The Hong Kong Polytechnic University Industrial Training Centre

Department of Electronic and Information Engineering Degree 2 Summer Term Proect

The Hong Kong Polytechnic University
Industrial Training Centre
Department of Electronic and Information Engineering
Degree 2 Summer Term Proect
Proect Title! "ED Thermometer
Proect #eport
Supervisor $ame! Ed%ard Cheung
&roup $um'er! ()$(*
&roup +em'er! Chung Kai +an ,--(((-./D0
1an Hoi 2ang ,--23/3-3D0
1ung Hon San ,--)-*3(3D0
Ho Ka 2ai ,--)4-(.-D0
Page !

The Hong Kong Polytechnic University Industrial Training Centre
Department of Electronic and Information Engineering Degree 2 Summer Term Proect
Ta'le of Contents
!" Introduction
!"! Proect #$ectives
!"2 %$out #ur Proect
2" Product &eatures and Specifications
2"! Descriptions
2"2 Technical Data 'specifications(
)" Proect *e+uirement
," Proect Planning
,"! -o$ responsi$ilities
,"2 Time scheduling
,") .aterials and development tools
/" Cost %nalysis
/"! .aterial costs
/"2 .anufacturing cost
/") End0product cost
1" .ar2et *esearch
1"! Target mar2et segment
1"2 Similar products in the mar2et
1") Comparison $et3een your product and those in the mar2et
1", Selling price level
4" Design philosophy
4"! Hard3are
4"2 Soft3are
4") .aterial5 casing and finishing
6" .anufacturing Process philosophy
6"! Choice of processes
7" Testing strategies
7"! Hard3are
7"2 Soft3are
7") .echanical
Page 2

The Hong Kong Polytechnic University Industrial Training Centre
Department of Electronic and Information Engineering Degree 2 Summer Term Proect
!8" .ass Production *ecommendations
!8"! Production .ethodology
!8"2 Production tools5 fi9tures and machines
!8") Production &lo3
!!" Conclusion
!2" *ecommendation and future enhancement
!)" *eferences
!," %ppendi9
!,"! .aterial : Parts ;ist
!,"2 Production Planning Chart 'PC<(
!,") Production Planning Chart 'Casing(
!,", .anufacturing Process Instruction 'PC<(
!,"/ .anufacturing Process Instruction 'Casing(
!,"1 Cost : Delivery Estimation &orm
Page )

The Hong Kong Polytechnic University Industrial Training Centre
Department of Electronic and Information Engineering Degree 2 Summer Term Proect
)5 Introduction
)5) Proect 6'ectives!
.anufacturing and development proects are gradually important" They are $ecoming
integral part in the 3or2ing lives that virtually all engineers 3ill come across at various
stages in their career path"
&or effective training5 the manufacturing proect 3or2 is structured that $oth staff of IC and
parent department act as the company top management5 student proect teams act as proect
groups 3ithin a company" Each proect is in the form of a prototype model and includes
component selection5 layout of circuits5 ma2ing parts5 assem$ly and testing a prototype"
&inally5 the stage is to document and present audiences the proect" In this year5 the
presentation style is changed from oral presentation5 to 3e$ site presentation in the Internet"
Useful materials and presentation video clips should $e found on the 3e$ site"
The proect is structured that 3e can $ring our previous 2no3ledge and e9perience together
into one coherent activity" It is $ased on the assumption that students have already underta2en
and completed successfully the re+uired $asic IC training programs" %lso it gives us a chance
to develop team3or2"
%fter completing this manufacturing proect e9ercise5 students 3ill $e e9pected to gain hand0
on e9perience of modern computer aids and e+uipment used in design5 advance machine used
in manufacturing" Students 3ill $e also e9pected to gain a good understanding of the
importance of costs related to any decisions ma2ing5 the methods used and factors considered
in the selection of the manufacturing process and materials" &inally5 this training is designed
to develop students= product development and manufacturing capa$ility in their immediate
career after their graduation"
Page ,

The Hong Kong Polytechnic University Industrial Training Centre
Department of Electronic and Information Engineering Degree 2 Summer Term Proect
)52 7'out 6ur Proect!
The ordinary types of thermometers are using alcohol or mercury for displaying temperature
values" Ho3ever5 due to the development technology5 electrical thermometers are said to $e
the ne3 trend of thermometers"
In general5 people prefer using 4 segment ;ED thermometers" It is $ecause the display can
sho3 the readings in numerical form so that the temperatures can $e read more easily"
In our proect5 3e had created a ;ED thermometer 3ith an innovative idea that using many
individual ;EDs for displaying temperature values" Such num$er of ;EDs is the main feature
of this product" It is $ecause the displaying style is completely different from that of 4
segment ;EDs thermometers"
#ur product is designed to measure room temperature" <y the use of cell $attery5 it can $e
porta$le"
#ur proect is divided into si9 stages5 including design and planning5 costing and parts
manufacture5 PC< and casing assem$ly5 testing5 documentation5 and final evaluation" &urther
descriptions of each part 3ill $e found in the follo3ing paragraphs" If you 3ould li2e to 2no3
more a$out the manufacturing process and the operation of our product5 ;ED thermometers5
you can refer to the Technical .anual and the User .anual"
Page /

