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GAS TORCH SOLDERING IRON WITH ADJUSTABLE LIGHT

(A TECHNICAL FEASIBILITY STUDY)




Gas Torch Soldering Iron with adjustable light:
A Technical Feasibility Study









In partial fulfillment
of the requirements for the degree
Bachelor of Science in Computer Engineering













MARY GRACE V. RAMOS
CARLA CAMILLE C. CLOSA
October 2014



BIOGRAPHICAL DATA

Carla Camille C. Closa was born on July 4, 1996 in Paradahan, Tanza, Cavite.
She is the second of child among three children of Mr. Roger and Norma Closa. She currently
resides at Tanza, Cavite.
She finished her primary years at Paradahan Elementary School and Secondary years at
Tanza National Trade School. And currently in her Second year college in Bachelor of Science
in Computer Engineering at Cavite State University-Main Campus Indang Cavite.
Mary Grace V. Ramos was born on July 8, 1997 in Fairview, Quezon City. She is the
youngest among the two children of Mr. Melchor Ramos and Mrs. Gloria Ramos. She is
currently resides at Tanza, Cavite
She finished her primary years at Maysan Elementary School and Secondary years at
Luis Aguado High School. And currently in her Second year college in Bachelor of Science in
Computer Engineering at Cavite State university-Main Campus Indang, Cavite.


ACKNOWLEDGEMENT
The author would like to express their warm appreciation to the following special persons
who given their precious time and support from the planning up to the completion of the study;
First the author would like to thank and show our love to the Almighty GOD for the good
health and guidance given to us through while the hardship and problem from the start up to the
end of the project.
Ms. Rey Ann Maramag and Mr. Jansee Dinco, our adviser, for their excellent ideas for
the completion of his project and for bringing out eexceptiona traits in us, for their valuable
support and suggestion, and enduring assistance throughout the development of the study and our
English critic for her suggestions and comments for the improvement of the study,
Ms. Keith Ann Closa and Mari Geo Hilary Ramos for their suggestion and
recommendations to improve this study;
Mrs. Norma, Mr. Roger Closa and Mrs. Gloria, Mr. Melchor Ramos, authors parents for
their financial and emotional assistance fo the completion this project;
The authors would like to thank their friends, especially Christian Alan Tambaoan and
John Daryll Agor for their suggestion for the improvement of the research;
Lastly we would like to thank our friends, and all BSCpE 2-1 batch 2014-2015
who were always there to spend their time in helping us finish this project.
TO GOD BE ALL THE GLORY!!
MARY GRACE V. RAMOS
CARLA CAMILLE C. CLOSA

Abstract
RAMOS, MARY GRACE V. and CLOSA, CARLA CAMILLE C., Gas Torch Soldering
Iron with Adjustable Light: A Technical Feasibility Study. Undergraduate Design Project.
Bachelor of Science in Computer Engineering. Cavite State University, Indang, Cavite. April
2014. Adviser: Mrs. Rey Ann Maramag and Mr. Jansee Dinco

This technical feasibility study aimed to design, test, and revise a gas soldering iron with
adjustable light as an answer to the foremost problem, which is inadequacy of tools and
equipment in electrical, electronics and shop laboratories.
Specifically this study attempted to construct a gas torch soldering iron with adjustable
light out of locally available materials.
The significant findings of the study show that the soldering iron can be of great
help to the student. It is feasible for the student to produce and improvise a gadget to enhance the
teaching learning process. The gas torch soldering iron with adjustable light is much cheaper
than its commercial counterpart.
The gas torch soldering iron with adjustable light is technical feasible that its design and
construction are simple since all supplies and materials needed in the construction are available
in the local market. The gadget cost is Php 771.00 only.


