ABSTRACT The field of electrical engineering cannot do without the soldering process.

The digital soldering workstation is a protion or piece of equipment in a given workshop that is provided for use during any soldering operation in the laboratory and it is assigned specially for soldering operation. The system consists of the soldering iron control system that controlss the heating temperature of the temperature. When the system is put on, the soldering iron gets heated the sensor ( heat sensor) monitors the temperature of the heater, when the temperature gets within a certain preset treshold set on the system, the heating of the heater is cut of by a relay provided inside the device. The device also provides an lcd display that gives the alphanumeric value of the temperature of the heater. And also displays the status of the system. The project consists of the LM35 temperature sensor which is used to monitor the temperature of the soldering iron used in the work station. The signal from the sensor is then passed to the ADC0804 that converts the signal int a digital signal the digital signal is then passed to the MCU that now prforms the nessesary calculations required for the operation of the project. The project finds a number of apllications expecially in the workshops.

1.0

INTRODUCTION A work station is a person's work area, including furniture, appliances, tools etc. where a specific type of activity is carried out in the work area by one person at a time. It is a high end mapped out section of a working area and includes everything that makes up such a place. In computer systems, the workstation is a high-end microcomputer designed for specific technical or scientific applications. Intended primarily to be used by one person at a time, they are commonly connected to a local area network and run multi-user operating systems. The term workstation has also been used to refer to a mainframe computer terminal or a PC connected to a network. The term soldering work station refers to a giving area in a work shop or any place were a complete setup is established with all the materials required for soldering operation is put in place for soldering of electrical and electronics components during an electrical or electronics maintenance or construction. Soldering is a process in which two or more metal items are joined together by melting and flowing a filler metal (solder) into the joint, the filler metal having a lower melting point than the work piece. Soldering differs from welding in that soldering does not involve melting the work pieces. In brazing, the filler metal melts at a higher temperature, but the work piece metal does not melt. Formerly nearly all solders contained lead, but environmental concerns have increasingly dictated use of lead-free alloys for electronics and plumbing purposes.. The soldering is a term that is used to describe the joining together of two nor more metals at a junction with the use of an alloy usually with a lower melting point in order to make up an electrical circuit or putting together of one or more electrical components. It is used during maintenance to maintain a continuous flow of electric current in an electrical circuit. The soldering work station encompasses one or more devices and components put together to make up the work station. These components includes

The Soldering Iron The soldering iron is a thin handheld tool about 10 inches long or more. An electrical cable connects it to the power supply. A heating element inside the soldering iron gets the metal
2

barrel and tip hot. The iron has a plastic handle and soft grip to keep your fingers cool and comfortable. The soldering iron is used to melt the lead alloy that is used for the soldering. The soldering Stand The soldering stand is usually a metal stand attached to the workstation provides a safe place to park the hot iron when you're not soldering. A metal cage encloses the iron and safely dissipates heat, preventing burns if touched. The soldering Sponge The soldering iron workstation has a holder for a small rectangular sponge. The soldering iron operator uses the sponge to clean burnt rosin and oxides from the iron's tip. Temperature control unit The soldering work station usually requires a temperature regulation system that is used to regulate the temperature of the heating element. This prevents overheating parts and speeds the soldering of larger connections. In many cases, you can adjust the temperature from a control on the power supply. Power Soldering irons for electronics fall in a power range of 5 to 30 watts. Some power supplies let you control the power going to the iron. Less power is better for delicate work. More power lets you solder components like power transistors and heavier-gauge wire. The soldering work station that is implemented in this project is designed around the 8051 microcontroller which is the heart of the system. A temperature sensor LM35 is also provided in the project whose sole function is to take the analog reading of the temperature of the soldering iron. The ADC is interfaced with the microcontroller whose main function is to convert the analog signal that is read from the LM35 temperature sensor into a digital form. The ADC also converts the digital signal into an 8-bit digital data that is read by the MCU (microcontroller unit) of the project. The project also provides an LCD (liquid crystal
3