The Hong Kong Polytechnic University Industrial Training Centre
Department of Electronic and Information Engineering Degree 2 Summer Term Proect
25 Product 1eatures and Specifications
25) Product 1eatures
The product name is called ;ED thermometer5 it is used for measuring room temperature" %s
mentioned in the introduction part5 digital ;ED thermometer using 4 segment ;ED display is
the most common type in the digital thermometer 3orld" %nd our product does not use 4
segment ;ED display5 in contrast5 3e use a certain num$er of ;EDs for displaying the
temperature values" %lthough 4 segment ;ED display can sho3 numerical values5 3hich can
$e more easily to read5 our product can $e more attractive since there are more ;EDs for
displaying the room temperature"
252 Technical Data ,specifications0!
;ED thermometer uses %T67C/! as the micro0controller and DS!128 as the thermal sensor"
%lthough the sensor is 3or2 from >//
o
C to ?!2/
o
C5 the temperature range of it is limited
from 8
o
C to ?/7"/
o
C 3ith the resolution 8"/
o
C since this product is designed for measuring
room temperature" The error over temperature range is @8"/
o
C" If the temperature e9ceeds
?/7"/
o
C5 all the ;EDs 3ill turn off"
&or convenient referencing5 a specification ta$le is provided as $elo3A
Sensor Bor2a$le range >//
o
C to ?!2/
o
C
Display range 8 to ?/7"/
o
C
*esolution 8"/
o
C
Error over temperature range @8"/
o
C
Supply voltage 7C
Dimension !/8mm 18mm )!8mm
85 Proect re9uirement
Page 1

The Hong Kong Polytechnic University Industrial Training Centre
Department of Electronic and Information Engineering Degree 2 Summer Term Proect
Students 3ere re+uired to form a proect group" Droup mem$ers had to divide their 3or2s
themselves" Bithin the training period5 the group mem$er 3ere e9pected to complete the
proect as per proect specification and deliver the proect in the form of a set of
documentation" Documentation includes proect report5 user manual and technical manual"
&urthermore5 time management is important" In general5 the mem$ers decide to do the
specification5 planning5 components costing in the first 3ee2" &or the second and third 3ee2s5
they decide to do the design5 dra3ing5 manufacturing and assem$ly" Ee9t5 for the fourth
3ee25 they decide to do the testing and evaluation5 and documentation and preparation of
presentation in the last 3ee2"
Bith the a$ove re+uirements5 in general5 the group mem$ers are divided into three groups"
The first one is for hard3are producing 3hich included designing5 manufacturing and testing
the PC<" %nother group is responsi$le for soft3are programming 3hich included deciding
3hat functions needed and testing 3hether the program 3or2 or not" The last group is for
casing 3hich included designing of outloo2 and manufacture of the case"
Ho3ever5 these regulations are only for reference5 for different proect groups5 they can
adust their plan and o$ responsi$ilities according to their needs"
/5 Proect Planning
Page 4

The Hong Kong Polytechnic University Industrial Training Centre
Department of Electronic and Information Engineering Degree 2 Summer Term Proect
/5) :o' responsi'ilities
&or our group5 there 3ere only four mem$ers5 the o$ responsi$ilities should $e carefully
divided to each mem$er"
Chung Kai +an! focusing on casing manufacturing5 finally assem$ling
1an Hoi 2ang! focusing on schematic design5 printed circuit $oard manufacturing
1ung Hon San! focusing on %T67C/! programming and 3e$ site development
Ho Ka 2ai! focusing on photographing5 documentation and miscellaneous 3or2
%ll the tas2s and responsi$ilities are listed $elo3A
Tas;s! #esponsi'le 'y!
.ar2et *esearch5 Proect Planning and Scheduling Ho Ka Bai
%T67C/!5 DS!128 and Serial Communication Studying &ung Hon San5 Ho Ka Bai
<read$oard Emulation &ung Hon San5 Ho Ka Bai
%T67C/! Programming &ung Hon San
Po3er;ogic5 Po3erPC< &ung Hon San5 &an Hoi Bang
&ilm .a2ing &an Hoi Bang
Printed Circuit <oard .anufacturing Chung Kai .an5 &an Hoi Bang5
&ung Hon San5 Ho Ka Bai
Casing Design Chung Kai .an5 &ung Hon San5
Ho Ka Bai
%utoC%D Chung Kai .an
Casing .anufacturing and &inally %ssem$ling Chung Kai .an5 &an Hoi Bang
Be$ Site Design and Development &ung Hon San
Photographing Ho Ka Bai
Documentation Chung Kai .an5 &an Hoi Bang5
&ung Hon San5 Ho Ka Bai
Cideo Presentation Chung Kai .an5 &an Hoi Bang5
&ung Hon San5 Ho Ka Bai
/52 Time scheduling
#verall scheduling ta$leA
2ee; $o5 2or;out
Bee2 ,, Specifications5 .ar2et *esearch5 Proect Planning
Bee2 ,/ Studying5 including %T67C/! Programming5 Sensor DS!128 Properties5
Serial Communication
Bee2 ,1 %T67C/! Programming Design5 Po3er;ogic and Po3erPC< Schematic
Design5 Casing Design
Page 6

The Hong Kong Polytechnic University Industrial Training Centre
Department of Electronic and Information Engineering Degree 2 Summer Term Proect
Bee2 ,45 ,6 BIEICE 68/!F/20E Emulator Demonstration and &unctional Testing
Bee2 ,65 ,7 &ilm .a2ing5 PC< Production and Casing %ssem$ling and &inal Evaluation
Bee2 /85 /! Documentation5 Be$ Site Development
2ee; //! Specifications< +ar;et #esearch< Proect Planning
In this 3ee25 our group designed the specification of the ;ED thermometer and also planned
the overall 3or2flo3 of the 3hole proect" The original period of this proect 3as from )
rd
-uly to 2
nd
%ugust 'from 3ee2 ,, to 3ee2 ,6(5 and the original schedule 3as planned at
sho3n in the follo3ing Dantt Chart"
Ho3ever5 this 3as an ideal plan" %s there 3ere some une9pected pro$lems5 3e could not
follo3 this plan to do our proect"
Ho3ever5 this 3as the ideal plan5 and the follo3ing 3as the actual schedule that 3e had
achievedA
Page 7