TABLE OF CONTENTS
BIOGRAPHICAL DATA............................................................................................................ii
ACKNOWLEDGEMENT...iii
ABSTRACT.....iv
LIST OF TABLES....v
LIST OF FIGURES..vi
Introduction..1
Statement of the Problem.2
Objective of the Study......3
Significance of the Study..4
Time and Place of the study..5
Scope and Limitation6
Definition of Technical Term...7
REVIEW OF RELATED LITERATURE9
MATERIALS AND METHODOLOGY.14
Material14
Method. ...17


Reference

A. BOOKS

Malvino, Albert, Bates David J. 2007, Electronic Principles,
the McGraw-Hill Companies, New York 7
th
Edition.

Neamen, Donald A. 2007, Micro Electronics Circuit Analysis and Design,
the McGraw-Hill Companies, New York 3
rd
Edition.

Kleinert, Eric 2007, Troubleshooting and Repairing major appliances,
The McGraw-Hill Companies, New York 2
nd
Edition.
Harper, Charles A. Electronic Assembly Fabrication,
The McGraw-hill Companies, New York, 1
st
Edition.

B.UNPUBLISHED MATERIAL

Bautista, Richard H., Mark G. Dela Cruz, and Mart V. Esquerra, 2006,
Rechargeable Soldering Iron: A Technical Feasibility Study
Cavite State University-Rosario

Buisel, Apollo Bryan F. and Cherrry Maty Enriquez, 2009
Soldering Station: A Technical feasibility Study
Cavite State university

Bangcaya, Cyndhee C., and Edmar V. Gaton, 2007
Electronic Circuit Board and Low Voltage Power Supply Trainer: A Technical
Feasibility Study
Cavite State University


C.ONLINE REFERENCE
https://www.google.com.ph/webhp?sourceid=chromeinstant&ion=1&espv=2&ie=UTF-8
http://en.wikipedia.org/wiki/Butane
http://en.wikipedia.org


Introduction

Across the globe, soldering of iron has been practiced for many years, as it used for
melting and flowing a filler metal into the joint, the filler metal having relatively low melting
point, and the two or more metals items will connect together. Soldering is characterized by the
melting point of the Ciller metal, which is below four hundred (400) degree Celsius. A skill in
soldering is required for each electrician and technician to have, as it is involved in fixing
wirings or electronic component. In the thesis conducted by Kurina Baksh entitled "Hand Tools
Analysis and Redesign" (2007), the researcher concluded that in a manufacturing panel. After
carefully observing the work process, the tool design and workspace design were identified.
Thus this paper seeks to evaluate the job task, tool design and workspace design with respect to
its ergonomic effectiveness and to suggest for improvement.
The usual soldering iron is powered by an electricity, it was plugged in to an electric
socket and it well served as a source of it energy to work. The intended use of the electricity
dictates the degree to which the electric will processed before being used. In some certain
construction, such as using gas in an equipment to run the soldering iron, while the other
equipment, including a rechargeable soldering iron but it still requires electric energy.
The researcher chose to design Gas Torch Soldering Iron with Adjustable Light because
this equipment is great for workings in location where there may be no main power supply are
available. It can reach into equipment without having to trail a power cord, so they work well in
difficult or inaccessible of electricity.

STATEMENT OF THE PROBLEM

The main focus of the study is on how to craft a gas torch soldering iron with adjustable
light is easy, meaningful and functional to use for soldering purposes.
There is some places locally located where may be experiencing the difficult power
supply. Poor power supply can cause several black out or power interruption. Electricity tools or
equipment can be used in this kind of situation. Instances like typhoon that can cause power
interruption and damage electronic properties and equipment that longing for more than a weeks.
In case of emergency that you need to solder, Gas Torch Soldering Iron with Adjustable Light
may use instead of electric soldering iron.
Wires and metal that need to solder are small and sometimes they are hard to fix. Many
of electronics repair shop are crowded and experience poor light source. Most of the shop are in
a small station and having small space, can occupy and install one light for the whole station. As
a technician needs to fix or solder metal item they need to use a flashlight to focus on their work.
As a solution for those problems the researchers develop and design a Gas Torch
Soldering Iron with Adjustable light.



