Project Report On Lathe Machine PR

The Hong Kong Polytechnic University Industrial Training Centre
Department of Electronic and Information Engineering Degree 2 Summer Term Project
The Hong Kong Polytechnic University

Industrial Training Centre
Department of Electronic and Information Engineering

Degree 2 Summer Term Project
Project Title: LED Thermometer

Project Report
Supervisor Name: Edward Cheung

Group Number: 01N05
Group Member: Chung Kai Man (99000964D)
Fan Hoi Wang (99274797D)
Fung Hon San (99195707D)
Ho Ka Wai (99189069D)
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Table of Contents
1. Introduction
1.1 Project Objectives
1.2 About Our Project
2. Product Features and Specifications
2.1 Descriptions
2.2 Technical Data (specifications)
3. Project Requirement
4. Project Planning
4.1 Job responsibilities
4.2 Time scheduling
4.3 Materials and development tools
5. Cost Analysis
5.1 Material costs
5.2 Manufacturing cost
5.3 End-product cost
6. Market Research
6.1 Target market segment
6.2 Similar products in the market
6.3 Comparison between your product and those in the market
6.4 Selling price level
7. Design philosophy
7.1 Hardware
7.2 Software
7.3 Material, casing and finishing
8. Manufacturing Process philosophy
8.1 Choice of processes
9. Testing strategies
9.1 Hardware
9.2 Software
9.3 Mechanical
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10. Mass Production Recommendations

10.1 Production Methodology
10.2 Production tools, fixtures and machines
10.3 Production Flow
11. Conclusion
12. Recommendation and future enhancement
13. References
14. Appendix
14.1 Material & Parts List
14.2 Production Planning Chart (PCB)
14.3 Production Planning Chart (Casing)
14.4 Manufacturing Process Instruction (PCB)
14.5 Manufacturing Process Instruction (Casing)
14.6 Cost & Delivery Estimation Form
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1. Introduction
1.1 Project Objectives:
Manufacturing and development projects are gradually important. They are becoming
integral part in the working lives that virtually all engineers will come across at various
stages in their career path.
For effective training, the manufacturing project work is structured that both staff of IC and
parent department act as the company top management, student project teams act as project
groups within a company. Each project is in the form of a prototype model and includes
component selection, layout of circuits, making parts, assembly and testing a prototype.
Finally, the stage is to document and present audiences the project. In this year, the
presentation style is changed from oral presentation, to web site presentation in the Internet.
Useful materials and presentation video clips should be found on the web site.
The project is structured that we can bring our previous knowledge and experience together
into one coherent activity. It is based on the assumption that students have already undertaken
and completed successfully the required basic IC training programs. Also it gives us a chance
to develop teamwork.
After completing this manufacturing project exercise, students will be expected to gain hand-
on experience of modern computer aids and equipment used in design, advance machine used
in manufacturing. Students will be also expected to gain a good understanding of the
importance of costs related to any decisions making, the methods used and factors considered
in the selection of the manufacturing process and materials. Finally, this training is designed
to develop students’ product development and manufacturing capability in their immediate
career after their graduation.
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1.2 About Our Project:

The ordinary types of thermometers are using alcohol or mercury for displaying temperature
values. However, due to the development technology, electrical thermometers are said to be
the new trend of thermometers.
In general, people prefer using 7 segment LED thermometers. It is because the display can
show the readings in numerical form so that the temperatures can be read more easily.
In our project, we had created a LED thermometer with an innovative idea that using many
individual LEDs for displaying temperature values. Such number of LEDs is the main feature
of this product. It is because the displaying style is completely different from that of 7
segment LEDs thermometers.
Our product is designed to measure room temperature. By the use of cell battery, it can be
portable.
Our project is divided into six stages, including design and planning, costing and parts
manufacture, PCB and casing assembly, testing, documentation, and final evaluation. Further
descriptions of each part will be found in the following paragraphs. If you would like to know
more about the manufacturing process and the operation of our product, LED thermometers,
you can refer to the Technical Manual and the User Manual.
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2. Product Features and Specifications

2.1 Product Features
The product name is called LED thermometer, it is used for measuring room temperature. As
mentioned in the introduction part, digital LED thermometer using 7 segment LED display is
the most common type in the digital thermometer world. And our product does not use 7
segment LED display, in contrast, we use a certain number of LEDs for displaying the
temperature values. Although 7 segment LED display can show numerical values, which can
be more easily to read, our product can be more attractive since there are more LEDs for
displaying the room temperature.
2.2 Technical Data (specifications):

LED thermometer uses AT89C51 as the micro-controller and DS1620 as the thermal sensor.
Although the sensor is work from –55oC to +125oC, the temperature range of it is limited
from 0oC to +59.5oC with the resolution 0.5oC since this product is designed for measuring
room temperature. The error over temperature range is ±0.5oC. If the temperature exceeds
+59.5oC, all the LEDs will turn off.
For convenient referencing, a specification table is provided as below:

Sensor Workable range –55oC to +125oC
Display range 0 to +59.5oC
Resolution 0.5oC
Error over temperature range ±0.5oC
Supply voltage 9V
Dimension 150mm × 60mm × 310mm
3. Project requirement
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Students were required to form a project group. Group members had to divide their works
themselves. Within the training period, the group member were expected to complete the
project as per project specification and deliver the project in the form of a set of
documentation. Documentation includes project report, user manual and technical manual.
Furthermore, time management is important. In general, the members decide to do the

specification, planning, components costing in the first week. For the second and third weeks,
they decide to do the design, drawing, manufacturing and assembly. Next, for the fourth
week, they decide to do the testing and evaluation, and documentation and preparation of
presentation in the last week.
With the above requirements, in general, the group members are divided into three groups.
The first one is for hardware producing which included designing, manufacturing and testing
the PCB. Another group is responsible for software programming which included deciding
what functions needed and testing whether the program work or not. The last group is for
casing which included designing of outlook and manufacture of the case.
However, these regulations are only for reference, for different project groups, they can
adjust their plan and job responsibilities according to their needs.
4. Project Planning
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4.1 Job responsibilities

For our group, there were only four members, the job responsibilities should be carefully
divided to each member.
Chung Kai Man: focusing on casing manufacturing, finally assembling

Fan Hoi Wang: focusing on schematic design, printed circuit board manufacturing
Fung Hon San: focusing on AT89C51 programming and web site development
Ho Ka Wai: focusing on photographing, documentation and miscellaneous work
All the tasks and responsibilities are listed below:
Tasks: Responsible by:

Market Research, Project Planning and Scheduling Ho Ka Wai
AT89C51, DS1620 and Serial Communication Studying Fung Hon San, Ho Ka Wai
Breadboard Emulation Fung Hon San, Ho Ka Wai
AT89C51 Programming Fung Hon San
PowerLogic, PowerPCB Fung Hon San, Fan Hoi Wang
Film Making Fan Hoi Wang
Printed Circuit Board Manufacturing Chung Kai Man, Fan Hoi Wang,
Fung Hon San, Ho Ka Wai
Casing Design Chung Kai Man, Fung Hon San,
Ho Ka Wai
AutoCAD Chung Kai Man
Casing Manufacturing and Finally Assembling Chung Kai Man, Fan Hoi Wang
Web Site Design and Development Fung Hon San
Photographing Ho Ka Wai
Documentation Chung Kai Man, Fan Hoi Wang,
Video Presentation Chung Kai Man, Fan Hoi Wang,
4.2 Time scheduling
Overall scheduling table:
Week No. Workout
Week 44 Specifications, Market Research, Project Planning
Week 45 Studying, including AT89C51 Programming, Sensor DS1620 Properties,
Serial Communication
Week 46 AT89C51 Programming Design, PowerLogic and PowerPCB Schematic
Design, Casing Design
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Week 47, 48 WINICE 8051~52-E Emulator Demonstration and Functional Testing

Week 48, 49 Film Making, PCB Production and Casing Assembling and Final Evaluation
Week 50, 51 Documentation, Web Site Development
Week 44: Specifications, Market Research, Project Planning

In this week, our group designed the specification of the LED thermometer and also planned
the overall workflow of the whole project. The original period of this project was from 3 rd
July to 2nd August (from week 44 to week 48), and the original schedule was planned at
shown in the following Gantt Chart.
However, this was an ideal plan. As there were some unexpected problems, we could not
follow this plan to do our project.
However, this was the ideal plan, and the following was the actual schedule that we had
achieved:
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On the other hand, we surfed the Internet to find information of some relevant products. More
detailed descriptions can be found from the Market Research part in this report.
Week 45: Studying, including AT89C51 Programming, Sensor DS1620 Properties,

serial communication
In this week, our group studied how to control the AT89C51 and learned how to access the
sensor DS1620. We surfed the Internet to get useful information, studied the data sheet of
both AT89C51 and DS1620, and also borrowed some books from library and studied them so
that we could be more familiar with its command sets. On the other hand, we spent some time
to study serial communication between AT89C51 and DS1620 since it was not included in
the training course last year. So, it was necessary to do some extra efforts.
Week 46: AT89C51 Programming Design, PowerLogic and PowerPCB Schematic

