the effectiveness of his
circuit design, the aim of researcher is the circuit to activate the interlock within the sequence
when the 175 degree Celsius has been reach the door will close it will open if the process has
been finished.
In this activity will also verify the possible impact on the machine once the circuit had
been installed and during actual simulation. This will also test the affectively and functionality of
the circuit.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


29

The evaluation will focus on the criteria of effectiveness and functionality. In proving its
effectiveness and functionality, data will be gathered through a survey which was analyzed
through a modified Likert Scale.
The Questions will be follows;
Effectiveness
1.) Is the machine performing auto-interlock when the machine stable at 175 degree.
2.) Celsius? Is there any occurrence of after the installation of the circuit?
Functionality
1.) No machine hang-ups or breakdown related to auto interlock.
2.) No machine downtime during starting up oven.

The format of a typical five-level Likert item is:


1. Strongly Disagree
2. Disagree
3. Undecided
4. Agree
5. Strongly agree
The results were used to compute for the weighted mean including the formula:

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


30

WM = (SA*5) + (A*4) + (U*3) + (D*2) + (SD*1)


_________________________________
TNR
Where:
WM = Weighted Mean
TNR = Total Number of Respondents

Table 1
Likert Scale for Evaluation
Rating

Rate

Scale

SA = Strongly agree

4.21 5.00

A = Agree

3.41 4.20

U = Undecided

2.61 3.40

D = Disagree

1.81 2.60

SD = Strongly Disagree

1.00 1.80

Table 1 shows the rating system used on the survey conducted on the new design of
interlock system. Five is the highest rating and zero for the lowest possible rating. This scale will
be used also to interpret the results.
It also presents the interpretation of the weighted mean on each criterion defined. The
researcher used this table as a reference where the weighted mean falls. The personnel based
their rating on how they understand the function as well as their experience with the new
sequence on the interlock system.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


31

Design Concepts
The purpose of this project is to design the circuit of Auto-interlock for Espec Oven
Machine. The circuit will execute the correct sequence of interlock which prevent bypassed the
door and procedure of curing time, safety of the user.
The researcher motivation for this project study is the principle of Poka-yoke concept. Its
purpose is to eliminate product defects by preventing, correcting, or drawing attention to human
errors as they occur. This is more of a concept than a procedure. Thus, its implementation is
governed by what people think they can do to prevent errors in their workplace, and not by a set
of step-by-step instructions on how they should do their job. This law is use in a three equivalent
forms depending on which quantity need to determine, whether it current, voltage or resistance.
Ohms Law helps a lot on the researcher, since this law mathematically describes how
voltage, current, and resistance related with each other in a circuit
In circuit design the researchers uses a Thevenins theorem, this theorem provides a
method of simplifying a circuit to a standard equivalent form. In many cases this can be used to
simplify the analysis of complex circuit.

1. Evaluate the actual operation of the prototype through actual connection to the Espec
Oven.
2. Prepare a simple questionnaire analyzing the affectivity, efficiency and safety and this
will be answered by the stakeholders via survey.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


32

3. Gather 5-10 persons consisting of a cross functional team, this will be from production,
engineering and from quality.
4. Perform needed modification or simplification in the prototype, as necessary.
5. Finalize and document the prototype circuit.
The researcher will be needed a statistical method use to tabulate the results of evaluation
was the so called Five Point Likert Scale Method. This method is the most appropriate approach
to evaluate the project effectiveness in a way of evaluation.

Unit IV
Results and Discussions

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


33

The content of this unit discusses the different steps for the realization of this project
study. It also provides the presentation and interpretation of the data gathered on how the
researcher conducted her method, design modification, analysis, procedure and the outcome of
the modified design of interlock system of ESPEC PV-212M Oven machine.

Data Gathering
The data gathered was fully studied to identify the sources of opportunities. Facts
obtained had to be formulated to determine the baseline prospect of this project study.
ESPEC PV-212M oven machine. The researcher gathered the following data shown in
Figure 2 and was fully studied to identify the source of opportunity. Below figures shows the
actual machine and electrical lay-out of ESPEC Oven PV-212M where the researcher focus the
interlock system to improve the safety of the user when using the machine.