Objectives of the study
The general objectives of the study is to design a gas torch soldering iron with adjustable
light.

Specific Objectives
1. To design and construct the soldering electronics equipment;
2. To design and construct soldering iron powered by a gas;
3. To design and construct a gas torch soldering iron with adjustable light;
4. To develop the gas torch soldering iron with adjustable light would be helpful in case
of emergency like power interruption.
5. To construct it out of locally available materials
6. To test and evaluate the performance of the equipment through testing; and
7. To determine the cost of the development







Significance of the Study
The study was conducted to develop a soldering tool that is more effecient to use. This
study is significant that it would give benefit.
To the student, this study would help them in their practical exam as it provides an add-
on feature that would simplify their work. This Gas Torch Soldering Iron with Adjustable Light
help the student do some independent thinking to acquire quality control. It serves as a new
project for the electronics shop expose to a production type of job that is similar in the field of
technology.
To the technician, this study would help them to simplify their work in soldering. It is good
for them to experience to the Gas Torch Soldering Iron for them to learn how to use, and know
the efficiency using Gas Torch Soldering Iron other than the usual soldering Iron
To the society, the use of Gas Torch Soldering Iron is an option in case of electricity
emergency. It can also help may be some areas having electricity difficulty.
For the future researchers, this study would give new insight, which hopefully, could be
developing in the future researcher.





Time and Place of the Study
This project design was constructed at Cavite State University-Main Campus Indang
Cavite at College of Engineering and information Technology under the Department of
Computer and Electronics Engineering. It was completed from July 2014 to October 2014.














SCOPE AND LIMITATION
The study was focused on the design, construction, test and evaluation of a Gas Torch
Soldering Iron with Adjustable Light. The project is intended for one-handed soldering operation
This study is limited only to the soldering and de soldering operation but not to soldering
electronic component. It takes about ten (10) seconds to fill the cylinder using Butane Gas Fuel.
The Gas Torch Soldering Iron could only use up to thirty (30) minutes in one full load of Butane
Gas. Light limited only to the soldering in case of dark operation can last at least five hours in
use, because it is only battery operated. It can solder without wasting gas, because it can be
turned off and on.
The researchers construct the Gas Torch Soldering Iron with Adjustable Light out of
locally available materials. It is constructing of Adjustable Knob, Torch, Copper Tube, Filter
Valve, Metal Multi Fill Adaptor, Gas Cylinder, Metal Tube Feasible, Soldering Torch and L.E.D
light. It is technically feasible due to the fact that its design is simple and construction is
available in the market.
The project would thereby help the student and technician to solder easily and effectively.
The design of the Gas Torch Soldering Iron allows the Butane Gas to serve as a
replacement of electricity. The built-in Adjustable Light for the Gas Torch Soldering Iron is
powered by a nine 9) volts battery, that give light to the part that is being soldered.
In case of emergency, problem in electricity black-out or power interruption. Electricity
black-out can be cause by a poor supply from its main power. The availability of the equipment
is reliable enough when some unexpected situation arises.
DEFINITION OF TERMS

For common understanding, the following terms are defined as used in the study:
Adjustable lights. It gives light to the surface that is being mounted in case of dark
operation.
Battery (9 volts). It gives power to the light.
Butane gas. Highly flammable, colorless and easily liquefied gas.
Gas torch soldering iron. It is a gadget that is fast heating metal using butane gas fuel.
Lead. It refers to a conductor that connects a winding to its terminal.
Soldering tip. The part of a device that is connected to the heating element that causes
the lead to melt.
Adjustment knob- controls the flow of gas.
Gas Cylinder- it is a gadget that is fast heating metal using butane gas fuel.
LED Light- source of light for the built-in adjustable in gas torch soldering iron
Plastic Multi-fill adaptor- this serves as reloading station of the butane gas
Gooseneck- it is flexible metal used to adjust the lights from where you want to apply the
lights
Filter valves- it filters the incoming flow of gas.