display) display that is used to provide a digital read out of the alphanumeric value of the temperature of the soldering iron in the work station. The project also provides an interface of relays that are used to provide the control of the various accessories of the work station. In the project, the relays acts as switches that put on the appliance whenever the MCU requests that. The operation is initiated upon the switching of the power supply into the system. As soon as the power supply is turn on, the LM 35 temperature sensor reads the temperature of the soldering iron and continuously sends the analog signal value of the temperature to the ADC which in turn converts the analog signal into an 8-bit digital equivalent of the temperature. This signal is then passed on to the MCU which interprets the signal and sends the alphanumeric value of the temperature for the LCD to display. When the control buttons is pressed, the MCU records the value of the temperature that is selected and ensures that the operating temperature of the soldering iron stays within that range. The control of the heating of the soldering iron is done by a relay that is designed to trip off the soldering iron when the temperature tries to go outside the operation range. The operation of the appliances that make up the work station is simply carried out by pressing a button that controls the required appliance and the MCU triggers the relay on thereby putting the appliance on or off as the case may be. 1.1 BACKGROUND OF THE STUDY Soldering, the art of connecting individual objects, is an age-old procedure. However, latest innovations stress more on the use of eco-friendly materials besides the use of the best physical and chemical components, especially that of the fluxes, for better results and greater compatibility. In a quest to find more eco-friendly materials, research organizations worldwide laid emphasis on the elimination of ozone-depleting chemicals and started experimenting with a variety of new combinations with potential materials and alternative processes. In the process, researchers tumbled upon a more reliable form of soldering, better than the established conventional soldering process. The traditional process involved the use of rosin flux. The landmark discovery in the field of soldering was the use of noclean flux for the soldering process. The main advantage being that it does away with the
4

laborious post-solder, which requires the use of CFCs or costly solvents for cleaning. This process has helped in saving time and energy, compared to the age-old practice when soldering was done manually. The introduction of the soldering work station also ensured that cold joints and other forms of abnormal soldering is averted in a given soldering operation. 1.2 AIMS AND OBJECTIVES The main aim of embarking on the design and implementation of the soldering work station in this project is to establish a platform with which soldering operation can be conveniently conducted in any electrical establishment. The project is also embanked on with the following objectives. To investigate the issues soldering operations in the engineering field of study. To combine the advantages offered by all types of soldering work stations that exists in the implementation of a more reliable and efficient system. To examine the best possible method of implementation of a digital work station that provides all the necessary requirements that is required for easy soldering. To design and implement an improved soldering work station that will give a digital display of the status of the temperature of the soldering iron during the soldering. 1.3 PROBLEM STATEMENT Various problems may arise in the soldering process which lead to joints which are non functional either immediately or after a period of use. This is because of abnormal temperatures that are used for soldering in many cases of soldering operation. The most common defect when hand-soldering results from the parts being joined not exceeding the solder's liquids temperature, resulting in a "cold solder" joint. This is usually the result of the soldering iron being used to heat the solder directly, rather than the parts themselves. Properly done, the iron heats the parts to be connected, which in turn melt the solder, guaranteeing adequate heat in the joined parts for thorough wetting. In electronic hand
5

soldering solders, the flux is embedded in the solder. Therefore heating the solder first may cause the flux to evaporate before it cleans the surfaces being soldered. A cold-soldered joint may not conduct at all, or may conduct only intermittently. Cold-soldered joints also happen in mass production, and are a common cause of equipment which passes testing, but malfunctions after sometimes years of operation. A "dry joint" occurs when the cooling solder is moved, and often occurs because the joint moves when the soldering iron is removed from the joint. The use of the digital soldering work station that is presented in this thesis solves the problems of temperature regulation that usually leads to abnormal soldering by providing an automated way of temperature control during soldering. 1.4 SIGNIFICANCE OF THE STUDY The digital soldering work station offers a wide range of advantages and applications in electrical and electronics engineering discipline and the entire engineering at alarge. It provides a platform where the user can automatically regulate the temperature at which he performs a soldering operation and also provides a digital read out of the value of the operating temperature of the soldering iron. The work station also allows the control of all the tools and equipment that make up the work station set up such as control of the soldering lights, the control of the sucker or the blower as the case may be. The soldering work station is indeed the most reliable setup for soldering in any work shop as it integrates all the materials used for soldering together in the workshop there by defining and separating the section from any other section in the work shop.