The Hong Kong Polytechnic University Industrial Training Centre
Department of Electronic and Information Engineering Degree 2 Summer Term Proect
#n the other hand5 3e surfed the Internet to find information of some relevant products" .ore
detailed descriptions can $e found from the .ar2et *esearch part in this report"
2ee; /*! Studying< including 7T4-C*) Programming< Sensor DS).2( Properties<
serial communication
In this 3ee25 our group studied ho3 to control the %T67C/! and learned ho3 to access the
sensor DS!128" Be surfed the Internet to get useful information5 studied the data sheet of
$oth %T67C/! and DS!1285 and also $orro3ed some $oo2s from li$rary and studied them so
that 3e could $e more familiar 3ith its command sets" #n the other hand5 3e spent some time
to study serial communication $et3een %T67C/! and DS!128 since it 3as not included in
the training course last year" So5 it 3as necessary to do some e9tra efforts"
2ee; /.! 7T4-C*) Programming Design< Po%er"ogic and Po%erPC= Schematic
Design< Casing Design
In this 3ee25 3e separated our group mem$ers into t3o main teams5 the first one 3as
responsi$le for %T67C/! programming design5 and the other team 3as responsi$le to use the
soft3are Po3er;ogic and Po3erPC< to design and dra3 the PC< circuit and also to use
%utoC%D to design the casing"
In fact5 the programming and the schematic layout should $e designed at the same time5 and
they 3ere highly related to each other" Each of them 3ould affect the other one" &or e9ample5
Page !8

The Hong Kong Polytechnic University Industrial Training Centre
Department of Electronic and Information Engineering Degree 2 Summer Term Proect
if one line of the schematic layout 3as changed5 the programming should $e adusted
correspondingly"
2ee; /3< /4! Hard%are Demonstration using 2I$ICE 4(*)>*2?E Emulator
%fter studying the %T67C/! and DS!128 in 3ee2 ,/ and the design stage of 3ee2 ,15 3e
started to 3rite the program in this 3ee2" There 3ere totally three stagesA
!( accessing DS!1285
2( programming for display5 and
)( com$ining the transferred data 3ith the display program to ma2e the thermometer
3or2a$le"
Be used $read$oard and the BIEICE 68/!F/20E emulator to do the hard3are
demonstration" &irstly5 3e tried to access the sensor DS!128" Ho3ever5 3e spent much time
in this stage since the serial communication $et3een t3o ICs 3as not covered in the training
course last year" %lthough 3e had studied the $oo2s5 3e still had some pro$lems to do this
tas2" So5 3e tried many times and finally 3e succeed" %fter that5 3e 3rote the program for
displaying ;EDs" In this stage5 3e have found some pro$lem for effective display" So 3e
simply adusted the PC< layout"
;astly5 3e 3rote the overall %T67C/! program" This program used ) 3ires of %T67C/! to
communicate 3ith the sensor DS!1285 one 3as data communication5 one 3as cloc2 pulse5
and the last one 3as *ESET" <y suita$le settings5 the %T67C/! could serially communicate
3ith the sensor5 and 3e used some internal memory registers to store the temperature values"
Using the displaying program 3e ust 3ritten5 the temperature values could $e visualiGed $y
;EDs"
2ee; /4< /-! 1ilm +a;ing< PC= Production and Casing 7ssem'ling and 1inal
Evaluation5
Page !!

The Hong Kong Polytechnic University Industrial Training Centre
Department of Electronic and Information Engineering Degree 2 Summer Term Proect
The hard3are manufacturing processes5 including film ma2ing5 PC< production5 casing
production and casing assem$ling 3ere done 3ithin these t3o 3ee2s" Be applied the
2no3ledge and s2ill 3e had learnt in last to perform the hard3are production" %fter finished
the hard3are product5 3e used the BIEICE 68/!F/20E emulator to do an evaluation" %fter
this5 3e $urnt the programme to the micro0controller %T67C/! and performed the final
evaluation"
2ee; *(< *)! Documentation< 2e' Site Development
In this 3ee25 3e focused on doing documentation 3or2 and also 3e$ site development"
Ho3ever5 in fact5 3e started to do documentation 3or2 at the very $eginning" Since 3e 2ne3
that documentation should $e done in certain progress"
Be used .S Bord5 .S E9cel5 .S Proect to ma2e different reports5 ta$les5 and charts" %ll
the contents and format of these documents 3ere fully follo3ed the proect guide" #n the
other hand5 3e used Dream3eaver and &lash to create our 3e$ site" The content of the 3e$
site 3as said to $e simplified version of the report and manuals" It also contained soft copy of
the report5 manuals5 PC< layout5 programme source code for do3nloading" Thus5 customers
could $ro3se to our 3e$ site5 then they 3ould have $rief idea of our proect" If they 3ere
interested5 they could do3nload the files provided5 and read them5 then they 3ould 2no3
more details a$out the idea5 manufacturing process and also the operations of our product"
/58 +aterials and development tools
Components "ist!
*esistorsA *!>*65 *!!>*!, H 228
*7 H !882
*!8 H 224
CapacitorsA C! H 62p&
Page !2

The Hong Kong Polytechnic University Industrial Training Centre
Department of Electronic and Information Engineering Degree 2 Summer Term Proect
C25 C) H !88n&
C, H !88m& !1C radial
SemiconductorsA D!>D27 H ;ED5 high efficiency5 red
D)85 D)!5 D)2 H ;ED5 high efficiency5 yello3
D)) H IE,!,6
IC! H DS!128
IC2 H %T67C/!
IC)5 IC, H 4,;S2,,
IC/ H 468/
.iscellaneousA PC!5 PC2 H solder pins
Development tools list!
Cathode0*ay #scilloscope
BIEICE 68/!F/20E Emulator
Photo &ilm .a2ing .achine
UC E9posure Unit
Po3er Supply
.ulti0meter 2
<read$oard 2
;athe .achine
Cutting .achine
Drilling .achine
EC Drilling .achine
Hand tools 'Drilling : tapping5 solder iron5 etc"(
*5 Cost 7nalysis
&or detailed information5 please refer to the Cost : Delivery Estimation &orm in the
appendi9"
*5) +aterial costs
Page !)

