Workshop Practice Manual-11

Department of Mechanical Engineering Galgotias University Greater Noida, UP

Contents

Soldering and Desoldering

Steps followed in soldering

Selection of the bit: According to the work, it should be small in size and can give good contact with the surface Cleaning the bit and surface to be soldered: Clean the bit frequently with a wire brush or emery paper or a special sponge pad. Surface should be cleaned completely and flux should be applied

Tinning the soldering iron bit: Coat the soldering iron on the surface of the tip which also looks bright silver color. Replace the tip if it is old or corroded
Applying flux: Flux may be applied to the surface to be soldered Applying solder: With the use of proper soldering bit, solder should be applied. The quantity depends on the size of the surface to be soldered.

Shapes of Soldering Bits

Figure: Shapes of soldering bits

Procedure of soldering
Clean the bit and switch on the supply. When hot, tin the soldering irons tip with a small amount of solder. A clean, well-tinned tip can do the job properly. Wipe the terminal of components
Bend the components leads to fit the holes on the boards. Do not bend over Heat the joint by placing the soldering irons tip against the component leads and circuit pad and touch the solder to the lead pad. Only after the flow of solder, remove the lead and hold the tip in place for one second and remove it without moving the part or board and let the joint cool Trim the excess component lead with the side cutter, no need to trim the short leads Inspect the joints, bends and leads, and pad smoothly together and have a bright finish

After finishing all soldering, clean the board to remove any flux residue.

Procedure of soldering
Clean the bit and switch on the supply. When hot, tin the soldering irons tip with a small amount of solder. A clean, well-tinned tip can do the job properly. Wipe the terminal of components Bend the components leads to fit the holes on the boards. Do not bend over

Heat the joint by placing the soldering irons tip against the component leads and circuit pad and touch the solder to the lead pad. Only after the flow of solder, remove the lead and hold the tip in place for one second and remove it without moving the part or board and let the joint cool

Procedure of soldering
Trim the excess component lead with the side cutter, no need to trim the short leads Inspect the joints, bends and leads, and pad smoothly together and have a bright finish After finishing all soldering, clean the board to remove any flux residue.

Figure: Steps in soldering

Desoldering
When an electronic component is to be removed from a circuit, Desoldering is needed.

Procedure of Desoldering.
Hold the terminal which is to be unsoldered by nose pliers. Place the tip of the soldering iron on the joint until the solder is melted and remove the terminal. Clean the terminal of the component as well as PCB.

Checking the continuity for electronic circuit

A continuity tester is used for checking circuit board tracks, wires and connections for continuity. With the use of tester, we can confirm whether the electricity can flow through a cord, wire and metallic track. Electricity needs a continuous path or circuit in order to flow. To ensure this, the continuity tester is used.

Figure: Circuit diagram for a continuity tester

Component of Continuity Tester

Components: The following are the components of a continuity tester: 9 V battery Red LED 390 resistor Crocodile clips While checking the continuity, the LED lights brightly, dimly or not at all, according to the resistance of the item. When the tester is not in use the 9 V batteries should be unclipped or the crocodile clips are attached to a piece of plastic to prevent them touching. An ON/OFF switch can be added in the red wire from the battery clip.

Working procedure
The continuity tester sends electricity from an internal battery through one side of the item and down the wires. If the LED gets electrical current, the other side lights up confirming that the path is good While using of a continuity tester, first disconnect the item being tested from the power source. Make sure switches on the device are ON

Attach the crocodile clip to one side of the item. Now touch the tip of the tester to the other side. If there is continuity, the LED will light up. Connect a crocodile clip on each side of the suspected fault.

Assembling Electronic Components on PCB

PCB (Printed Circuit Board): A printed circuit board is the base plate over which all electronic components are mounted with soldered condition. The interconnection between two components is made by the metallic tracks. Fabrication and assembling electronic components on PCB: There are many types of PCBs out of which the single-sided PCB is taken for our discussion. The single-sided PCB fabrication consists of the following steps: PCB pattern designing Pattern transformation on to PCB Developing PCB Cleaning of PCB Finishing and assembly components

Figure: Sample for PCB diagram

PCB pattern designing

The design factors should be considered for all components, converted into PCB tracks of appropriate shape and size. While designing the PCB, the following factors should be considered. Component position on the board The grounding system should be properly connected for good ground conduction. There should not be any conductive loop. To withstand a possible short circuit in a system. Jumpers should be avoidable. After these design considerations with the help of self adhesive pads and lines, the master pattern of PCB is made on a thick sheet with a reverse carbon placed underneath to take the mirror image on the reverse side of sheet.

Pattern transformation onto PCB

Before doing the pattern transformation onto the PCB, the copper side of the PCB should be thoroughly cleaned with the help of alcoholic spirit or petrol, and must be made free from dust and contaminants. Base laminate is a board of insulating material, which is given a coating of a conducting material that is copper and alluminium. For a simple circuit, the phenolic board is preferred. Developing PCB: This process removes all the excessive copper from the base laminate. After this, only the printed pattern is left behind. A solution of 750 C hot tap water and ferric chloride is used to remove the excess copper. The above said solution is thoroughly stirred and to speed up the process, a few drops of HCl may be added. The board, with its copper side facing upwards, is placed in the above prepared solution. It takes nearly one hour to complete the process.

Contd..
Cleaning of PCB: After the developing process, the board should be washed under running water and should be dried. Now we can see the printed pattern very clearly. If any unwanted lines are thereby means or using petrol or alcohol the paint or inkline is removed from the PCB. Finishing and assembling the components: For finishing the board should be fully dried. Now using high speed drilling, the holes are drilled according to the component size and shape. After preparing PCB, we have to assemble the electronic components to make the circuit work. The components are soldered in the correct position and the circuit is tested with a continuity tester. Now the circuit is ready to us

Thank You