1.5

SCOPE AND LIMITATIONS OF THE STUDY The digital soldering work station that is implemented in this project cover a quite wide area of application. It can be used in both home and industrial soldering or any scale of soldering though its operation may depend on the size of material being soldered. If soldering is required for larger size situations, all that is required is to change the size of the soldering iron that is used for the soldering as the temperature regulation is not limited to any size of soldering iron. The project offers a wide range of advantages but it is also faced with several limitations which includes; High cost of purchase due to its uniqueness. The use of the soldering work station requires a proper knowledge of the operating principles making the use difficult for the lay man technician.
The project is only limited for people with knowledge of different temperature

requirements for soldering The use of the system requires proper knowledge of the system and operation requires a trained personnel.

2.0 2.1

LITERATURE REVIEW Introduction Soldering, the art of joining two or more metal items together by melting and flowing a filler metal (solder) into the joint, the filler metal having a lower melting point than the work piece, the soldering process is an age-old procedure. However, latest innovations stress more on the use of eco-friendly materials besides the use of the best physical and chemical components, especially that of the fluxes, for better results and greater compatibility. In a quest to find more eco-friendly and efficient platform for soldering, research organizations worldwide and various researchers laid emphasis on the meas of providing an ease and reliable platform for soldering and the elimination of ozonedepleting chemicals and started experimenting with a variety of new combinations with potential materials and alternative processes during soldering. In the process, researchers tumbled upon a more reliable form of soldering, better than the established conventional soldering process. This has lead to the various evolutionary trend of soldering work stations.

2.2

Historical Overview of the Work Station The evolutionary trend on the development of the modern soldering iron work station has passed through series of transformations. These began with the discovery of the soldering itself. Soldering was invented in 1916 by a Holland company but the wording is a little non-specific and gives no credit to the original inventor. "The company was founded in 1916 as a manufacturing company under the name ZEVA. This name had much to do with the introduction of an innovative product: the electric soldering iron (as differing from then-popular petrol and gas irons). Major customers included Philips Radio and Dutch Telecom." Since the invention of the soldering, there have existed many methods by which the soldering is being done. These methods include the use of the blowing lamp, the use of the soldering gun and the use of the soldering irons which is the most popular today. The soldering iron itself was invented about the same time as its original constituent metals Lead (Pb in Chemistry) and Tin (Sn in Chemistry) - were discovered several thousand years ago. (www.wikiananswers.com). German inventor Ernst Sachs patented the first
8

electric soldering iron in 1921, according to ERSA Global Connectors, the company Sachs founded later that year to produce his device. The company exists today and has its headquarters in Wertheim, Germany. (www.answerbag.com). the modifications on this great invention were made severally in a quest to develop more reliable soldering irons. The introduction of the work station began with the soldering iron stand which is setting where a hot soldering iron is places in the workshop. The soldering iron stands where introduced in the late 18th century in the United States. Since then, the soldering iron stand has being severally modified in various ways leading to the discovery of the work station in the 19th century which can be used both as the stand and as a control station for the soldering operation capable of controlling the temperature of the tools used for soldering such as the soldering iron and the sucker. 2.3 An Overview of the Soldering Work Station The soldering work station that is implemented in this project is designed around the 8051 microcontroller which is the heart of the system. A temperature sensor LM35 is also provided in the project whose sole function is to take the analog reading of the temperature of the soldering iron. The ADC is interfaced with the microcontroller whose main function is to convert the analog signal that is read from the LM35 temperature sensor into a digital form. The ADC also converts the digital signal into an 8-bit digital data that is read by the MCU (microcontroller unit) of the project. The project also provides an LCD (liquid crystal display) display that is used to provide a digital read out of the alphanumeric value of the temperature of the soldering iron in the work station. The project also provides an interface of relays that are used to provide the control of the various accessories of the work station. In the project, the relays acts as switches that put on the appliance whenever the MCU requests that. The operation is initiated upon the switching of the power supply into the system. As soon as the power supply is turn on, the LM 35 temperature sensor reads the temperature of the soldering iron and continuously sends the analog signal value of the temperature to the ADC which in turn converts the analog signal into an 8-bit digital equivalent of the temperature. This signal is then passed on to the MCU which interprets the signal and sends the alphanumeric value of the temperature for the LCD to display. When the control buttons is pressed, the MCU records the value of the temperature that is
9

selected and ensures that the operating temperature of the soldering iron stays within that range. The control of the heating of the soldering iron is done by a relay that is designed to trip off the soldering iron when the temperature tries to go outside the operation range. The operation of the appliances that make up the work station is simply carried out by pressing a button that controls the required appliance and the MCU triggers the relay on thereby putting the appliance on or off as the case may be.