The Hong Kong Polytechnic University Industrial Training Centre
Department of Electronic and Information Engineering Degree 2 Summer Term Proect
&rom the Cost : Delivery Estimation &orm5 3e can see that the material cost for
manufacturing a ;ED thermometer is I!1!"41"
*52 +anufacturing cost
In the manufacturing process5 3e found that the total man0hour should $e ) hours" These )
hours are the period of mass manufacturing5 so5 the period is much shorter than that 3e
manufacture the product manually" The rate of a man0hour is I)85 so the la$our cost in
manufacturing is I78"
*58 End?product cost
&rom the .S EJCE; file5 3e can see that the total cost of manufacturing is I)16"41" So 3e
considered that the selling price of the ;ED thermometer 3ould $e I,,2"/!"
.5 +ar;et #esearch
.5) Target mar;et segment
The product is ;ED thermometer5 and it is mainly used to measure the room temperature" #n
the other hand5 it can $e used as decoration5 it is suita$le placing at office and home"
Page !,

The Hong Kong Polytechnic University Industrial Training Centre
Department of Electronic and Information Engineering Degree 2 Summer Term Proect
So5 the target mar2et is very large5 every$ody 3anted to have a room temperature
thermometer are the target mar2et of our product"
.52 Similar products in the mar;et
&rom the Internet5 many same 2inds of products can $e found" ;ED thermometers using 4
segment ;ED for displaying temperature values are very common" Ho3ever5 3e could not
find any e9amples using as much ;EDs as our product"
Product Eame Price Descriptions
Economical and versatile ;ED
Digital Thermometer
HK I/,, ;arge5 $rightly lit display easily reada$le from long distances"
/=connector tu$ing to air pro$e for sensing air temperature in remote
location 'longer lengths availa$leK contact us for pricing("
Designed to $e surface mounted 3ith t3o L, scre3s through caseK to
flush mount5 simply cut a 8"64/M !"4/Mopening on a panel and
fasten 3ith t3o scre3s"
#ptional flush mount on stainless steel electrical $o9 cover plate5
3hich installs on conventional electrical $o95 found at local hard3are
stores
DisplayA ;ED red in color 8"/1M high"
*angeA %vaila$le in eitherA 0,8 to ?!28
o
& or 0,8 to ?/8
o
C"
Po3erA !2 C%C or !2 CDC5 recogniGed transformer included"
Cali$ration scre3 located on $ac2 of unit to allo3 for easy
adustment of temperature reading"
%ccuracyA 2
o
&
DimensionsA 8"6/M !"4/M 2M'B ; H(
Digital Solar Po3ered %ir
Thermometer
HK I2)2 Can mount on outside of room to read inside air temperature or
directly in room" /1M connector tu$ing to air pro$e for sensing air
temperature in remote location" Solar po3ered 3ith a $attery '%%%(
$ac20up system ena$les instrument to operate in lo3 light levels"
Estimated $attery life is )0, years"
%ccuracyA @2N &
Page !/

The Hong Kong Polytechnic University Industrial Training Centre
Department of Electronic and Information Engineering Degree 2 Summer Term Proect
*angeA 0/8N to ?!/6N& '0/8 to ?48NC5 availa$le $y special
order(
DimensionsA ,OM 3ide 9 OM deep 9 !M high
#ne year 3arranty
Digital ;ED Thermometer HK I2,8 This high $right ;ED digital thermometer uses an ;.)/ Eational
Semiconductor IC as its temperature sensor" It sho3s the temperature
3ith an accuracy of 8"/NC on its digital display" The thermometerPs
range is from 8 0 77NC"
Digital Thermometer Sensor
Bith ;ED Display
HK I,/8 It is 3ell suited for use as a conventional thermometer" The digital
display gives the current temperature5 the minimum temperature and
the ma9imum temperature consecutively" Bhen a PrestP 2ey is pressed
the highest and lo3est temperatures measured are stored and5 if
necessary5 adusted" %n aluminum case is supplied 3ith the 2it5 to
allo3 the thermometerQsensor to $e mounted on a 3all" The sensor
can $e mounted any3here 3ith plain telephone 3ire" .inimumA 1
inches long5 .a9imumA / feet long" Use a s3itch to flip $ac2 and
forth $et3een inside temperature and outside temperature" E9tra
sensors are sold separately"
*angeA 0/8NC to ? !/8NC
;inearity from 0!8Nto ?/8NA $etter than 8R/S
%ccuracyA $etter than 2S
%dusta$le to degrees &ahrenheit
DisplayA )!Q2 digits '8R!N display accuracy(
Supply voltageA !2 to !/C DCQI/8m%
DimensionsA !,, /8 22mm
IndoorQ#utdoor Thermometer HK I26, Dreat for measuring temperature variances of 3al20in coolers5
ripening rooms5 any refrigerated area5 or home inside Q outside
temperatures"
!8P sensor cord allo3s for easy remote monitoring"
.a9Q.in memory records the high and lo3 temperatures"
!"2/T ;CD Display
Page !1

The Hong Kong Polytechnic University Industrial Training Centre
Department of Electronic and Information Engineering Degree 2 Summer Term Proect
0/6N to ?!/6N& 'NC model availa$le $y special order(
!"/ volt $attery included
Hangs or Stands
.58 Comparison 'et%een your product and those in the mar;et
%s mentioned $efore5 the main difference $et3een our product and those in the mar2et is the
display style" .ost of the products in the mar2et are using 4 segment ;EDs for displaying the
temperature values5 and our product uses large num$er of ;EDs for the display"
Secondly5 the siGe of our product is larger than that of those in the mar2et" The reason is that5
our product is a standalone ;ED thermometer and it can $e used as decoration too" In
contrast5 those digital ;ED thermometers in the mar2et can $e used as add0ons to other
electronic products"
In general5 the 4 segment ;ED thermometers can $e used as room temperature thermometers5
clinical thermometer5 and also can $e used as add0ons accessory to other electronics products
such as computer mother$oards"
.5/ Selling price level
&rom the a$ove ta$le5 the thermometers selling prices are generally from a$out I288 up to
a$out I188"
35 Design philosophy
Page !4