Figure 2: ESPEC PV-212M Oven Machine


Existing process flow chart. In Figure 3 illustrate the process flow chart of ESPEC PV212M Oven.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


34

Start Mode

End Mode

Rising up TempStabilization of temp 175

Door will unlock

Operational Complete

5hrs End

Start 5hrs

Door will Lock


Take note: When
machine stop while in
middle of 5hrs curing
process the door unlock.

Figure 3: Operational process flow ESPEC oven


On figure 3 shown the operational process flow of ESPEC oven to the line production
output is the most important because of the commitment in customer because of highly demand
in output the process of the ESPEC oven was been ignore because of long curing time process it
also note even in the middle of 5hrs the interlock will be unlock by stop the machine so the unit
can take out prematurely which maybe affect to the unit because of this the researcher study to
modify the existing interlock system and lessen the bypassed of the curing time of a oven.

Existing Schematic Diagram. Shown in figure 4 is the existing schematic diagram of


ESPEC Oven wherein built in automatic interlock in the system has been the researchers
problem every time theres a fluctuation in power the interlock has been release can be bypassed
so it may possible the process tech didnt know if the unit has been cured. To prevent
unnecessary bypassed is to change the system of the interlock by using microcontroller.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


35

Figure 4: Existing Schematic Diagram

Data in figure 5 shows that the most critical curing of the unit stable in 175 degree
Celsius unit inside the chamber can be take out prematurely, since door can be open all times if
wanted because of the unnecessary procedure so why the line process technician didnt know if
the cycle was done.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


36

Figure 5: ESPEC Oven Normal Operation

System Design Modification


The Researcher focused on the modification of the interlock system of ESPEC PV-212M
to improve the sequence by design using a microcontroller.
Proposed Process Flow. In this figured 6 shows the process improvement sequence of
interlock system and also include the flow chart of programming.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


37

Start Mode

Stabilization of temp 175Start


Rising up Temp

5hrs
1

End Mode

Door will unlock

5hrs End

Door will Lock

Operational Complete
Door Lock Steadily

End Mode

Door will unlockEnter

Password
Only Process Tech can access

Figure 6: Upgrading Sequence of Interlock System


It explains the additional flow system to prevent bypass shows in no. 1. A new sequence
appear once theres an error encountered. The door will be locked and only the process
technician who has access to the door would be able to unlock and investigate the error happened
with this the researcher comes up an idea by using a microcontroller to improve the sequence of
interlock system and also added features to the machine.
System Flow Chart. On Figure 7 the flow chart process of microcontroller where the
researcher created a program on how will execute the system of interlock. The researcher also
used MPLAB software to create a program to improve the sequence of the interlock system.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


38

Start

Machine:
Temp:
Count

No
Is
Machine Ok

Yes
No
Is
Temp 175

Yes
Lock Solenoid

Count = Count +1
Delay=10000ms

No

No
Is
Count

Is the Machine Turn Off?

Yes
Open Solenoid

END

Enter Password

No
Is Password Correct?
Yes

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


39

Figure 7: Flow Chart of the Source Code of the Microcontroller


Block Diagram. As illustrated in Figure 8, the first section is the power supply. An input
signal of 220 volts AC is applied to the power supply which will give source across the system of
ESPEC PV-212M Oven. The ESPEC Oven section is the main body chamber wherethey process
the unit carried out accordingly (e.g. temperature and time) and also for test reliability of heating
the unit.

Power Supply

ESPEC OVENModification Interlock System Interlock

Figure 8: Block Diagram of Whole System ESPEC Oven


In this section where the researcher focused on the Modification Interlock System by
interfacing the signal to the ESPEC oven machine and take control of microcontroller. The Final
section Interlock, a type of electromechanical used by a 5/2 way valve solenoid and piston
cylinder that perform to be lock and unlock the door.
Circuit Design
The development of proposed project study covers the hardware and wiring connection of
the modified design.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


40

Material Selection. During the circuit development of this project study, included were
the selection of the precise component and materials shown in figure 9 which are electronic
standard and are readily available in the market. These materials are the essence of this project
study since it will define how reliable and efficient this project would be.