Design, Casing Design
In this week, we separated our group members into two main teams, the first one was
responsible for AT89C51 programming design, and the other team was responsible to use the
software PowerLogic and PowerPCB to design and draw the PCB circuit and also to use
AutoCAD to design the casing.
In fact, the programming and the schematic layout should be designed at the same time, and
they were highly related to each other. Each of them would affect the other one. For example,
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if one line of the schematic layout was changed, the programming should be adjusted
correspondingly.
Week 47, 48: Hardware Demonstration using WINICE 8051~52-E Emulator

After studying the AT89C51 and DS1620 in week 45 and the design stage of week 46, we
started to write the program in this week. There were totally three stages:
1) accessing DS1620,
2) programming for display, and
3) combining the transferred data with the display program to make the thermometer
workable.
We used breadboard and the WINICE 8051~52-E emulator to do the hardware

demonstration. Firstly, we tried to access the sensor DS1620. However, we spent much time
in this stage since the serial communication between two ICs was not covered in the training
course last year. Although we had studied the books, we still had some problems to do this
task. So, we tried many times and finally we succeed. After that, we wrote the program for
displaying LEDs. In this stage, we have found some problem for effective display. So we
simply adjusted the PCB layout.
Lastly, we wrote the overall AT89C51 program. This program used 3 wires of AT89C51 to
communicate with the sensor DS1620, one was data communication, one was clock pulse,
and the last one was RESET. By suitable settings, the AT89C51 could serially communicate
with the sensor, and we used some internal memory registers to store the temperature values.
Using the displaying program we just written, the temperature values could be visualized by
LEDs.
Week 48, 49: Film Making, PCB Production and Casing Assembling and Final
Evaluation.
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The hardware manufacturing processes, including film making, PCB production, casing
production and casing assembling were done within these two weeks. We applied the
knowledge and skill we had learnt in last to perform the hardware production. After finished
the hardware product, we used the WINICE 8051~52-E emulator to do an evaluation. After
this, we burnt the programme to the micro-controller AT89C51 and performed the final
evaluation.
Week 50, 51: Documentation, Web Site Development

In this week, we focused on doing documentation work and also web site development.
However, in fact, we started to do documentation work at the very beginning. Since we knew
that documentation should be done in certain progress.
We used MS Word, MS Excel, MS Project to make different reports, tables, and charts. All
the contents and format of these documents were fully followed the project guide. On the
other hand, we used Dreamweaver and Flash to create our web site. The content of the web
site was said to be simplified version of the report and manuals. It also contained soft copy of
the report, manuals, PCB layout, programme source code for downloading. Thus, customers
could browse to our web site, then they would have brief idea of our project. If they were
interested, they could download the files provided, and read them, then they would know
more details about the idea, manufacturing process and also the operations of our product.
4.3 Materials and development tools

Components List:
Resistors: R1–R8, R11–R14 = 220Ω
R9 = 100kΩ
R10 = 2kΩ7
Capacitors: C1 = 82pF
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C2, C3 = 100nF
C4 = 100mF 16V radial
Semiconductors: D1–D29 = LED, high efficiency, red
D30, D31, D32 = LED, high efficiency, yellow
D33 = IN4148
IC1 = DS1620
IC2 = AT89C51
IC3, IC4 = 74LS244
IC5 = 7805
Miscellaneous: PC1, PC2 = solder pins
Development tools list:

Cathode-Ray Oscilloscope
WINICE 8051~52-E Emulator
Photo Film Making Machine
UV Exposure Unit
Power Supply
Multi-meter × 2
Breadboard × 2
Lathe Machine
Cutting Machine
Drilling Machine
NC Drilling Machine
Hand tools (Drilling & tapping, solder iron, etc.)
5. Cost Analysis
For detailed information, please refer to the Cost & Delivery Estimation Form in the
appendix.
5.1 Material costs
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From the Cost & Delivery Estimation Form, we can see that the material cost for
manufacturing a LED thermometer is $161.76.
5.2 Manufacturing cost

In the manufacturing process, we found that the total man-hour should be 3 hours. These 3
hours are the period of mass manufacturing, so, the period is much shorter than that we
manufacture the product manually. The rate of a man-hour is $30, so the labour cost in
manufacturing is $90.
5.3 End-product cost

From the MS EXCEL file, we can see that the total cost of manufacturing is $368.76. So we
considered that the selling price of the LED thermometer would be $442.51.
6. Market Research
6.1 Target market segment
The product is LED thermometer, and it is mainly used to measure the room temperature. On
the other hand, it can be used as decoration, it is suitable placing at office and home.
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So, the target market is very large, everybody wanted to have a room temperature
thermometer are the target market of our product.
6.2 Similar products in the market

From the Internet, many same kinds of products can be found. LED thermometers using 7
segment LED for displaying temperature values are very common. However, we could not
find any examples using as much LEDs as our product.
Product Name Price Descriptions

Economical and versatile LED HK $544 Large, brightly lit display easily readable from long distances.
Digital Thermometer 5’connector tubing to air probe for sensing air temperature in remote
location (longer lengths available; contact us for pricing).
Designed to be surface mounted with two #4 screws through case; to

flush mount, simply cut a 0.875” × 1.75”opening on a panel and
fasten with two screws.
Optional flush mount on stainless steel electrical box cover plate,

which installs on conventional electrical box, found at local hardware
stores
 Display: LED red in color 0.56” high.