The Hong Kong Polytechnic University Industrial Training Centre
Department of Electronic and Information Engineering Degree 2 Summer Term Proect
The hard3are should match 3ith the soft3are" Either one of them had $een changed5 the
other one should also $e adusted" This sho3ed the importance of the relationship $et3een
hard3are and soft3are"
In order to give out an impression that the product is a thermometer5 the arrangement of
;EDs is limited5 the $est 3ay for displaying temperature values is one single vertical line"
This arrangement can provide clear vie3 for reading" <esides5 it also can give an impression
that the temperatures rise from lo3 to high"
35) Hard%are
%t the heart of the circuit is a %T67C/! micro0controller" The micro0controller reads
temperature data from a sensor IC" The micro0controller has the o$ of displaying the
measured value on )2 ;EDs"
In order to minimiGe the num$er of connections for a large num$er of display elements5 the
)2 ;EDs are driven in a multiple9ed fashion" &our additional ;EDs are permanently lit and
indicate the tens of degrees5 ma2ing the display easier to read"
Ho3ever5 since so many ;EDs should $e connected to the ,8 pins %T67C/! micro0
controller5 and 3e should arrange the ;EDs in a single vertical line5 the circuit lines 3ould $e
tight"
#n the other hand5 the %T67C/! should communicate 3ith the sensor DS!128 and control
t3o $uffers 4,;S2,,5 the circuit 3ould $e complicated and it 3as impossi$le to cover all the
lines 3ithout shorting in single side" %s a result5 3e used dou$le sides PC< at our $oard" <y
this method5 the circuit could $e routed 3ithout shorting"
352 Soft%are
%s the %T67C/! microprocessor is used for controlling the temperature sensor DS!1285 all
data are communicated over an I2C $us" <y serial communication5 the data generated from
the sensor DS!128 3ill $e sent to the %T67C/! for calculation" %nd the num$er of light
;EDs 3ill sho3 the corresponding temperature values"
Page !6

The Hong Kong Polytechnic University Industrial Training Centre
Department of Electronic and Information Engineering Degree 2 Summer Term Proect
<y the use of %T67C/! programming5 3e can drive )2 ;EDs through !, ports only" The
;ED matri9 is divided into four groups5 the first and second columns consisting of !8 ;EDs5
the third column consisting of 7 ;EDs and the last column consisting of ) ;EDs" These
groups are driven from port pins !,>!4 in se+uence5 so that at most ten ;EDs are ever lit
simultaneously" The ;EDs are turned on $y setting port pins 2!5 225 and )2>)7 to high" Bith
a lo3 level of port pins !,>!45 the appropriate group of ;EDs is ena$led" %lthough only at
most ten ;EDs are on at any one time5 the multiple9ing happens so fast that the visual
appearance is that up to )2 ;EDs are lit"
The overall temperature range from 8
o
C to ?/7"/
o
C is divided into t3o ranges '8 to ?27
o
C
and ?)8 to ?/7
o
C(5 as indicated $y the t3o ;EDs D)! and D)2 respectively" The odd 8"/
o
C is
indicated $y the remaining range ;ED D)8" So5 for e9ample5 at 28"/
o
C5 the ;ED D)8 turns
on5 and also the ;ED D)! lit for indicating a temperature $et3een 8
o
C and 27
o
C" If the
temperature e9ceeds the minimum and ma9imum limits5 i"e" 8
o
C and ?/7"/
o
C5 all the ;EDs
3ill turn off" So5 it 3as necessary to consider the temperature values during calculation" <y
separating the values into 2 parts5 3e could use different ;EDs for indication"
358 +aterial< casing and finishing
3585) +aterial
#ur product comprise of there parts5 they are the acrylic surfaces5 aluminum frames and
PC<" The surfaces are made of t3o piece of acrylic sheets5 3e choose this material to
ma2e the surface is $ecause acrylic sheet is tough enough to avoid $rea2ing5 and it is
relatively lighter than the others materials5 such as aluminum sheet5 stainless steel sheet
etc" %lso5 acrylic sheet is easy to $e cut and drilled 3hen compare 3ith the other
materials5 and the surface of acrylic sheet is clean and smooth for a good appearance5 so it
is a good material to use as a surface part of our product" &urthermore5 after the sheets
are cut and drilled5 3e 3ant to add some colors on the $ac2 of the acrylic surfaces to
improve the appearance" Since acrylic sheet is transparency5 so prints the colors on the
$ac2 of the surfaces 3ill provide a $righten surfaces5 and the effect are really good"
Page !7