Transistor BC547

LED 5mm

Ceramic

1N4007 Diode

LM 317

Conn
ector

Photo

C Socket

coupler

Relay 5volts

Crystal Oscillator

Electrolytic

Coin Cell

Trimmer Resistor

Fixed Resistor

Tact Switch

DS1307

24LS2
PIC16F88-I/P

56P

LCD Display

Matrix Keyboard

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


41

Figure 9: Electronics Components Used


Schematic Diagram. Figure 10 illustrates the prototype circuit which were specially
designed for ESPEC Oven to create a systematically sequence of interlock door by using a
programmable circuit which called microcontroller.

Figure 10: Schematic Diagram of Interlock System


Circuit Diagram. The circuit diagrams below shows the computation per parts of the
schematic diagram, based on the input, output and processing of the project.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


42

Figure 11: Circuit Diagram of Interlock System

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


43

Input: ESPEC OVEN

Figure 12: Input Signal ESPEC Oven


Input Section the internal infrared LED with 15mA, we could assure that the
phototransistor will be in the saturate state (ON), because the minimum current to make the
phototransistor on is about 10mA. The following circuit is use optocoupler to interfacing the
Idiode = 15 mA (0.015 A), VLED = 2 Volt to interfacing the microcontroller in I/O shown in Figure
12.
R1 = (Vcc VLED) / IB = (24 2) / 0.015 = 1466.66 Ohm, use 1.8k Ohm resistor
P = (Vcc VLED) x IB = (24 2) x 0.015 = 0.33 watt, use 0.25 Watt resistor

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


44

And the output of optocoupler in collector have a resistor of 10k ohms pull-up to stable the
signal gave to microcontroller port.
INPUT: KEYPAD MATRIX

Figure 13: Input Keypad Matrix

Keypad Pin

Connects to Arduino Pin...

D9

D8

D7

D6

D5

D4

D3

D2

The matrices are actually an interface technique. It can be used to interface inputs like
the PC keyboard keys, but also to control multiple outputs like LEDs. According to this
technique, the I/O are divided into two sections: the columns and the rows.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


45

INPUT: POWER SUPPLY

Figure 14: Input Power Supply

The LM317 is an adjustable voltage regulator which can output a range of voltages (1.5
to 37V) based on the resistors R1 and R2. Normally the value of R1 is 240, the recommended
value by the manufacturer. However, the value of R1 may be any value from 100 to 1000.
The resistor R2 then is the chief resistor which allows for the swings in different voltage outputs.
The formula is below.
Using the voltage divider theorem to compute for the output, R1=240 and R2=720
will produce an output voltage of exactly 5V, being that VOUT= 1.25V * (1+ R2/R1) = 1.25V *
(1 + 720/240) = 5V.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


46

Output Section by using 5 Volt power supply and solenoid coil with 24 Volt and 60mA
operating current shown in Figure 15.
OUTPUT: ESPEC OVEN

Figure 15: Transistor drive of a Solenoid Valve


RC = 0 Ohm can be directly drive to coil
IB = IC / hFE = .1 A / 450 = 0.0002
R16, R17 = (VPORT VBE) / IB = (4.2 0.7) / 0.0002 = 17500 Ohm, use 5K1 Ohm resistor
P = (VPORT VBE) x IB = (4.2 0.7) x 0.0002 = 0.0007 watt, use 0.25 Watt resistor

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


47

Wiring Diagram. On figure 16 shows on how to be connect the wiring from the machine
of ESPEC Oven to Modification Design of system interlock circuit.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


48

Output Signal

Input Signal

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


49

Figure 16: Wiring to ESPEC Oven

2 condition signal

The wiring diagram shows the connections of the prototype to the ESPEC Oven. The first
connection established was that of the microcontroller and the oven. That was the first input. The
second was that of the keypad matrix which is then connected to the microcontroller and has an
output in the LCD module. This set up will control the solenoid valve which acts as the main
switch to the oven door.
PCB Layout. This shows the layout of the components on the presentesized PCB. The
task was done using CAD software for component layout called EAGLE software. This was to
ensure that all the wirings are done and that proper spacing for each component is made.