 Range: Available in either: -40 to +120oF or -40 to +50oC.
 Power: 12 VAC or 12 VDC, recognized transformer included.
 Calibration screw located on back of unit to allow for easy
adjustment of temperature reading.
 Accuracy: ± 2oF
 Dimensions: 0.85” × 1.75” × 2”(W × L × H)
Digital Solar Powered Air HK $232 Can mount on outside of room to read inside air temperature or
Thermometer directly in room. 56” connector tubing to air probe for sensing air
temperature in remote location. Solar powered with a battery (AAA)
back-up system enables instrument to operate in low light levels.
Estimated battery life is 3-4 years.
 Accuracy: ±2° F
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 Range: -50° to +158°F (-50 to +70°C, available by special

order)
 Dimensions: 4½” wide x ½” deep x 1” high
 One year warranty
Digital LED Thermometer HK $240 This high bright LED digital thermometer uses an LM35 National
Semiconductor IC as its temperature sensor. It shows the temperature
with an accuracy of 0.5°C on its digital display. The thermometer's
range is from 0 - 99°C.
Digital Thermometer Sensor HK $450 It is well suited for use as a conventional thermometer. The digital
With LED Display display gives the current temperature, the minimum temperature and
the maximum temperature consecutively. When a 'rest' key is pressed
the highest and lowest temperatures measured are stored and, if
necessary, adjusted. An aluminum case is supplied with the kit, to
allow the thermometer/sensor to be mounted on a wall. The sensor
can be mounted anywhere with plain telephone wire. Minimum: 6
inches long, Maximum: 5 feet long. Use a switch to flip back and
forth between inside temperature and outside temperature. Extra
sensors are sold separately.
 Range: -50°C to + 150°C

 Linearity from -10°to +50°: better than 0·5%
 Accuracy: better than 2%
 Adjustable to degrees Fahrenheit
 Display: 31/2 digits (0·1° display accuracy)
 Supply voltage: 12 to 15V DC/I50mA
 Dimensions: 144 × 50 × 22mm
Indoor/Outdoor Thermometer HK $284 Great for measuring temperature variances of walk-in coolers,
ripening rooms, any refrigerated area, or home inside / outside
temperatures.
 10' sensor cord allows for easy remote monitoring.

 Max/Min memory records the high and low temperatures.
 1.25" LCD Display
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 -58° to +158°F (°C model available by special order)

 1.5 volt battery included
 Hangs or Stands
6.3 Comparison between your product and those in the market

As mentioned before, the main difference between our product and those in the market is the
display style. Most of the products in the market are using 7 segment LEDs for displaying the
temperature values, and our product uses large number of LEDs for the display.
Secondly, the size of our product is larger than that of those in the market. The reason is that,
our product is a standalone LED thermometer and it can be used as decoration too. In
contrast, those digital LED thermometers in the market can be used as add-ons to other
electronic products.
In general, the 7 segment LED thermometers can be used as room temperature thermometers,
clinical thermometer, and also can be used as add-ons accessory to other electronics products
such as computer motherboards.
6.4 Selling price level