The Hong Kong Polytechnic University Industrial Training Centre
Department of Electronic and Information Engineering Degree 2 Summer Term Proect
%nd a$out the frame of our product5 3e have chosen aluminum $ar to support the acrylic
surfaces" The reason for us to choose aluminum $ars and do not use the acrylic $ars or
the other materials is if 3e use acrylic $ars to support the surfaces5 then our product 3ill
$e totally used plastic to accomplish5 since 3e had chosen acrylic sheet to use as our
product=s surfaces5 so 3e have chosen the other materials to used as our product=s frame"
Bhen comparing the common used materials5 3e thin2 aluminum is the $est material to
do as our frame5 since it is lighter than the other materials5 such as $rass5 copper5 stainless
steel5 etc" %lso5 it is easy to cut on the lathe5 and the appearance of the surface of the
aluminum $ar is very good and $right" .oreover5 the com$ination of acrylic sheet and
aluminum $ar can give an attractive appearance"
35852 Casing
Since our fello3s 3ant to use one piece of PC< for circuit design5 so the siGe of our case
3ill $e $ased on the siGe of the PC<" %lso the shape of the case is $ased the application
of the product to design5 since our product is a ;ED Thermometer5 so 3e 3ill design a
thing that can impress the user thin2 it is related to temperature" %s the result5 3e decided
to use a Ucactus= diagram as the shape of our product=s casing5 since cactus is a plant
gro3n in desert area5 so it can impress the user thin2 of temperature" %part from this5
designing our surface as a Ucactus= shape can also provide a decorative purpose" %nd
since 3e 3ill place the PC< on the casing5 so 3e decide to produce four aluminum $ars to
attach the PC< on the casing" %nd the four aluminum $ars are used as a $olts and nuts5
so that they can attach the surfaces and the PC<"
&urthermore5 our product is a thermometer5 so the sensor must $e placed in a good
ventilated area" In order to overcome this pro$lem5 3e attach the PC< $et3een the t3o
same shape surfaces li2e a Usand3iches=5 thus the sensor can directly contact the
surrounding5 and this can improve the accuracy of the thermometer" .oreover5 since the
$ac2 of the surfaces 3ill $e printed 3ith oil5 so in order to let the ;EDs can $e sho3n
clearly5 3e decide to cut a gap and drill some holes on the front surface to let the ;EDs
e9pose on the surface"
Page 28

The Hong Kong Polytechnic University Industrial Training Centre
Department of Electronic and Information Engineering Degree 2 Summer Term Proect
45 +anufacturing Process philosophy
45) Choice of processes
a" PC< layout design
$" &ilm .a2ing
c" Production of PC< $oard
d" Casing Production
a5 Procedures of PC= layout design
Be applied the 2no3ledge 3e learnt last year to produce the PC< layout"
&irstly5 3e used the soft3are Po3er;ogic to design the circuit" %nd then 3e used the
auto route function of soft3are Po3erPC< to design the layout"
'5 Procedures of 1ilm +a;ing
In last year5 3e attended a class tal2ing a$out ho3 the film could $e made" Ho3ever5
3e did not have hand0on e9periences" In this year5 technicians arranged a $rief tal2 to
remind us a$out the film ma2ing procedures" %fter that5 3e follo3ed the procedures
to ma2e the film" The procedures are listed $elo3"
!" prepare a piece of paper that the re+uired circuit 3as printed on it5 the layout
should $e printed as the actual circuit siGe of the product
2" $ring this PC< layout to the dar2 room
)" put the layout copy on the photo film ma2ing machine
," adust the focus of the machine so that 3e can ma2e photo film at !A! scale 'in
general5 the scale should $e 2A! so that the film can $e more accurate5
ho3ever5 since our PC< layout 3as too large5 the scale is limited and 3e
finally used the scale of !A!(
/" turn off the light and place the film on the machine
1" undergo the e9posure film
4" undergo developing and fi9ing
6" dry out the film
Page 2!

The Hong Kong Polytechnic University Industrial Training Centre
Department of Electronic and Information Engineering Degree 2 Summer Term Proect
c5 Procedures of PC= Production
#ur group applied the s2ill that 3e learned in last year to produce the printed circuit
$oard5 the procedures are listed $elo3"
!" use EC drilling machine to drill re+uired holes of the PC<
2" use sand paper to ma2e $oth sides of the PC< smooth
)" clean the $oard and put it in the oven at 18
o
C for fe3 minutes
," after the $oard is cooled do3n5 cut dry film to siGe 'the siGe of dry film has to
$e e+ual to or smaller than the siGe of the PC<(
/" remove unnecessary s2in of the dry film
1" use a heat rolling machine to attach the dry film on the copper side of the
$oard
4" $y the UC light machine5 the circuit layout could $e printed on the dry film
6" repeat step , to step 4 for another side of the PC<
7" remove another s2in of the dry films and then drill a hole5 tighten a 3ire on it
!8" put the $oard into developer so that only the circuit layout is remained5 repeat
step ) again
!!" chec2 the circuit lines clear or not5 if the lines are not clear5 use PC< mar2er to
fill them
!2" put the $oard into the etching tan2 'ferrous chloride( to corrode unnecessary
copper
!)" put it into the stripper to remove the remaining dry film and then repeat step )
!," chop the $oard in siGe and de$ur edges
!/" assem$le re+uired components and 3ires on the $oard
!1" apply voltage the circuit and test 3hether it is 3or2 or not
d5 Procedures of Casing Production
Surface Production!
!" use pencil to dra3 the desired Ucactus= diagram on the acrylic sheet
2" cut it out $y using sa3s
)" then file the edges of the surface until the edge $ecome smooth and accurate
enough
Page 22

The Hong Kong Polytechnic University Industrial Training Centre
Department of Electronic and Information Engineering Degree 2 Summer Term Proect
," place the Upolished= surface on the other piece of acrylic sheet
/" use pencil to copy the shape on the sheet
1" then repeat the a$ove procedure until t3o surfaces have $een polished
4" use pencil to mar2 the desired gap on the front surface
6" drill t3o holes on the upper and lo3er part of the Ugap= $y using a suita$le
t3ist drill
7" then use a sa3 to cut the gap out of the surface
!8" file the edge of the gap until it reaches the mar2ed pencil line and $ecome
smooth enough
!!" for the other holes5 using appropriate t3ist drills to drill after using pencil
mar2ed
1rame Production!
!" use some cutting tools in the lathe to cut the $ar into suita$le diameter
2" drill holes on the lathe $y using appropriate t3ist drills
)" use cutting 2nife to cut the parts out of the aluminum $ar
," to produce a $olt5 cramp the parts on the vice
/" then turn the die cloc23ise to cut the a9is 3ith scre3
1" to produce a nut5 cramp the parts on the vice
4" turning the tap cloc23ise to cut the hole 3ith scre3
6il printing!
!" dra3 the desired diagrams on the paper of the surface
2" cut the paper out $y using a 2nife
)" use oil sprayer to spray the suita$le color onto the e9posed surfaces
," then repeat the a$ove process until the 3hole surfaces are filled 3ith colors
Page 2)