Chapter II

Review Related Literature

This chapter deals with the review of related literature and studies, the operational definition of
terms used in the study and the conceptual framework of the study.

SOLDERING IRON
Makiyenko (1990) stated that soldering is applied to the process of joining metals together by
means of fusible metal or alloy known as solder. The process called brazing is closely related
soldering, but uses harder materials hard solders and requires a higher temperature.
Illingworth (1998) discussed the process of brazing and soldering of metals, wherein permanent
connection of solid materials is obtained though their local contact meeting and coalescence on
solidification, the gap between them being in progress, wetted by and filled with a molten filter
materials spreading over it. Brazing and soldering system build up is a process of applying layer
materials with the local contact melting of the layer and coalescence of both on solidification.



Emm (1998) discussed that the process of mechanical connection should be secured before you
apply solder, and the parts should not move in relation to each other. The heat of the iron
vaporizes the flux and the vapors will clean the surfaces of any oxidation (often invisible to the
naked eye) allowing the solder to flow freely onto the metal surfaces.
Ingalls (2006) noted that soldering is the connection of two metal pieces by the use of a solder, a
tin or lead alloy, which is melted at a relatively low temperature by a soldering iron and applied
between the original components to connect the gap while it is soft and malleable. Soldering is
most commonly associated with electronic work, but the practice has a long story and is also
utilized for plumbing, jewelry, crafting and a variety of other trades that requires the ability to
manipulate metal.
Soldering is a process in which two or more metal are joined together by melting and flowing a
filler metal into the joint, the filler metal into the joint, the filler metal having a relatively low
melting point. Soft soldering is characterized by melting point of the filler metal, which is below
400 degrees Celsius. The filler metal used in the process is called solder. (Wikipedia, 2007)






Related Studies
Garcia and Nons (2006) study entitled Digital Soldering Iron Controller with Thermometer: A
feasibility Study sought to design, construct, test, revise and develop soldering iron controller
with thermometer for use in electronics and electrical laboratories. With the use of this device
we can control the heat produced by the soldering iron. This component was constructed and
developed utilizing locally available supplies and materials so that the cost of the production is
minimal compared to its commercial counterpart sold in the market. This device can enhance the
lifespan of the soldering tip and you do not even have to try and touch the soldering iron if it is
already hot.

Buisel and Enriquezs (2009) study entitled Soldering Station: A technical Feasibility Study
sought to design, construct, test, evaluate and revise a working model of soldering station in
response to the need for it in troubleshooting. This study was also conceived due to the need in
repairing surfaces mounted components. The soldering station has been tested to be effective.
The materials used in this project were of high quality and few had been busted in testing. The
difficulty encountered in this project was the amount of heat necessary to solder and desolder the
components produced a low voltage power supply in testing. The study revealed that it could
repair surface mounted component. The construction is easy to understand and follow. This
project is relatively cheaper compared to those available in the market.
Arca, Babaylon, and Quijanos (2005) study entitled Rechargeable Soldering Iron: A
technical Feasibility Study sought to design, construct, test and revise a Rechargeable soldering
iron. The soldering iron can be of great help to the student who is soldering whenever there is
power interruption. It is feasible for the teacher to produce and improvise a gadget to enhance the
teaching and learning process. The rechargeable soldering iron is economical in terms of labor
and manpower, versatility and dependability of the operation composed of other kinds of
soldering iron made by other researchers.
Lerin, Samartino, and Torress (2007) study Improvised Light Illuminator Device: A
Technical Feasibility Study sought to design, construct, test and revise an Improvised Light
Illuminator device out of locally available materials. This device is composed of AC sensor and
Remote control switch. The findings of the study shows that it is technically feasible to construct
an Improvised Light Illuminator device, which it is simple, made out of locally available
materials, and can be manufactured by the students with the guidance of the instructor. The
findings of the study show that it is possible for the student to produce gadgets to enhance the
teaching and learning process in electrical shop and other training centers. It likewise proven that
it is economical because local materials are used.
Esguerra, Dela Cruz, and Bautistas (2006) study entitled A Improvised Rechargeable
Soldering Iron: A Technical Feasibility Study sought to design, construct, test and revise a
working model of a Rechargeable Soldering Iron to meet the urgent needs for instructional
equipment in electronics technology. This project was conceived because of the necessity for this
kind of soldering iron designed in the school. This technical feasibility study can be designed and
constructed easily using charger and switch. The findings of the study show that the soldering
iron could perform effectively. The result of the study further reveals that the soldering iron is a
great help to the electronics student is soldering more conveniently. Furthermore, it is feasible
for the student and teacher to produce a gadget to enhance the teaching and learning process.
Synthesis