From the above table, the thermometers selling prices are generally from about $200 up to
about $600.
7. Design philosophy
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The hardware should match with the software. Either one of them had been changed, the
other one should also be adjusted. This showed the importance of the relationship between
hardware and software.
In order to give out an impression that the product is a thermometer, the arrangement of
LEDs is limited, the best way for displaying temperature values is one single vertical line.
This arrangement can provide clear view for reading. Besides, it also can give an impression
that the temperatures rise from low to high.
7.1 Hardware
At the heart of the circuit is a AT89C51 micro-controller. The micro-controller reads
temperature data from a sensor IC. The micro-controller has the job of displaying the
measured value on 32 LEDs.
In order to minimize the number of connections for a large number of display elements, the
32 LEDs are driven in a multiplexed fashion. Four additional LEDs are permanently lit and
indicate the tens of degrees, making the display easier to read.
However, since so many LEDs should be connected to the 40 pins AT89C51 micro-
controller, and we should arrange the LEDs in a single vertical line, the circuit lines would be
tight.
On the other hand, the AT89C51 should communicate with the sensor DS1620 and control
two buffers 74LS244, the circuit would be complicated and it was impossible to cover all the
lines without shorting in single side. As a result, we used double sides PCB at our board. By
this method, the circuit could be routed without shorting.
7.2 Software
As the AT89C51 microprocessor is used for controlling the temperature sensor DS1620, all
data are communicated over an I2C bus. By serial communication, the data generated from
the sensor DS1620 will be sent to the AT89C51 for calculation. And the number of light
LEDs will show the corresponding temperature values.
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By the use of AT89C51 programming, we can drive 32 LEDs through 14 ports only. The
LED matrix is divided into four groups, the first and second columns consisting of 10 LEDs,
the third column consisting of 9 LEDs and the last column consisting of 3 LEDs. These
groups are driven from port pins 14–17 in sequence, so that at most ten LEDs are ever lit
simultaneously. The LEDs are turned on by setting port pins 21, 22, and 32–39 to high. With
a low level of port pins 14–17, the appropriate group of LEDs is enabled. Although only at
most ten LEDs are on at any one time, the multiplexing happens so fast that the visual
appearance is that up to 32 LEDs are lit.
The overall temperature range from 0oC to +59.5oC is divided into two ranges (0 to +29 oC
and +30 to +59oC), as indicated by the two LEDs D31 and D32 respectively. The odd 0.5oC is
indicated by the remaining range LED D30. So, for example, at 20.5 oC, the LED D30 turns
on, and also the LED D31 lit for indicating a temperature between 0oC and 29oC. If the
temperature exceeds the minimum and maximum limits, i.e. 0oC and +59.5oC, all the LEDs
will turn off. So, it was necessary to consider the temperature values during calculation. By
separating the values into 2 parts, we could use different LEDs for indication.
7.3 Material, casing and finishing

7.3.1 Material
Our product comprise of there parts, they are the acrylic surfaces, aluminum frames and
PCB. The surfaces are made of two piece of acrylic sheets, we choose this material to
make the surface is because acrylic sheet is tough enough to avoid breaking, and it is
relatively lighter than the others materials, such as aluminum sheet, stainless steel sheet
etc. Also, acrylic sheet is easy to be cut and drilled when compare with the other
materials, and the surface of acrylic sheet is clean and smooth for a good appearance, so it
is a good material to use as a surface part of our product. Furthermore, after the sheets
are cut and drilled, we want to add some colors on the back of the acrylic surfaces to
improve the appearance. Since acrylic sheet is transparency, so prints the colors on the
back of the surfaces will provide a brighten surfaces, and the effect are really good.
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And about the frame of our product, we have chosen aluminum bar to support the acrylic
surfaces. The reason for us to choose aluminum bars and do not use the acrylic bars or
the other materials is if we use acrylic bars to support the surfaces, then our product will
be totally used plastic to accomplish, since we had chosen acrylic sheet to use as our
product’s surfaces, so we have chosen the other materials to used as our product’s frame.
When comparing the common used materials, we think aluminum is the best material to
do as our frame, since it is lighter than the other materials, such as brass, copper, stainless
steel, etc. Also, it is easy to cut on the lathe, and the appearance of the surface of the
aluminum bar is very good and bright. Moreover, the combination of acrylic sheet and
aluminum bar can give an attractive appearance.
7.3.2 Casing
Since our fellows want to use one piece of PCB for circuit design, so the size of our case
will be based on the size of the PCB. Also the shape of the case is based the application
of the product to design, since our product is a LED Thermometer, so we will design a
thing that can impress the user think it is related to temperature. As the result, we decided
to use a ‘cactus’ diagram as the shape of our product’s casing, since cactus is a plant
grown in desert area, so it can impress the user think of temperature. Apart from this,
designing our surface as a ‘cactus’ shape can also provide a decorative purpose. And
since we will place the PCB on the casing, so we decide to produce four aluminum bars to
attach the PCB on the casing. And the four aluminum bars are used as a bolts and nuts,
so that they can attach the surfaces and the PCB.
Furthermore, our product is a thermometer, so the sensor must be placed in a good

ventilated area. In order to overcome this problem, we attach the PCB between the two
same shape surfaces like a ‘sandwiches’, thus the sensor can directly contact the
surrounding, and this can improve the accuracy of the thermometer. Moreover, since the
back of the surfaces will be printed with oil, so in order to let the LEDs can be shown
clearly, we decide to cut a gap and drill some holes on the front surface to let the LEDs
expose on the surface.
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8. Manufacturing Process philosophy

8.1 Choice of processes
a. PCB layout design
b. Film Making
c. Production of PCB board
d. Casing Production
a. Procedures of PCB layout design

We applied the knowledge we learnt last year to produce the PCB layout.
Firstly, we used the software PowerLogic to design the circuit. And then we used the
auto route function of software PowerPCB to design the layout.
b. Procedures of Film Making