Figure 17: Printed and Lay-out Components


System Integration. Interfacing system show, theres a two condition signal before the
interlock must be functionone is Machine Operation and two is Stable 175 degree Celsius
once the signal are satisfy. The microcontroller who take action to lock the door base on the
program in IC while in production running the LCD display show the time and other minor
activities if there any error encounter into door lock. The matrix keypad will access to unlock the

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


50

door if there errors encounter and only process technician who have access door to investigate
what happen and why the process stops.
Specification Requirements
The list of specific requirement of each electronics component has been searched through
the internet and other existing items used in the line but the researcher exhaust all avenues at
arriving the correct specification of materials to be used in attaining success on these project
study, have also search at RS catalogue and Alexan to obtain the high end product commonly
used in the industry today. The list is composed of the main components used in the proposed
project study as shown in table 2.

Table 2:
Specification Requirements

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


51
Component

PC817

Transistor
BC547 NPN
Silicon
LED
Resistor

Specific Requirement
Forward current IF 50 mA
Collector-emitter voltage V CEO 35 V
Emitter-collector voltage V ECO 6 V
Collector current IC 50 mA
Collector power dissipation P C 150 mW
BaseEmitter Saturation Voltage
(IC = 10 mA, IB = 0.5 mA)
CollectorEmitter Voltage ( 45V)
CollectorBase Voltage (50V)
EmitterBase Voltage (6.0)
Size 3mm (Red, Green and Yellow)
Fixed Resistor watt

Model Required

Brand

DIL-Package

Sharp

TO-92

Motorolla

3mm

Avago
Technologies

603

Vishay

Molded

Bourns

Trimmer
Resistor

10K Ohms

LCD

LCD Display

Ceramic

.1uf, 22nf and 104nf

Polyester

Vishay

Electrolytic

470uf /63v

TH Aluminum

Nichicon

X-tal Oscillator

10Mhz and 32.768Khz

Through Hole

Micro X-tal

Relay

5volts/2amp contact

PCB Mount

Nais

LM 317

Adjust Voltage Regulator

TO-220

On Semi

Coin Cell

3volts

Coin

Maxwell

1n4007

Rectifier Diode

DO-41

On Semi

Matrix Keyboard

Keyboard

Alexan

LCD Display

LCD

Alexan

PIC16F88 P/I

PIC Microcontroller 20mhz 256B


7168 B Flash, 368 B Ram, 12c 18-Pin PDIP

DS1307

24LC256P

Maximum Operating Supply Voltage 5.5v


User RAM 56B
Function: Clock
Maximum Operating Supply Voltage 5.5v
Memory size 256kbit
Programming Voltage 3.3v, 5v

Alexan

PDIP

Microchip

PDIP

Maxim

PDIP

Microchip

Presensitized Board

Prototype Board

PCB

Alexan

Tact Switch

SPST-NO 50ma @ 12Vdc

Switch

Alps

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


52

Bill of Materials
Enumerated in Table 3 are the materials costing table for Auto Interlock system of
ESPEC Oven. Project prototype and development cannot be completed without the total cost on
all items that will be used and must be approved by the product team. A list of resource
Requirements and those project partners that can support these requirements will be
created during the definition stage of the project. Any additional funding requirements will be
identified as soon as possible and will require approval from MTs before becoming available.
After generating PR at SPEED system the total incurred amount is the total cost of the project
and is equivalent to 1,688.409 pesos. This figure denotes the initial investment cost for the
prototype circuit and will be charged to special projects cost in Power department.
Table 3:
Bill of Materials
Part Number

Description

Quantity (pc)

Electrical Supply

Price (PhP/pc)

708-5483

Photocoupler

RS

PHP 25.582

545-2232

BC547

RS

PHP 4.43

806-6373

Resistor

32

RS

PHP 11.10

247-1498

LED 3mm

RS

PHP 10.314

Matrix Keyboard

Alexan

PHP 80.00

805-1362

LM317

RS

PHP 13.512

117-372

Ceramic

RS

PHP 8.00

440-6597

Electrolytic

RS

PHP 30.24

649-1187

1N4007

RS

PHP 2.708

LCD Display

Alexan

PHP 175.00

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


53

600-7760

IC Socket

RS

PHP 15.00

PCB
Presensitized

Alexan

PHP 180.00

623-0487

PIC16F88-I/P

RS

PHP 212.43

786-0745

DS1307N

RS

PHP 237.975

667-8242

24LC256

RS

PHP 77.112

425-6049

Tact Switch

RS

PHP 38.00

Prototype Fabrication
Using the EAGLE 6.0 software the researcher able to design the modified interlock
system circuit and the parts placement on the PCB by auto routing the board design or manage
desire position of the components. The software has a lot update components and term user
friendly.