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3.0

DESIGN ANALYSIS The techniques employed in investigating the application principles of the 8051 microcontroller is based on gathering observable, empirical and measurable evidence through research of primary and secondary sources. Primary data acquisition is through practical experience on electrical engineering principles and through lecture notes. Secondary data were collected from the internet and from textbooks. The design of the project will be implemented by splitting the project into various sub-units, which are:

The power supply unit The MCU Oscillations input unit The reset circuit The ADC unit The output LCD display unit The relaying unit METHOD OF DESIGN AND IMPLEMENTATION The design of this project is made by splitting the project into various sectional units in the course of the design. This is to facilitate easy design and to enable the system to be easily trouble shot at the end of the design and implementation of the project.

3.2

3.3

THE POWER SUPPLY UNIT The power supply unit is designed to continuously supply power to all the sub-sections of the board. The power supply design is carried out using the following circuit diagram;

11

Figure 3.1; Circuit Diagram for the Power Supply Unit The power supply unit is designed using a 12V step-down transformer, which supplies the bridge rectifier circuit in the unit. The rectified output voltage is passed through a set of capacitors that filters off any unwanted ripples in the output. The filtered output is then passed through a 5V linear regulator (7805) that keeps a constant 5v output on the unit. Since the Transformer used for the power supply unit design takes a 220V input and gives an output voltage of 12V, then the transformation ratio can be calculated as: Ni/No = Ei/Eo = , Where =transformation ratio Ni=Number of primary turns No=Number of secondary turns Ei=primary voltage Eo=secondary voltage. From Ei/Eo = ,
12

220/12 = 18.33 Therefore, the transformation ratio is 18.33. Output is given by: V (out) = 1/2 x V V (out) = 0.71 X V = 0.707 X 12V = 8.48V (This equation is similar for the negative rail as well) The capacitor value for the power supply is given by C=Q/V Where C=capacitance Q = Charge across the circuit V = Voltage across the circuit But Q = it Where I = current T = time. Also T = 1/f Where f = frequency = 50Hz. T= 1/50 = 0.02seconds Hence Q = 0.02 x 500 x 10-3 (from transformer current rating.) = 0.01C Therefore C = 0.01/12 = 0.000833Farads = 833uF. But capacitors of this range is not obtainable thus we use 1000uf for the design.
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3.4

THE MCU OSCILLATION INPUT UNIT The 8051 requires the existence of an external oscillator unit. The oscillator circuit usually runs around 12 MH2, although the 8051 (depending on which specific mode) is capable of running at a maximum of 40MH2. Each machine cycle in the 8051 is a clock cycle giving an attentive cycle at IMH2 clock. The configuration circuit for the external clock of the 8051 can be illustrated as follows.

C3
PIN 18
33p

X1
CRYSTAL

C4
PIN 19
33p

Fig 3.2; The Oscillation Circuit Of 8051 3.4.1 Finding the period circle Find the period of the machine cycle for 11.0592 MHz crystal Frequency for the crystal oscillator used we have; 11.0592/12 = 921.6 kHz; Thus the machine cycle is given by 1/921.6 kHz = 1.085s Therefore the machine circle for the microcontroller using a crystal oscillator of 11.0592 crystals is equal to 1.085s 3.5 THE RESET CIRCUIT The RESET is an active high input when RESET is set to High, 8051 goes back to the power on state. The 8051 is reset by holding the RST high for at least two machine cycles and then returning it law. The circuit diagram for the rest cycle and returning it low is illustrated below.