In last year, we attended a class talking about how the film could be made. However,
we did not have hand-on experiences. In this year, technicians arranged a brief talk to
remind us about the film making procedures. After that, we followed the procedures
to make the film. The procedures are listed below.
1. prepare a piece of paper that the required circuit was printed on it, the layout
should be printed as the actual circuit size of the product
2. bring this PCB layout to the dark room
3. put the layout copy on the photo film making machine
4. adjust the focus of the machine so that we can make photo film at 1:1 scale (in
general, the scale should be 2:1 so that the film can be more accurate,
however, since our PCB layout was too large, the scale is limited and we
finally used the scale of 1:1)
5. turn off the light and place the film on the machine
6. undergo the exposure film
7. undergo developing and fixing
8. dry out the film
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c. Procedures of PCB Production

Our group applied the skill that we learned in last year to produce the printed circuit
board, the procedures are listed below.
1. use NC drilling machine to drill required holes of the PCB
2. use sand paper to make both sides of the PCB smooth
3. clean the board and put it in the oven at 60oC for few minutes
4. after the board is cooled down, cut dry film to size (the size of dry film has to
be equal to or smaller than the size of the PCB)
5. remove unnecessary skin of the dry film
6. use a heat rolling machine to attach the dry film on the copper side of the
board
7. by the UV light machine, the circuit layout could be printed on the dry film
8. repeat step 4 to step 7 for another side of the PCB
9. remove another skin of the dry films and then drill a hole, tighten a wire on it
10. put the board into developer so that only the circuit layout is remained, repeat
step 3 again
11. check the circuit lines clear or not, if the lines are not clear, use PCB marker to
fill them
12. put the board into the etching tank (ferrous chloride) to corrode unnecessary
copper
13. put it into the stripper to remove the remaining dry film and then repeat step 3
14. chop the board in size and debur edges
15. assemble required components and wires on the board
16. apply voltage the circuit and test whether it is work or not
d. Procedures of Casing Production

Surface Production:
1. use pencil to draw the desired ‘cactus’ diagram on the acrylic sheet
2. cut it out by using saws
3. then file the edges of the surface until the edge become smooth and accurate
enough
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4. place the ‘polished’ surface on the other piece of acrylic sheet

5. use pencil to copy the shape on the sheet
6. then repeat the above procedure until two surfaces have been polished
7. use pencil to mark the desired gap on the front surface
8. drill two holes on the upper and lower part of the ‘gap’ by using a suitable
twist drill
9. then use a saw to cut the gap out of the surface
10. file the edge of the gap until it reaches the marked pencil line and become
smooth enough
11. for the other holes, using appropriate twist drills to drill after using pencil
marked
Frame Production:
1. use some cutting tools in the lathe to cut the bar into suitable diameter
2. drill holes on the lathe by using appropriate twist drills
3. use cutting knife to cut the parts out of the aluminum bar
4. to produce a bolt, cramp the parts on the vice
5. then turn the die clockwise to cut the axis with screw
6. to produce a nut, cramp the parts on the vice
7. turning the tap clockwise to cut the hole with screw
Oil printing:
1. draw the desired diagrams on the paper of the surface
2. cut the paper out by using a knife
3. use oil sprayer to spray the suitable color onto the exposed surfaces
4. then repeat the above process until the whole surfaces are filled with colors
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9. Testing strategies
9.1 Hardware
Firstly, having etched, use a multi-tester to check any open or short circuit of the PCB circuit
board. Secondly, using multi-tester to check the accurate values of the resisters and
capacitors. Thirdly, the correct model numbers of the ICs. With a power supply +5V
connected to the ICs on the breadboard, we use a CRO to test the wave forms of the signals
from ICs. Checking whether there is signal in the ports required.
Finally, as incorrectly fitted LED, capacitors or ICs may be hard to track down, the polarities
of those components should be correctly oriented in the copper board.
The sensor device should be positioned at the bottom of the circuit, allowing remote
mounting if it is desired to measure the temperature outside. Also it should be positioned far
away from IC5 (7805) which is very hot if the device operates for a long time to avoid
affecting the temperature measured by the sensor.
9.2 Software
We used the emulator to test the software. First, we separated the program into 2 parts, the
sensor communication part and LED display part, and test both part one by one.
For the sensor communication part, we use the testing board to simulate the hardware and use
the CRO to test the input and output signal.
For the LED display part, we use the emulator and the final hardware product to test the
program. We set the port value of the emulator to test the program and the LED display.
Finally, we combine 2 parts together and get the final program.
9.3 Mechanical
Page 24
In fact, the mechanical testing strategies were not complicated. What we necessary to do was
checking whether the aluminum frame could tightly mount the acrylic sheet and PCB or not.
10. Mass Production Recommendations