Figure 18: Etching Procedure of PCB

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


54

In Figure 18 shown, After making a design of the circuit in eagle software the researcher
prepare a etching PCB where the design will be appear a form of circuit to the PCB Board. The
first step will be expose the fluorescent lamp by 8 minutes to marked the design to the PCB next
is the developer solution where the PCB will dissolve the rendering area of PCB and appear the
desire circuit and last is the ferric chloride dissolved the copper and appear a last form of circuit
PCB after Exposure and Etching the board next step is soldering the components where the
researcher assemblies one by one to complete the components shown in Figure 19.

Figure 19: Soldering Components


After a long procedure the board has been finalize which will use for installation of
Interlock system PV-212M Oven for improve capability of the machine shown Figure 20.

Figure 20: Interlock Circuit for PV-212M

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


55

Installation. This section showed the installation of the prototype into the PV-212 oven
by defining the connection of each input and illustrating the process of each connection. Figure
21 shows the main signal connection from the oven. Tha data coming from this connection is the
temperatureand the status of being locked or unlocked.

Figure 21: Signal Interconnection for PV-212M

Figure 22 showed the main system, wherein the relays used to unlock and lock the oven
are located. A connection from the output of the prototype, which is like a pulse, switches the
relay on or off. This was the main focus of the prototype; that is to prevent any unauthorized
unlock of the relays.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


56

Figure 22: Main System for PV-212M


The main lock latch, showed in Figure 23, was what kept the door closed and was
controlled by the microcontroller to open only if the correct pin was inputted into the keypad of
the prototype. The results are shown on the LCD module.

Figure 23: Solenoid Valve and Cylinder for PV-212M

Users Manual
1. Press on to power the ESPEC PV-212M Oven.
2. Run the machine by press start button means the machine is operational which will

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


57

trigger the 1st condition of the signal goes to microcontroller. (The setting was already
set-up base of revision of our engineering process.)
3. While the oven is running the temperature rising which will be stable at 175 degree.
4. When the temp stable at 175 degree the 2nd condition will trigger and the timer of the
ESPEC oven start in 5hrs parallel to the circuit of microcontroller.
5. The door will be lock until the curing time is not finish.
6. When the 5hrs are finish the door will be unlock base on the program of microcontroller
which will be safe of the unit and prevent bypassed operation.
7. End of process.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


58

Cost Benefit Analysis.


On figure 24 shown the actual price quotation from the O.E.M way to expensive versus
to the in house fabrication of prototype.

Project Quotation
Cost!!!!
US $ 14,838 per unit
or Php 771,576
In house Fabrication
Cost of PHP 1688.409 VS
O.E.M. PHP 771,576

Figure 24: Project Quotation in O.E.M pricing.


Base of the pricing of O.E.M vs. in house fabrication it prove a big dissimilar value of
project cost. This project will add to cost saving program of NXP Semiconductor. The researcher
is confident enough on the capability of his circuit design and its contribution. It may bring when
it will be fanned out to all ESPEC Oven in APP Cabuyao.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


59

Testing and Evaluation


On figure 25 shows after installing with the new modified interlock system the sequence
improve.

Figure 25: ESPEC Interlock system graph analysis


Figure 25 shows the rise of process heating. The door interlock will not activate until the
set point of temperature has been not stable. After stable at 175 degree Celsius and curing time is
in process the door activate close once the 5hrs elapse the door will open. The researcher show
the modified interlock was effectively and functionality base on the design circuit.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