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Figure 3.3; Circuit Diagram for the Reset In the diagram, the reset is configured as power on reset and the manual rest. In the poweron Rest mode, initially charging of the capacitor make RST High and when the capacitor charge fully it blocks the DC. In the manual rest mode, the closing of the switch momentarily will make RST High. After the rest in the both modes, the program counter is loaded with 0000H but the content of on-chip RAM is not attested. (Ablilav .V. etal.) 3.6 The ADC Unit Analog to digital converters find huge application as an intermediate device to convert the signals from analog to digital form. These digital signals are used for further processing by the digital processors. Various sensors like temperature, pressure, force etc. convert the physical characteristics into electrical signals that are analog in nature. The ADC0804 that is used in this project is used to convert the analog temperature into an 8-bit digital signal that is read by the MCU. ADC0804 is a very commonly used 8-bit analog to digital convertor. It is a single channel IC, i.e., it can take only one analog signal as input. The digital outputs vary from 0 to a maximum of 255. The step size can be adjusted by setting the reference voltage at pin9. When this pin is not connected, the default reference voltage is the operating voltage, i.e., Vcc. The step size at 5V is 19.53mV (5V/255), i.e., for every 19.53mV rise in the analog input, the output varies by 1 unit. To set a particular voltage level as the reference value,
15

this pin is connected to half the voltage. For example, to set a reference of 4V (Vref), pin9 is connected to 2V (Vref/2), thereby reducing the step size to 15.62mV (4V/255). ADC0804 needs a clock to operate. The time taken to convert the analog value to digital value is dependent on this clock source. An external clock can be given at the Clock IN pin. ADC 0804 also has an inbuilt clock which can be used in absence of external clock. A suitable RC circuit is connected between the Clock IN and Clock R pins to use the internal clock. Features Compatible with 8080 P derivatives-no interfacing logic needed - access time - 135 Easy interface to all microprocessors, or operates "stand alone" Differential analog voltage inputs Logic inputs and outputs meet both MOS and TTL voltage level specifications Works with 2.5V (LM336) voltage reference On-chip clock generator 0V to 5V analog input voltage range with single 5V supply No zero adjust required 0.3[Prime] standard width 20-pin DIP package 20-pin molded chip carrier or small outline package 3.7 Operates ratiometrically or with 5 VDC, 2.5 VDC, or analog span adjusted voltage reference LM35 Precision Centigrade Temperature Sensor The LM35 series are precision integrated-circuit temperature sensors, whose output voltage is linearly proportional to the Celsius (Centigrade) temperature. The LM35 thus has an advantage over linear temperature sensors calibrated in Kelvin, as the user is not required to subtract a large constant voltage from its output to obtain convenient Centigrade scaling. The LM35 does not require any external calibration or trimming to provide typical accuracies of C at room temperature and C over a full -55 to +150C temperature range. Low cost is assured by trimming and calibration at the wafer level. The LM35's low output impedance, linear output, and precise inherent calibration make interfacing to readout or control circuitry especially easy. It can be used with single power supplies, or with plus and minus supplies. As it draws only 60 A from its supply, it has very low self16