After examining studies, the researcher found out that developing a soldering iron must
focus not only on its design or construction, but also on incorporating or innovation the use of
soldering iron so it can be more helpful.
In the study conducted by, Esguerra, Dela Cruz, and Bautistas (2006) study entitled
A Improvised Rechargeable Soldering Iron: A Technical Feasibility Study, the proponents
improved the iron to be rechargeable. It can power up using charger and switch. On the other
hand, Garcia and Nons (2006) study entitled Digital Soldering Iron Controller with
Thermometer: A feasibility Study, produced a new design equipped with a thermometer so it
can control, if not totally, cases of overheating.
It is noticeable through that nobody has attempted to produce a soldering iron with built-
in light source with it to make soldering works handier or more convenient, especially whien
users are working in a dimly lit setting. Thus, the proponent decided to produce a gas torch
soldering iron with adjustable light.

Chapter III
Materials and Methods

This chapter presents the materials and methodology that were used in the completion of
the design project.
Design Consideration
The materials used were based on the specifications, durability, affordability and
availability of the materials. The butane gas was used as a source of energy. Orifice was used to
pass a particular flow rate through a filter assembly to maintain cleanliness of a closed-loop fluid
system. An L.E.D light 3v was used as a light source to make soldering works more convenient
in a dimly lit setting. Battery was used as a source of L.E.D light. Metal tube serves as the body
of the gas torch soldering iron. Filter valve allows gas to bypass the filter and to protect the
soldering iron from gas starvation.
Materials
Butane Gas- Butanes are highly flammable, colorless, easily liquefied gases. It is an
organic compound found in natural gas and produced from petroleum. Butane is used as a
household fuel, refrigerant, and propellant in aerosol cans. It is used as a source of energy for gas
torch soldering iron.
In this project amount matter, you need 10 ml butane gas.
Soldering tip- A hand tool consisting of a handle fixed to a copper tip that is heated,
electrically or in a flame, and used to melt and apply solder.
Adjustment knob- controls the flow of gas.
Filter valve- Regulate the flow of gases, liquids, or loose materials through piping or
through apertures by opening, closing, or obstructing ports or passageways. It is movable control
element of the gas torch soldering iron to regulate the flow of gas. It is used to filter the incoming
butane gas.
Orifice- An opening or an aperture as of a tube or pipe. It is used to pass a particular flow
rate through a filter assembly to maintain cleanliness of a closed-loop fluid system. It also used
to release the gas.
Panasonic ultra-heavy duty 9v- Is a high quality alkaline battery. It is consisting of
one or more electrochemical cells that convert stored chemical energy into electrical energy. It is
used as a source of L.E.D light in the gas torch soldering iron.
L.E.D light 3v- 3v LEDs are used in any place that needs a bright light. It is attached at
the top of the gas torch soldering iron. An L.E.D light 3v was used as a light source to make
soldering works more convenient in a dimly lit setting.
Battery holder- It is one or more compartments or chambers for holding a battery.. A
battery holder is either a plastic case with the shape of the housing molded as a compartment or
compartments that accepts a battery or batteries, or a separate plastic holder that is mounted with
screws, eyelets, glue, double-sided tape, or other means. Battery holders may have a lid to retain
and protect the batteries, or may be sealed to prevent damage to circuitry and components from
battery leakage.
Multi-fill adaptor- It is used to connect for refilling butane gas to gas torch soldering
iron. Serve as reloading station of the butane gas fuel.
Gas Cylinder- Serve as storage of butane gas. Storage store gases at
above atmospheric pressure.
Switch- use to turn on and off the adjustable light of the soldering iron.
Solid Wire- use to hold the adjustable of the gas soldering iron.
Shielded wires and Magnetic wire- use for the connection of the battery holder and the
LED light.