60
600000.00
500000.00
400000.00
Yield per Month

300000.00

Reject Per Month

200000.00
100000.00
0.00
1

Figure 26: ESPEC Oven Yield Vs Reject


Oct-14
44678
3.00
11169.
58

Nov-14
45346
8.00
11336.
70

Dec-14
57342
9.00
14335.
73

Jan-15
55363
8.00
2768.1
9

Feb-15
56272
1.00
1688.1
6

Survey Results. Table 4 illustrates the summary of ratings from respondents which were
composed of 12personnels from different departments of Power BFG; they were operators,
technical operators, line maintenance technicians, preventive maintenance technicians,
preventive maintenance engineer, industrial engineering technician and automation technician.
The operators who closely knew the daily routine of the machine, preventive maintenance and
line technicians who knew the technical aspect and performance of the machine and to validate
the efficiency of the project were the industrial and automation technicians.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


61

Table 4
Survey Results
Auto Interlock PV-212M Oven
Survey Questionnaire

S
A

N D
A

SD
A

Tot
al

Weighte
d Mean

Effectiveness

1. The machine is performing automatic


interlock every time the machine is in
operation.
2. Auto interlock didnt stop while in operation
3. The keypad system was effective in
providing security for the lock system.
4. The machine was effective in locking the
oven at 175 degrees Celsius.
5. The machine was effective in preventing
unauthorized unlock in the oven.

12

4.583333

6
1
0
9

5
1

0
0

0
0

12
12

4.416667
4.75

12

4.75

1
1

12

4.916667

12

4.583333

12

4.5

1
0
7

12

4.833333

12

4.5

12

4.75

1
1

Functionality

1. No machine hung-ups or breakdown related


to auto interlock.
2. No machine downtime during stabilization of
heating.
3. The machine did not unlock at a different
password.
4. The machine password input system did not
experience any hang-ups related to data
interfacing.
5. The machine served its function as an AutoInterlock System at 175 degrees Celsius
temperature in the oven.

Most of the respondents had a positive response on the survey, it is a proof that the
researcher meets the four major concerns in this circuit design which are; the effectiveness by
knowing the respondents observation regarding the design, efficiency by gathering their
feedback deemed at the circuits effect to the machine performance, maintainability by giving
their insights on how to maintain the machine when trouble comes related to the automatic

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


62

Interlock circuit and safety on how to address the respondents security concerns with regards to
the project. By giving their positive responses on the survey, the researcher is confident enough
on the capability of his circuit design and its contribution to NXP in terms of efficiency,
maintainability, safety and cost savings it may bring when it will be fanned out to all ESPEC
Oven in APP Cabuyao.

Summary of Findings
After the implementation of the Modified Design of Interlock System of ESPEC PV212M oven several improvements were realized.
1. Based on the modification of the existing design, the prototype improved the Oven
operations by prohibiting unauthorized unlock once it reaches 175 degrees Celsius.
2. The circuit design, which involved designing of the schematic diagram and wiring
diagram, featured the parts needed for the system to be effective and to function well. This
improvement was realized through the respondents survey result. This result was analyzed after
a brief demonstration to the respondents on the operation of the system. The main improvement
realized in the system was the decrease in the reject yield as soon as the circuit design of the
prototype was implemented.
3. In Fabrication of the modified interlock system, a trial and error was made to allow the
production of the most applicable PCB Design. This allowed the best outcome for the main
circuit, thus improving the effectiveness and functionality of the whole system.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


63

4. Evaluation of the finished project gave the average results of Strongly Agree on the
Likert questions as to how effective and functional the system is.
During testing of the modified interlock system to attain the sequence of interlock the
researcher conduct test trial in line production as many as do if the design circuit will be problem
base on result the circuit has meet the condition sequence. Judgment criteria have been set and
the standardization of this procedure is ongoing and will be deliberated by Central Line
production where the ESPEC Oven lay.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


64

Unit V
Conclusions and Recommendations
Conclusions
The main goal of the project study is to produce safe quality of the product and also to the
user through the installation of Modification of Interlock system on ESPEC PV-212M Oven
which will activate during stabilization of heating process. The researcher learned many things
along the way during the creation of his design and concluded the following observations;
1.

The original design of the interlock system of ESPEC oven was modified
effectively to prevent unauthorized unlocking.

2.

A circuit was designed for the main objective which is to create a modified
interlock system of an ESPEC oven. This design allowed the best outcome from
the prototype as it was designed specifically for the oven.

3.