heating, less than 0.1C in still air. The LM35 is rated to operate over a -55 to +150C temperature range, while the LM35C is rated for a -40 to +110C range (-10 with improved accuracy). The LM35 series is available packaged in hermetic TO-46 transistor packages, while the LM35C, LM35CA, and LM35D are also available in the plastic TO-92 transistor package. The LM35D is also available in an 8-lead surface mount small outline package and a plastic TO-220 package. In the project, the LM35 is used to sense the temperature of the soldering iron in the project. Calibrated directly in Celsius (Centigrade) Linear + 10.0 mV/C scale factor 0.5C accuracy guaranteeable (at +25C) Rated for full -55 to +150C range Suitable for remote applications Low cost due to wafer-level trimming Operates from 4 to 30 volts Less than 60 A current drain Low self-heating, 0.08C in still air Nonlinearity only C typical Low impedance output, 0.1 Ohm for 1 mA load 3.8 The Liquid Crystal Display (LCD) Unit The liquid crystal display (LCD) is a device that is used to give an alphanumeric display of data on a crystal screen. Frequently, an 8051 program must interact with the outside world using input and output devices that communicate directly with a human being. One of the most common devices attached to an 8051 is an LCD display. Some of the most common LCDs connected to the 8051 are 16x2 and 20x2 displays. This means 16 characters per line by 2 lines and 20 characters per line by 2 lines, respectively. Fortunately, a very popular standard exists which allows us to communicate with the vast majority of LCDs regardless of their manufacturer. The standard is referred to as HD44780U, which refers to the controller chip which receives data from an external source (in this case, the 8051) and communicates directly with the LCD. The 44780 standard requires 3 control lines as well as either 4 or 8 I/O lines for the data bus. The user may
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select whether the LCD is to operate with a 4-bit data bus or an 8-bit data bus. If a 4-bit data bus is used the LCD will require a total of 7 data lines (3 control lines plus the 4 lines for the data bus). If an 8-bit data bus is used the LCD will require a total of 11 data lines (3 control lines plus the 8 lines for the data bus). The three control lines are referred to as EN, RS, and RW. That is the enable, register select and the read write respectively. The EN line is called "Enable." This control line is used to tell the LCD that you are sending it data. To send data to the LCD, your program should make sure this line is low (0) and then set the other two control lines and/or put data on the data bus. When the other lines are completely ready, bring EN high (1) and wait for the minimum amount of time required by the LCD datasheet (this varies from LCD to LCD), and end by bringing it low (0) again. The RS line is the "Register Select" line. When RS is low (0), the data is to be treated as a command or special instruction (such as clear screen, position cursor, etc.). When RS is high (1), the data being sent is text data which should be displayed on the screen. For example, to display the letter "T" on the screen you would set RS high. The RW line is the "Read/Write" control line. When RW is low (0), the information on the data bus is being written to the LCD. When RW is high (1), the program is effectively querying (or reading) the LCD. Only one instruction ("Get LCD status") is a read command. All others are write commands--so RW will almost always be low. Finally, the data bus consists of 4 or 8 lines (depending on the mode of operation selected by the user). In the case of an 8-bit data bus, the lines are referred to as DB0, DB1, DB2, DB3, DB4, DB5, DB6, and DB7. As we've mentioned, the LCD requires either 4 or 7 I/O lines to communicate with. For the sake of this project, we are going to use a 4-bit data bus--so we'll be using7 of the 8051's I/O pins to interface with the LCD.

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As seen, we've established a 1-to-1 relation between a pin on the 8051 and a line on the 44780 LCD. Thus as we write our assembly program to access the LCD, we are going to equate constants to the 8051 ports so that we can refer to the lines by their 44780 name as opposed to P0.1, P0.2, etc. Let's go ahead and write our initial equates: DB4 DB5 DB6 DB7 EN RS RW DATA EQU P1 Having established the above equates, we may now refer to our I/O lines by their 44780 name. For example, to set the RW line high (1), we can execute the following instruction: RW=1 Handling The EN Control Line As we mentioned above, the EN line is used to tell the LCD that you are ready for it to execute an instruction that you've prepared on the data bus and on the other control lines. It is Noted that the EN line must be raised/lowered before/after each instruction sent to the LCD regardless of whether that instruction is read or write, text or instruction. In short, you must always manipulate EN when communicating with the LCD. EN is the LCD's way of knowing that you are talking to it. If you don't raise/lower EN, the LCD doesn't know you're talking to it on the other lines. Thus, before we interact in any way with the LCD we will always bring the EN line low with the following instruction: EN=0 And once we've finished setting up our instruction with the other control lines and data bus lines, we'll always bring this line high:
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EQU EQU EQU EQU EQU EQU EQU

P1.4 P1.5 P1.6 P1.7 P3.7 P3.6 P3.5

EN=1 The line must be left high for the amount of time required by the LCD as specified in its datasheet. This is normally on the order of about 250 nanoseconds, but check the datasheet. In the case of a typical 8051 running at 12 MHz, an instruction requires 1.08 microseconds to execute so the EN line can be brought low the very next instruction. However, faster microcontrollers (such as the DS89C420 which executes an instruction in 90 nanoseconds given an 11.0592 Mhz crystal) will require a number of NOPs to create a delay while EN is held high. The number of NOPs that must be inserted depends on the microcontroller you are using and the crystal you have selected. The instruction is executed by the LCD at the moment the EN line is brought low with a final CLR EN instruction. The LCD interprets and executes our command at the instant the EN line is brought low. If you never bring EN low, your instruction will never be executed. Additionally, when you bring EN low and the LCD executes your instruction, it requires a certain amount of time to execute the command. The time it requires to execute an instruction depends on the instruction and the speed of the crystal which is attached to the 44780's oscillator input.