The Hong Kong Polytechnic University Industrial Training Centre
Department of Electronic and Information Engineering Degree 2 Summer Term Proect
-5 Testing strategies
-5) Hard%are
&irstly5 having etched5 use a multi0tester to chec2 any open or short circuit of the PC< circuit
$oard" Secondly5 using multi0tester to chec2 the accurate values of the resisters and
capacitors" Thirdly5 the correct model num$ers of the ICs" Bith a po3er supply ?/C
connected to the ICs on the $read$oard5 3e use a C*# to test the 3ave forms of the signals
from ICs" Chec2ing 3hether there is signal in the ports re+uired"
&inally5 as incorrectly fitted ;ED5 capacitors or ICs may $e hard to trac2 do3n5 the polarities
of those components should $e correctly oriented in the copper $oard"
The sensor device should $e positioned at the $ottom of the circuit5 allo3ing remote
mounting if it is desired to measure the temperature outside" %lso it should $e positioned far
a3ay from IC/ '468/( 3hich is very hot if the device operates for a long time to avoid
affecting the temperature measured $y the sensor"
-52 Soft%are
Be used the emulator to test the soft3are" &irst5 3e separated the program into 2 parts5 the
sensor communication part and ;ED display part5 and test $oth part one $y one"
&or the sensor communication part5 3e use the testing $oard to simulate the hard3are and use
the C*# to test the input and output signal"
&or the ;ED display part5 3e use the emulator and the final hard3are product to test the
program" Be set the port value of the emulator to test the program and the ;ED display"
&inally5 3e com$ine 2 parts together and get the final program"
-58 +echanical
Page 2,

The Hong Kong Polytechnic University Industrial Training Centre
Department of Electronic and Information Engineering Degree 2 Summer Term Proect
In fact5 the mechanical testing strategies 3ere not complicated" Bhat 3e necessary to do 3as
chec2ing 3hether the aluminum frame could tightly mount the acrylic sheet and PC< or not"
)(5 +ass Production #ecommendations
)(5) Production +ethodology
PC=!
To $egin 3ith mass production5 3e first prepare the PC< circuit file5 EC drilling file and
film" The production department should $e divided into / main sections in se+uenceA PC<
<oard Section5 %ssem$ling Section5 Circuit Testing Section5 Casing Section and Vuality
Control SectionA
)5 In the PC= =oard Section!
It aims to produce drilled PC< $oards" To prepare copper $oard5 it is desira$le to
prepare copper $oard 3ith the siGes are multiple of the standard $oard"
The copper $oards are drilled $y EC drilling machines $efore e9posing UC light" The
copper $oards 3rapped 3ith dry film are e9posed $y UC light in UC light Unit to
produce PC< art3or2s layout onto the copper $oard $efore etching" In the process of
etching5 a num$er of copper $oards are etched together" %t the end of etching process5
there is visual chec2ing for any incomplete etching $oards or damaged traces on the
circuit"
&inally5 a num$er of etched copper $oards are transported to the %ssem$ling Section"
25 In the 7ssem'ling Section!
It aims to assem$le all the re+uired components onto the etched copper $oards" &or
the sa2e of convenience of assem$ling components5 all the resistors are $end 3ith siGe
fitted 3ith the siGe of holes" %ll the components are randomly tested $y C*# or
multitester to minimiGe the possi$ility of malfunction of the components" Having
placed all the components onto the copper $oards $y ro$ot arms5 those $oards are
transported to the 3ave soldering machines for soldering" %t the end of soldering5
there is visual chec2ing for any incomplete soldering components"
Page 2/

The Hong Kong Polytechnic University Industrial Training Centre
Department of Electronic and Information Engineering Degree 2 Summer Term Proect
85 In the Circuit Testing Section!
It aims to test the function of the device ';ED Thermometer( 3ith po3er supply
provided and investigate any infects" The ICs are tested $y C*# to chec2 their signal
functions" This process is done $y la$our" %ny failed devices 3ill $e disposed into
*ecycle Unit"

/5 In the Casing Section!
Having tested5 the painted cases are assem$led 3ith the circuit $oards together $y
ro$ot arms"
*5 In the @uality Control Section!
The ;ED Thermometers are randomly pic2ed up for VC chec2ing" %ny failed ;ED
Thermometers are transported to the Circuit Testing Section for further investigation"
&inally the ;ED Thermometers are pac2ed $y machines that 3ill $e distri$uted to
retailers"
Casing!
The fa$rication process of the product U;ED Thermometer= can $e divided into three partsK
they are '!( Surfaces production5 '2( &rame production and ')( #il printing" Then 3e 3ill
descri$e each part $riefly as follo3sA
)5 Surface production
To produce the surfaces of the U;ED thermometer=5 for the mass production5 3e 3ant
to dra3 the desired diagram in the %utoC%D in a suita$le scale5 then save this file"
Then import this file into the computer cutting machines5 and then the cutting
machine 3ill cut and polish the surfaces automatically and accurately" &inally5 import
the same file into the computer drilling machines5 the drilling machine 3ill drilling
the holes 3ith appropriate diameters"
Page 21