The designed circuit was fabricated into a prototype using the most appropriate
materials and components that made it effective and functional in avoiding
unauthorized unlocking of the system.

4.

Through a survey that was conducted to a group of respondents that witnessed the
operation of the prototype, the effectiveness and functionality was rated and
evaluated. The results of the evaluation were that the prototype was effective and
functional in avoiding unauthorized unlocking.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


65

Recommendations
After validating all the findings and conclusion and measured system study the researcher
recommended the following:
1. In the modification of the design circuit the researcher highly recommend conducting
series of studies, gathering information and do not hesitate to ask the experts. With this
information you will be able to design a circuit based on the ability to prevent
unauthorized unlocking.
2. In the development of circuit design, the researchers recommends the use of EAGLE 6.0
software because of friendly use and draw a schematic and printed circuit board of a
3.

project.
In the fabrication of the prototype, the researcher uses an olden procedure using a
chemical of ferric chloride to etch the PCB. It also recommends use of pre-sensitized

board, a modern type procedure that can easily to design the circuit fast.
4. In evaluating the effectiveness and functionality of the project, the researcher
recommends that the modified of interlock system applied to the NXP Semiconductor
Cabuyao Laguna where the address issue in Central Area Station.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


66

References:
Alexander, C. K. (2004). Fundamentals of Electric Circuit. McGraw-Hill Inc.
Boylestad, R. L., & Nashelsky, L. (2002). Electronic Device and Circuit Theory (4th ed.).
(pp.

147-216)

Floyd, T. L. (2010). Principles of Electric Circuits (9th ed.). ( pp 452- 485)


Gibilisco, S. (2006) Electricity and Electronics, Second Edition. Singapore: McGraw Hill
Book Company.
Grob, B. (2007). Basic Electronics. ( page 59) Schultz Hill Inc.
John, L. (2004). PIC Robotics a Beginners Guide to Robotics Projects Using the PIC Micro.
( pp 200-210 ) The McGraw-Hill Companies.
Lojek, B. (2006). History of semiconductor engineering,
( pp. 212215 ) Springer.
Wu, F. (2004). "Theory of resistor networks: The two-point resistance".

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


67

Appendices
Appendix A
ESPEC PV-212M Oven

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


68

Appendix B
PC817 Series

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


69

Appendix C
DS1307

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


70

Appendix D
BC547

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


71

Appendix E
PIC16F7/88

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


72

Appendix F
LM317 Regulator

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


73

Appendix G
24LC265

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


74

Appendix H
LCD Display

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


75

Appendix I
Matrix Keyboard

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


76

Appendix J
1N4007

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


77

Appendix K
Crystal Oscillator

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


78

Appendix L
Carbon Film Resistor

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


79

Appendix M
Tact Switch

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


80

Appendix N

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


81

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


82

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


83

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


84

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


85

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


86

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


87

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


88

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


89

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


90

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


91

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


92

Curriculum Vitae

ALVIN JOSEPH FLORES PEA


471 San Fernando Malvar Batangas City
Cell no: 09159688120/09065144478
CAREER AIM I am therefore looking for a position, one that will build on my
skills and experiences in Electronics and related fields and allow
me scope for upward movements.
EDUCATION
College

Secondary

Technological University of the Philippines


Ayala Boulevard, Ermita, Manila
Course: Electronics Engineering Technology

2002-2005

Las Pias National High School, LPC.

1998-2002

WORKING EXPERIENCE
Oct. 15, 2004 - Mar. 27, 2005
AMKOR TECHNOLOGY PHILIPPINES P3/P4
SIP Department (FOL Wirebond)
OJT-Technician trained in KNS 8026
RESPONSIBILTY
Supporting manufacturing through maintaining, line sustaining activities.
Set-up Conversion and Change Capillary.
Calibration like Bond Force, clamp, magazine and etc...
Log every set-up and trouble shoot of the machine.
Monitoring downtime machines.
Installed GASO Units to KNS 8026 Wirebonder machines.
Aug. 13, 2005- Oct. 13, 2007
PHILIPS SEMICONDUCTOR PHILIPPINES
Preventive Maintenance (FOL & EOL)
Technician I
RESPONSIBILTY
Responsible for maintenance activity such lubrication, overhaul machine, change spare
parts of the machine if ever defective and trouble shoot and follow our checklist PM
Calibration of the Machines (FCM-Flip Chip Mounting, EAGLE 60, Datacon APM)