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Checking the Busy Status of the LCD As previously mentioned, it takes a certain amount of time for each instruction to be executed by the LCD. The delay varies depending on the frequency of the crystal attached to the oscillator input of the 44780 as well as the instruction which is being executed. While it is possible to write code that waits for a specific amount of time to allow the LCD to execute instructions, this method of "waiting" is not very flexible. If the crystal frequency is changed, the software will need to be modified. Additionally, if the LCD itself is changed for another LCD which, although 44780 compatible, requires more time to perform its operations, the program will not work until it is properly modified. A more robust method of programming is to use the "Get LCD Status" command to determine whether the LCD is still busy executing the last instruction received. The "Get LCD Status" command will return to us two tidbits of information; the information that is useful to us right now is found in DB7. In summary, when we issue the "Get LCD Status" command the LCD will immediately raise DB7 if it's still busy executing a command or lower DB7 to indicate that the LCD is no longer occupied. Thus our program can query the LCD until DB7 goes low, indicating the LCD is no longer busy. At that point we are free to continue and send the next command. The LCD in this project is used for the display of the value of the temperature of the soldering iron. 3.9 The Operation of the System The digital soldering workstation is a protion or piece of equipment in a given workshop that is provided for use during any soldering operation in the laboratory and it is assigned specially for soldering operation. The system consists of the soldering iron control system that controlss the heating temperature of the temperature. When the system is put on, the soldering iron gets heated the sensor ( heat sensor) monitors the temperature of the heater, when the temperature gets within a certain preset treshold set on the system, the heating of
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the heater is cut of by a relay provided inside the device. The device also provides an lcd display that gives the alphanumeric value of the temperature of the heater. And also displays the status of the system. The circuit diagram for the system is designed around the 8051 micrcontroller which is the heat of the system. The system also consists of an LM35 temperature which takes the temperature of the heater and sends the output in an analogue form into the analog to digital converter. The analog to digital digital converter (ADC) converts the anolog signal received fron the sensor into a digital signal which is readeable by the microcontroller. The ADC used for the system is and ADC0804 ADC which is an 8-bit system. It recieves the an analog signal from the sensor and gives out an 8-bit digital output. The device also provides a liquid crystal display (LCD) which anables the display of an alphanumeric display of the value of the temperature of the system. The LCD used for the system is a 2*16 LCD. The device also consists of a relay which controls the switchin of the heater. The relay controls the switching of the heater provided. When the system is put on, the sensor starts the reading of the temperature of the heater and sends the analog signal into the ADC input the ADC acts on the analog signal and converts it into an 8-bit digital signal which it passes into the microcontroller. The microcontroller performs necessary mathematical calculations on the signal and gives an alphanumeric display of the value of the temperature on the LCD display. When the temperature is beyond the preset valueu, the microcontroller actuates the relay which puts off the heater. When the teprature falls bellow the preset value. The micrcontroller reconnects the heater. 3.10 The Circuit Diagram for the Project The generalised circuit diagram for the design of the project can be illustarated by the figure below.

22

LCD1
L M 016L

VSS VDD VEE

RS RW E 4 5 6

1 2 3

C4 U2
33p

X1

19

X TA L1

C5 R8
10k

C R Y S TA L 18 X TA L2

C6
10u

33p 9 RST

39 P 0 .0/A D 0 38 P 0 .1/A D 1 37 P 0 .2/A D 2 36 P 0 .3/A D 3 35 P 0 .4/A D 4 34 P 0 .5/A D 5 33 P 0 .6/A D 6 32 P 0 .7/A D 7 21 P 2 . 0 /A 8 22 P 2 . 1 /A 9 23 P 2 .2 /A 1 0 24 P 2 .3 /A 1 1 25 P 2 .4 /A 1 2 26 P 2 .5 /A 1 3 27 P 2 .6 /A 1 4 28 P 2 .7 /A 1 5 10 P 3 .0 /R X D 11 P 3 .1 /T X D 12 P 3 .2 /IN T 0 13 P 3 .3 /IN T 1 14 P 3 .4 /T 0 15 P 3 .5 /T 1 16 P 3 .6 /W R 17 P 3 .7 /R D