Soldering Torch- Serves as the leading point of the gadget. A hand tool consisting of a
handle fixed to a copper tip that is heated, electrically or in a flame, and used to melt and apply
solder
Gooseneck- a curved object resembling the neck of a goose, as a section of pipe or a
long, flexible metal. It is used to connect the cylinder gas to the gas soldering iron.
Tools
Side cutting pliers- Pliers with cutting jaws at an angle to the handles to permit cutting
off wires close to terminals. It also trims wires.
Hack saw- A hacksaw is a fine-toothed saw, originally and principally for cutting metal.
They can also cut various other materials, such as plastic and wood for
example, plumbers and electricians often cut plastic pipe and plastic conduit with them. It used
to cut the edges of the metal case.
Screw driver- is a tool, manual or powered, for turning (driving or removing) screws. A
typical simple screwdriver has a handle and a shaft, and a tip that the user inserts into the screw
head to turn it. It serves to loosen and tightens screw.
Hand drill- a small portable drill held and operated by hand. It used to drill tubes.
Construction Procedure




Figure 1 Flow Chart of Activity
Legend:
D Designing
L Lay out
C Cutting
A Assembly
T/R Try out and Revision




L
D
C A T/R
Design
Built-in light were placed on the top of the gas soldering iron that can be adjust depend
on the user. Gas cylinder was connected with a goose neck placed at the back of the gas torch
soldering iron.


Figure 2 Isometric View of Gas Torch Soldering Iron with Adjustable Light




Lay out
Get a ruler and measure the copper tube for 16cm. Copper tube will act the body of the
gas soldering iron. Measure the solid wire for 1 yard. Using hand drill, drill the copper tube with
two holes for both 1cm from the end.


Figure 2 Exploded view of Gas Torch Soldering Iron with Adjustable light

Cutting
Using a hack saw, saw the copper tube into half horizontally, be sure that it is equal. Get
a side cutting plier and cut the shielded wire into yard.
Assembly
Connect the plastic tube into the gas cylinder, and then connect the filter valve into the other end
of the plastic tube. Then tighten the orifice to the filter valve. Put all the material inside the
copper tuber and then enclose it by the adjustment knob in the front and rubber cap at the back of
the copper tube. Connect the soldering torch and the metal tube that holds the soldering tip and
then connect it to the adjustment knob.
For a built-in adjustable light l fix the two shielded wires (the shielded wire that you
divided into two) to the battery holder and connect it into the switch. Connect the LED light into
the resistor of the battery holder using the magnetic wire, then as you done connecting the light
use the gooseneck to connect the LED Light to be adjustable.

Figure 3 Orthographic view of Gas Torch Soldering Iron with Adjustable Light

Try out and revision
This part briefly describes the initial and first try of the project, the defects and the
revision made to correct the defects. The defects found and revisions made are shown in Table 1.
Table 1
Defects Founds and Revisions Made

Defects


Revisions

Gas cylinder leakage

Applied epoxy to the surface damage

Loose connection

Tightened loose connections and
reconnected them firmly