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Table of Contents
DIY Soldering Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARTS LIST: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
File Downloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
http://www.instructables.com/id/DIY-Soldering-Station-1/
Interface is going to be simple: I want to use a couple of buttons, rotary encoder and a 16x2 LCD display(HD44780).
As it happens with most of my projects I will try to keep the cost to a bare minimum and scavenge as many parts for this creation as I can.
SO WHY MAKE YOUR OWN?
The reason why cheap aftermarket soldering stations suck is that you never know what you are getting, unless you can do a full test drive, disassemble to evaluate parts
and assembly quality and most importantly, check with other owners of this exact model for feedback on quality and reliability: same company keeps popping the exact
same product under different name/brand every couple of years just to confuse buyers.
As an example : about 2 years ago I bought a rework station online, and while I was(and still am) very happy with it's performance, I got very tired of a dumb design
choices, like making power cord and compressor-less rework wand non-detachable and extremely short. These issues make it very uncomfortable to use (even move it
on the table): station keeps flipping over as you move the wand around :( The insides were flooded with hot melt glue, so it took me a week to clean it and fix all critical
and noncritical issues. Cabling for rework handle was poorly attached, so the insulation constantly slips off, creating potential wire breaks and fire hazard.
http://www.instructables.com/id/DIY-Soldering-Station-1/
Original socket costs a lot less and is almost identical to an old cassette stereo connector I've just destroyed.
Power switch $0.50-$1.00
AC plug of your choice. I'm using a socket from an old PC power supply $1.00
5A fuse and fuse holder $2.00
http://www.ebay.com/itm/Fuse-Holder-Panel-Mount-fo...
http://www.ebay.com/itm/FF-F5A-15pcs-5A-250V-5x20m...
TOTAL BUDGET: anywhere from $35.00 to $50.00 (depending on what you already have and whether you want it look cool)
TIME TO COMPLETE: 4-5 days
P.S. Just to make it easier for you to look for parts: absolutely everything on this list can be purchased on eBay from both Chinese and US retailers.
http://www.instructables.com/id/DIY-Soldering-Station-1/
Resistor values at this stage are purely theoretical approximations and may be adjusted in the final design.
Pins 1 and 2 correspond to ceramic heater wires.
Pins 4 and 5 (thermistor) wired to the output connector, which we will use as inputs of LM358 op-amp on our control board.
Pin 3 is an ESD connection from the soldering iron.
CONTROL BOARD
At the heart of my design is an ATMega8 microcontroller. This is actually the first time I work with something other than ATTiny13 or ATTiny2313.
This MCU gives us enough IO pins to avoid using shift registers for I/O and simplify our design.
Three OC pins will provide enough PWM channels for future upgrades (secondary iron for example), while tons of available ADC channels can provide additional
temperature monitoring capabilities. As you've probably noticed, I've already added an extra PWM channel and an extra temperature sensor connectors for future addons.
At the top right corner we have our rotary encoder connections (A and B for direction, plus the push button).
LCD connector has been separated into 2 parts: 8-pin Supply and Data, 4-pin contrast/backlight control.
In addition to essential connectors I've added 4-pin UART for preliminary debugging (we'll only use RX,TX and GND pins).
ISP connector is not implemented. We will use a DIP-28 socket to connect our microcontroller and take it out for re-programming whenever we need.
R4 and R8 control the gain of corresponding amplifier circuits (x100 max gain).
Some things may change in the final design, but overall structure stays the same.
Image Notes
1. It's easier to test resistances here
http://www.instructables.com/id/DIY-Soldering-Station-1/
Image Notes
1. Rotary encoder with button
2. Temperature sensors
3. LCD and UART
4. Heater control
Image Notes
1. Prepping for new connector
http://www.instructables.com/id/DIY-Soldering-Station-1/
Image Notes
1. LCD connectors
2. My fancy iron connector
3. Matching socket with connector wires already soldered. Connector is not
Image Notes
1. Negative photo mask for photoresist film
Image Notes
1. Don't forget the heatsink!
File Downloads
http://www.instructables.com/id/DIY-Soldering-Station-1/
Image Notes
1. This is my failed attempt at silkscreen...
[NOTE: When saving, if you see .tmp as the file ext, rename it to 'SID.zip']
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Comments
http://www.instructables.com/id/DIY-Soldering-Station-1/
Control System
by Komal Manoj
Thakur