ROBOTIC SOLDERING ARM

2025-06-28 16:28:59 - Adil Khan

Project Title

Project Area of Specialization Electrical/Electronic EngineeringProject Summary

Automation is creating a revolution in the present industrial sector, as it reduces manpower and time of production. Our project mainly deals with the soldering operation, where the soldering is manually placed on soldering the object which involves the risk factor that the soldering is proper or Not. Our challenge is designing 3 different types of needles and operating them. We will make that kind of soldering machine, it sold the 3different object with 3 different kinds of needles at the time of soldering without changing any one of the needles. We have gone through different research papers, and articles and had observed the advanced technologies used in other industries for similar operations. After a related study, we have achieved the design of a 5-jointed robotic arm where the base is fixed and the remaining joints move in vertical and horizontal directions. The end effector is also designed to solder the electronic devices with different needles.

Here we used AutoCAD360 design and Autodesk-Inventor to simulate the designed model.

Soldering robots automate the Manual soldering process. A soldering iron mounted to the end effector of the robot is moved to previously programmed positions, where it will solder the joint.

Mechanics deals with the analysis of the forces that cause a body to be in physical motion. The motion of the robot arm will be achieved with the use of dc motors as actuators.

Project Objectives

Designing, Modelling, and Simulation of the pick and place mechanism.
The frequency of this operator, its repeatability, lifetime, etc. is to be found out.
To soldering the object at the same time with 3 Different types of needles with appropriate needs.
Saves time.
It reduces human effort.
It Saves money as fewer employees would be required.
It is much more efficient than humans.
It does the given tasks only and does not disturb anyone.
As electronics components get smaller this issue of inaccuracy grows even greater.
One way to solve this is through automation.
Using soldering robot results in improved accuracy, repeatability, and throughput of the whole soldering process. By removing the risk of human error, absolute positional accuracy can be maintained.
Plus, errors when soldering manually are inconsistent and difficult to detect.
We need to have a time study between currently undergoing a manual operation and a newly designed automated operation.
By automating the process, it is easy to identify any errors and reprogram the soldering robot to ensure they won’t be repeated.
The choice of the end effector, its design, and analysis should be carried out and documented.

Project Implementation Method

Project Selection (ROBOTIC SOLDERING ARM).
Background Study.
Research Problem.
Scope of Implementation.
Objectives.
Research.
Preliminary Discussion.
Articulated Arm Robots.
End Effector of the Robot.
Related Works.
Design & Drafting.
Materials Selection.
Simulation & Analysis.
Analytical Model.
Results & Final Discussions.
Summary &Conclusions.

Benefits of the Project

A major benefit of automating the soldering process is improving speed and efficiency. Not only are soldering robots fast when completing tasks, but they also don't require breaks, annual leave, or slow down due to eye strain or fatigue. Soldering robots can operate 24/7 if necessary, increasing production. Also, we soldered 3 kinds of soldering needles without replacing another two needles.

Design selection of robotic arm :

In choosing the materials and the shape for the robotic arm, the following were taken into consideration.

The ease of soldering.
Easy to change the mode of soldering you want.
Ease to soldering on SMD we used that kind of tip.
Strength and durability of the parts.
Weight as compared to a plastic robotic arm.
Easy to operate wireless or joy stick.

Technical Details of Final Deliverable

This functionality is best supported in our arm, which is used to create four needles on the arm tip (wrist).

They classified the several features:

Our design of the robotic arm is simple as we all see on internet sites.
The design of the arm is to define its 4 degrees of freedom.
In the design, we enhance the tipping capacity to hold 4 needles with its wires.
We put the 4 types of needles( likes: 0,1,4,6) with also soldering wire (i.e.: 2mm,2.25mm,3.50mm,4mm) .
We also used 3 DC motors ( 200rpm, 3.5rpm, and 5.12rpm motors).
The reason for using tiny tips is for SMD components and sort components to soldering because the normally soldering iron machines sold a standard shape or size.

ROBOT DETAILS

Number of Axes: 6 Axes
Horizontal Reach: 450mm
Vertical Reach: 570mm
Driver: 6 PMDC Servo Motor
Configuration:

1) All Axes with Soldering Machine.

2) All Axes are entirely independent.

3) All Axes can be controlled simultaneously.

Working Envelope: Degree of Rotation.

A) Body Rotation 350 degrees.

B) Shoulder Rotation 150 degrees.

C) Arm Rotation: 90 degrees.

D) Elbow Rotation 180 degrees.

E) Forearm Rotation: 90 degrees

F) Wrist Rotation 180 degrees

G) Soldering machine 90 to 100 degrees.

Final Deliverable of the Project HW/SW integrated systemCore Industry ManufacturingOther Industries Education Core Technology RoboticsOther Technologies Artificial Intelligence(AI)Sustainable Development Goals Industry, Innovation and Infrastructure, Responsible Consumption and ProductionRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	78200
Microprocess	Equipment	1	10000	10000
Connection Wires	Equipment	100	40	4000
Motors	Equipment	8	850	6800
Robot Body	Equipment	1	15000	15000
Soldering Machine	Equipment	1	20000	20000
Documentation/Report or Webside excess for AutoCad	Miscellaneous	1	10000	10000
Soldering Wire	Equipment	3	800	2400
Power supply	Equipment	1	10000	10000

ROBOTIC SOLDERING ARM

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