29 P SEN 30 A LE 31 EA

9 8 7 6 5 4 3 2

7 8 9 10 11 12 13 14

D0 D1 D2 D3 D4 D5 D6 D7

U1
1 2 3 4 5 8 10 9 19 6 7 CS RD WR C L K IN IN T R A GND D GND V R E F /2 CLK R V IN + V IN A D C 0804 20 VCC 18 D B 0 (L S B ) 17 D B1 16 D B2 15 D B3 14 D B4 13 D B5 12 D B6 11 D B 7 (M S B ) 1 2 3 4 5 6 7 8 P 1 .0 P 1 .1 P 1 .2 P 1 .3 P 1 .4 P 1 .5 P 1 .6 P 1 .7 8 0 C 51

R P1
R E S P A C K -8

R7 C7
10k 1 50p

R1
4k7

Q1
B C 548

s u p p ly

R L1 R L2 R3 R2
4k7 4k7

O V1
OVEN

D1
D IO D E

1 2V

Q3
H e a te r
12V

R L3

B C 548

Q2

12V B C 548

F IL E N A M E :

g la g g a .D S N

DA

D E S IG N T IT L E : PATH:

3 C : \P r o g r a m F ile s ( x 8
C : \ P r o g r a m F il e s ( x 8 6 ) \ L a b c1e
RE V:

PA

Figure 3.4: The Generalized Circuit Diagram for the Project

BY:

TI

3.11

The Block Diagram for the Project

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Figure 3.5: The Block Diagram for the Project.

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4.0 4.1

SUMMARY AND CONCLUSION Summary The digital soldering workstation is a protion or piece of equipment in a given workshop that is provided for use during any soldering operation in the laboratory and it is assigned specially for soldering operation. The system consists of the soldering iron control system that controlss the heating temperature of the temperature. When the system is put on, the soldering iron gets heated the sensor ( heat sensor) monitors the temperature of the heater, when the temperature gets within a certain preset treshold set on the system, the heating of the heater is cut of by a relay provided inside the device. The device also provides an lcd display that gives the alphanumeric value of the temperature of the heater. And also displays the status of the system. The design of the soldering ironwork station designed in this project is aimed at providing a platform for an efficient and reliable soldering operation in a work shop. The thesis is divided into four major chapters. The abstract of the project gives a comprehensive summary of digital soldering iron work station. It highlights the problems the objectives and the operating principles of the project in summary. The chapter one of the project introduces the concept of access control systems, the existing types and the background of digital soldering iron work station; it highlights the problems, the aims and objectives of the research, the background and the scope of the soldering iron work station. The chapter one of the project gives the reader an insight of what the research is about. The chapter two of the project presents the literature review of the project. It pre-examines the historical background of the project and also reviews previous works done relating to the same aims and objectives, reviewing their success and failures as well as the modifications to be input on the works to achieve a more reliable system to make the system more reliable and efficient. The chapter three of the project presents the design analysis of the project it reviews the various sections of the project there design procedures and the implementation process. It
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also presents the necessary calculations carried out in the course of the design. It also presents the block diagram, the circuit diagram and the flow chart of the project. The chapter four of this thesis presents the summary and conclusion of the entire work. 4.2 Conclusions The field of electrical engineering cannot do without the soldering process. The digital soldering workstation is a protion or piece of equipment in a given workshop that is provided for use during any soldering operation in the laboratory and it is assigned specially for soldering operation. The system consists of the soldering iron control system that controlss the heating temperature of the temperature. When the system is put on, the soldering iron gets heated the sensor ( heat sensor) monitors the temperature of the heater, when the temperature gets within a certain preset treshold set on the system, the heating of the heater is cut of by a relay provided inside the device. The device also provides an lcd display that gives the alphanumeric value of the temperature of the heater. And also displays the status of the system.

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