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


93

Handle PM Documentation (PM Masterplan, PM Database etc)


ESD Ground installation and monitoring
Monitoring downtime machine
Supporting to the PROJECT (Auto Shut off Pressure, UV Curing w/ PLC NAIS Control,
ACS)
Supporting line sustaining activities specialties in EAGLE 60 Wirebonder

Oct. 13, 2007 Oct. 13, 2008


NXP Semiconductor Founded by Philips
Equipment Technician (FOL Wirebond & Diebond)
Technician I
RESPONSIBILITY:
Supporting manufacturing through maintaining, line sustaining activity
Log every set-up and downtime machine when start-up of the shift
Do set-up and calibration of the machine
Oct. 14, 2008 Present
NXP Semiconductor Founded by Philips
Automation Technician (Electrical Board Repair)
Technician II
RESPONSIBILITY:
Repairing a circuit board like power supply, monitor LCD, Parset Cabinet, Temp.
Controller, Driver motor, Rack panel, etc.
Installed CCTV or ACS monitoring LAN cable
Set-up a computer desktop installed application/reformat OS and can also make a backup of the harddisk and also to the machine by using NORTON GHOST
Every log when repaired & updating cost reduction & support major downtime machine
offline & online.
Member of ESD committee(Maintenance of continuous Checker)
Creating a prototype project for the better performance of the machine & can design own
circuit by using EAGLE software and Create a PCB design by using presentisized board
(ALEXAN)
INTEREST/SKILL
Knowledge in PLC Programming (Omron, KV builder Keyence)
Knowledge in Electropneumatics
Electronics Circuit Design (EAGLE / Livewire Software)
Digital Electronics Techniques
Industrial and Process Control Calibration and Maintenance Instruments.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


94

TRAININGS ATTENDED:
ELECTROPNEUMATICS CONTROL
Conducted: Oct. 4, 5, 20 & 21, 2005
Place: Philips Semiconductors Cabuyao
Instructor: Arwin F. Habaa
CERTIFICATE by: DUALTECH CENTER
ASM EAGLE 60 WIREBONDER
Conducted: July 21, 22, 2005
Place: ASM Agency (Alabang Madrigal Business Park)
Instructor: Sir Roque
CERTIFICATE by: ASM (Automation Assembly Machine)
PRESENTATION SKILLS
Conducted: Oct. 11, 2005
Place: Philips Semiconductor Cabuyao
Instructor: Connie F. Kahanap
CERTIFICATE by: Philips Semiconductor
SENSOR/STEPPER MOTOR
Conducted: Sep. 26, 27, 2005
Place: Philips Semiconductors Philippines
Instructor: Sir. Philip Demagante
QUANTUM FCQ-Flip Chip Quantum (Programming)
Conducted: Sep. 21-23, 2005
Place: Philips Semiconductors Philippines
Instructor: Mr. Teddy
CERTIFICATE by: Philips Semiconductors Philippines
FPMEA (Failure Process Monitoring and Effective Analysis)
Conducted:
Place: Admin Building
Instructor: Ms. Kaye Diao
CERTIFICATE by: NXP Semiconductor Philippines
Training ESD ASEMEP (Electro Static Discharge Technical)
Conducted: June 25, 2010
Place: Alabang Business Cyberzone
Instructor: Member of ESD Committee

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


95

PERSONAL
Age 29
Nationality: Filipino
Civil Status: Married
Height: 58
Weight: 176lbs
Good Health
Willing and eager to learn
CHARACTER REFERENCES
Junifer Padrique
(Engineering Equipment in Backend)
NXP Semiconductor Philippines
POWER Department
09192658298
Mr. Reynold Pantaleon
(MEE Engineering)
Philips Semiconductors Philippines
SIPS Department
816-2617 loc. 2437
Mr. Romeo G. Mendoza
Electronics Department Head
Technological University of the Philippines
College of Industrial Technology
Electronics Department
302-7750 loc. 206

__Alvin Joseph Pena__


Signature over printed name

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE


96