10.1 Production Methodology
PCB:
To begin with mass production, we first prepare the PCB circuit file, NC drilling file and
film. The production department should be divided into 5 main sections in sequence: PCB
Board Section, Assembling Section, Circuit Testing Section, Casing Section and Quality
Control Section:
1. In the PCB Board Section:

It aims to produce drilled PCB boards. To prepare copper board, it is desirable to
prepare copper board with the sizes are multiple of the standard board.
The copper boards are drilled by NC drilling machines before exposing UV light. The
copper boards wrapped with dry film are exposed by UV light in UV light Unit to
produce PCB artworks layout onto the copper board before etching. In the process of
etching, a number of copper boards are etched together. At the end of etching process,
there is visual checking for any incomplete etching boards or damaged traces on the
circuit.
Finally, a number of etched copper boards are transported to the Assembling Section.
2. In the Assembling Section:

It aims to assemble all the required components onto the etched copper boards. For
the sake of convenience of assembling components, all the resistors are bend with size
fitted with the size of holes. All the components are randomly tested by CRO or
multitester to minimize the possibility of malfunction of the components. Having
placed all the components onto the copper boards by robot arms, those boards are
transported to the wave soldering machines for soldering. At the end of soldering,
there is visual checking for any incomplete soldering components.
Page 25
3. In the Circuit Testing Section:

It aims to test the function of the device (LED Thermometer) with power supply
provided and investigate any infects. The ICs are tested by CRO to check their signal
functions. This process is done by labour. Any failed devices will be disposed into
Recycle Unit.
4. In the Casing Section:

Having tested, the painted cases are assembled with the circuit boards together by
robot arms.
5. In the Quality Control Section:

The LED Thermometers are randomly picked up for QC checking. Any failed LED
Thermometers are transported to the Circuit Testing Section for further investigation.
Finally the LED Thermometers are packed by machines that will be distributed to
retailers.
Casing:
The fabrication process of the product ‘LED Thermometer’ can be divided into three parts;
they are (1) Surfaces production, (2) Frame production and (3) Oil printing. Then we will
describe each part briefly as follows:
1. Surface production
To produce the surfaces of the ‘LED thermometer’, for the mass production, we want
to draw the desired diagram in the AutoCAD in a suitable scale, then save this file.
Then import this file into the computer cutting machines, and then the cutting
machine will cut and polish the surfaces automatically and accurately. Finally, import
the same file into the computer drilling machines, the drilling machine will drilling
the holes with appropriate diameters.
Page 26
2. Frame production
To produce the frames of the ‘LED thermometer’, for the mass production, we want
to draw the desired dimensions of the frame in the AutoCAD, then save this file.
Then import this file into the computer lathes, and then adjust the cutting priorities,
then the lathes will cut, drill and tapping the frames automatically and accurately.
3. Oil printing
To add some colors onto the surfaces of the casing, for mass production, we want to
set up a program to control the oil printing machines. First, we use the oil printing
machine built-in program to design which areas will want which color, then the
machine will be print the desired colors onto the surfaces.
10.2 Production tools, fixtures and machines

PCB Production tools:
1. NC Drilling Machine
2. UV Exposure Unit
3. Image Maker
4. Etching Tank
5. Wave Soldering Machine
6. Cutting Machine
7. Cathode-Ray Oscilloscope
8. Multi-meter
Casing Production tools:

1. Lathe Machine
2. Drilling Machine
3. Cutting Machine
Page 27
10.3 Production Flow
PCB Production
PCB Board Section
In case of
Assembling Section failure
Recycle Unit or
Circuit Testing
Investigation
Unit
Casting Section
Quality Control
Section
Retailer
Page 28
Surface Production Frame Production Oil Printing
Design the outlook of Design the outlook Design the

of the frames graphics of the
the surfaces
surfaces
Consideration of Consideration of Color selections

the surfaces the frames
dimension dimension
Oil printing
Draw the desired Draw the desired
design on the design on the
AutoCAD AutoCAD
Acrylic sheet Aluminum bars

cutting cutting
Holes drilling Holes drilling
Tapping
Page 29
11. Conclusions
11.1 Problem Encountered
There were several problems encountered within the manufacturing processes. In fact, the
original LED thermometer used COP8782 as the micro-controller. It was a 20-pin integrated
circuit that had many features that make it particularly well suited to this project:
1.1 4096 × 8 (OTP) EPROM