The Hong Kong Polytechnic University Industrial Training Centre
Department of Electronic and Information Engineering Degree 2 Summer Term Proect
25 1rame production
To produce the frames of the U;ED thermometer=5 for the mass production5 3e 3ant
to dra3 the desired dimensions of the frame in the %utoC%D5 then save this file"
Then import this file into the computer lathes5 and then adust the cutting priorities5
then the lathes 3ill cut5 drill and tapping the frames automatically and accurately"
85 6il printing
To add some colors onto the surfaces of the casing5 for mass production5 3e 3ant to
set up a program to control the oil printing machines" &irst5 3e use the oil printing
machine $uilt0in program to design 3hich areas 3ill 3ant 3hich color5 then the
machine 3ill $e print the desired colors onto the surfaces"
)(52 Production tools< fiAtures and machines
PC= Production tools!
!" EC Drilling .achine
2" UC E9posure Unit
)" Image .a2er
," Etching Tan2
/" Bave Soldering .achine
1" Cutting .achine
4" Cathode0*ay #scilloscope
6" .ulti0meter
Casing Production tools!
!" ;athe .achine
2" Drilling .achine
)" Cutting .achine
Page 24

The Hong Kong Polytechnic University Industrial Training Centre
Department of Electronic and Information Engineering Degree 2 Summer Term Proect
)(58 Production 1lo%
Page 26

PC= =oard Section
7ssem'ling Section
Circuit Testing
Casting Section
@uality Control
Section
#etailer
PC= Production
#ecycle Unit or
Investigation
Unit
In case of
failure
The Hong Kong Polytechnic University Industrial Training Centre
Department of Electronic and Information Engineering Degree 2 Summer Term Proect
Page 27

Design the outloo;
of the frames
Consideration of
the frames
dimension
Dra% the desired
design on the
7utoC7D
7luminum 'ars
cutting
Holes drilling
Tapping
Design the outloo; of
the surfaces
Consideration of
the surfaces
dimension
Dra% the desired
design on the
7utoC7D
7crylic sheet
cutting
Holes drilling
Design the
graphics of the
surfaces
Color selections
6il printing
Surface Production 1rame Production 6il Printing
The Hong Kong Polytechnic University Industrial Training Centre
Department of Electronic and Information Engineering Degree 2 Summer Term Proect
))5 Conclusions
))5) Pro'lem Encountered
There 3ere several pro$lems encountered 3ithin the manufacturing processes" In fact5 the
original ;ED thermometer used C#P6462 as the micro0controller" It 3as a 280pin integrated
circuit that had many features that ma2e it particularly 3ell suited to this proectA
!"! ,871 W 6 '#TP( EP*#.
!"2 !26 $ytes *%.
!") ! ms cycle time at !8 .HG
!", !1 $it timer 3ith automatic reload5 e9ternal event counter and capture functions
!"/ !1 IQ# pins5 !, of 3hich can $e individually programmed as inputs or outputs
!"1 Selecta$le tri0state5 push0pull or pull0up IQ# pin configuration
!"4 .icro3ire interface
!"6 Timer5 soft3are5 and e9ternal interrupt sources5 3ith programma$le polarity
%nd the original schematic design is sho3n as follo3ing diagram"
Page )8

The Hong Kong Polytechnic University Industrial Training Centre
Department of Electronic and Information Engineering Degree 2 Summer Term Proect
This 3as designed $y the Ele2tor Electronic Company" %s 3e can see from the diagram5
C#P6462 3as used as the micro0controller to control the thermal sensor DS!12!" <ecause of
the limitation of development tools5 3e use the %T67C/! as the micro0controller and the
DS!128 as the thermal sensor"
Ho3ever5 %T67C/! is ,80pin integrated circuit5 the original schematic design used in Ele2tor
Electronics proect should $e revised" Be changed the design $y setting the num$er of each
column from 6 to !8"
))52 EAperience gained
%fter this industrial training programme5 3e had gained much valua$le e9periences" Be had
refreshed our memory of assem$ly programming5 PC< manufacturing procedures" Be also
learnt ho3 to use the cutting machine and lathe machine to produce the casing"
<esides5 manufacturing process5 3e 2no3 the importance of proect planning" If a good
schedule 3as made $efore doing any process5 the efficiency 3ill $e much $etter than no
schedule and no planning"
Page )!

The Hong Kong Polytechnic University Industrial Training Centre
Department of Electronic and Information Engineering Degree 2 Summer Term Proect
)25 #ecommendation and future enhancement
Since decoration can $e su$ective5 no suggestions can $e provided" Ho3ever5 focusing on
the functions5 3e have thought a$out several recommendations or future enhancement"
%lthough our production can function properly5 the temperature display is flashing during
measuring the temperature values" To overcome this5 the delayed function of the programme
and the fre+uency of the crystal should $e considered and changed"
<y adding e9tra components to the PC< and design computer programme 3ith an interface5
the thermometer can communicate 3ith computer" <y the use of this programme5 ma9imum
temperature record and minimum temperature record of the 3hole day can $e displayed"
.emory refresh should $e done 3ithin the programme too"
#n the other hand5 if availa$le5 adding a microphone and e9tra circuit design5 the
thermometer can $e used to measure and display sound noise" % s3itch can activate this
function" <y pressing the same s3itch5 the product 3ill measure temperature again"
)85 #eferences
!" Dallus Semiconductor httpAQQ333"dalsemi"com
2" Ele2tor Electronic Company httpAQQ333"ele2tor0electronics"co"u2
)" *S Components ;td" httpAQQ333"rs333"com"h2
," .ET%; Design and &a$rication Q David and Susan &risch5 Ee3 Xor2 A Bhitney
;i$rary of design5 !776"
/" The 68/! microcontroller and em$edded systems Q .uhammad %li .aGidi5 -anice
Dillispie .aGidi5 Upper Saddle *iver5 E"-" A Prentice Hall5 c2888"
Page )2

The Hong Kong Polytechnic University Industrial Training Centre
Department of Electronic and Information Engineering Degree 2 Summer Term Proect
1" The 68/! microcontroller A architecture5 programming5 and applications Q %yala5
Kenneth -"5 .inneapolisQSt" Paul A Best Pu$"5 c!774"
Page ))