1.2 128 bytes RAM
1.3 1 ms cycle time at 10 MHz
1.4 16 bit timer with automatic reload, external event counter and capture functions
1.5 16 I/O pins, 14 of which can be individually programmed as inputs or outputs
1.6 Selectable tri-state, push-pull or pull-up I/O pin configuration
1.7 Microwire interface
1.8 Timer, software, and external interrupt sources, with programmable polarity
And the original schematic design is shown as following diagram.
Page 30
This was designed by the Elektor Electronic Company. As we can see from the diagram,
COP8782 was used as the micro-controller to control the thermal sensor DS1621. Because of
the limitation of development tools, we use the AT89C51 as the micro-controller and the
DS1620 as the thermal sensor.
However, AT89C51 is 40-pin integrated circuit, the original schematic design used in Elektor
Electronics project should be revised. We changed the design by setting the number of each
column from 8 to 10.
11.2 Experience gained

After this industrial training programme, we had gained much valuable experiences. We had
refreshed our memory of assembly programming, PCB manufacturing procedures. We also
learnt how to use the cutting machine and lathe machine to produce the casing.
Besides, manufacturing process, we know the importance of project planning. If a good

schedule was made before doing any process, the efficiency will be much better than no
schedule and no planning.
Page 31
12. Recommendation and future enhancement

Since decoration can be subjective, no suggestions can be provided. However, focusing on
the functions, we have thought about several recommendations or future enhancement.
Although our production can function properly, the temperature display is flashing during
measuring the temperature values. To overcome this, the delayed function of the programme
and the frequency of the crystal should be considered and changed.
By adding extra components to the PCB and design computer programme with an interface,
the thermometer can communicate with computer. By the use of this programme, maximum
temperature record and minimum temperature record of the whole day can be displayed.
Memory refresh should be done within the programme too.
On the other hand, if available, adding a microphone and extra circuit design, the
thermometer can be used to measure and display sound noise. A switch can activate this
function. By pressing the same switch, the product will measure temperature again.
13. References
1. Dallus Semiconductor http://www.dalsemi.com
2. Elektor Electronic Company http://www.elektor-electronics.co.uk
3. RS Components Ltd. http://www.rswww.com.hk
4. METAL Design and Fabrication / David and Susan Frisch, New York : Whitney
Library of design, 1998.
5. The 8051 microcontroller and embedded systems / Muhammad Ali Mazidi, Janice
Gillispie Mazidi, Upper Saddle River, N.J. : Prentice Hall, c2000.
Page 32
6. The 8051 microcontroller : architecture, programming, and applications / Ayala,

Kenneth J., Minneapolis/St. Paul : West Pub., c1997.
Page 33

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The Hong Kong Polytechnic University Industrial Training Centre

Department of Electronic and Information Engineering Degree 2 Summer Term Project

The Hong Kong Polytechnic University

Department of Electronic and Information Engineering

Project Title: LED Thermometer

Supervisor Name: Edward Cheung

10. Mass Production Recommendations

1.2 About Our Project:

2. Product Features and Specifications

2.2 Technical Data (specifications):

For convenient referencing, a specification table is provided as below:

Furthermore, time management is important. In general, the members decide to do the

4.1 Job responsibilities

Chung Kai Man: focusing on casing manufacturing, finally assembling

All the tasks and responsibilities are listed below:

Tasks: Responsible by:

Week 47, 48 WINICE 8051~52-E Emulator Demonstration and Functional Testing

Week 44: Specifications, Market Research, Project Planning

Week 45: Studying, including AT89C51 Programming, Sensor DS1620 Properties,

Week 46: AT89C51 Programming Design, PowerLogic and PowerPCB Schematic

Week 47, 48: Hardware Demonstration using WINICE 8051~52-E Emulator

We used breadboard and the WINICE 8051~52-E emulator to do the hardware

Week 50, 51: Documentation, Web Site Development

4.3 Materials and development tools

Development tools list:

5.1 Material costs

5.2 Manufacturing cost

5.3 End-product cost

6.2 Similar products in the market

Product Name Price Descriptions

Designed to be surface mounted with two #4 screws through case; to

Optional flush mount on stainless steel electrical box cover plate,

 Display: LED red in color 0.56” high.

 Range: -50° to +158°F (-50 to +70°C, available by special

 Range: -50°C to + 150°C

 10' sensor cord allows for easy remote monitoring.

 -58° to +158°F (°C model available by special order)

6.3 Comparison between your product and those in the market

6.4 Selling price level

7.3 Material, casing and finishing

Furthermore, our product is a thermometer, so the sensor must be placed in a good

8. Manufacturing Process philosophy

a. Procedures of PCB layout design

b. Procedures of Film Making

c. Procedures of PCB Production

d. Procedures of Casing Production

4. place the ‘polished’ surface on the other piece of acrylic sheet

Finally, we combine 2 parts together and get the final program.

10. Mass Production Recommendations

1. In the PCB Board Section:

2. In the Assembling Section:

3. In the Circuit Testing Section:

4. In the Casing Section:

5. In the Quality Control Section:

10.2 Production tools, fixtures and machines

Casing Production tools:

10.3 Production Flow

PCB Board Section