I'm amazed that the solder bubble's shape can be controlled so well. I realize that molten solder has very high surface tension, but I wonder if there's more to the shaping process than that.
-Phil
I totally agree phil. It amazes me that they have that much control over the shape! American technology!
This is the solder that we'll be using to fill the Pot with. It's got to get cut into 4" long pieces (down from the 14" raw lengths shown) to fit into the pot.
These Bars are not exactly usable for "fine work", but once they're melted, they'll become the medium for the "little silver fountain"...
The video is correct, but only after the "bulk" of the pot is initially filled.
When the level drops, then the spool feed "tops it off" as necessary - kind of a cool way to accomplish the initial task of filling from scratch - otherwise it would take a lot of spools to fill a pot with molten solder this size!
I'm just biding my time, biiiding my tiiiime, until Parallax outgrows the building they're in. Then they can start shipping all that cool equipment to their Parallax NW annex -- which would be in Port Townsend never-a-tornado-or-temp-above-90, WA, of course!
I'm just biding my time, biiiding my tiiiime, until Parallax outgrows the building they're in. Then they can start shipping all that cool equipment to their Parallax NW annex -- which would be in Port Townsend never-a-tornado-or-temp-above-90, WA, of course!
No tornados, but not much sun either. It'll all rust within a year.
I wish they knew about some of these nice solutions (using nitrogen) in the 70's. I used to operate a wave solder machine and "the generation of dross" was dealt with all day long added up to 45 minutes to my work day while I cleaned and generally "uncontaminated" the machine for the next work day.
So Kevin (from ACE) is here this week training our intrepid production crew on how the KISS 102 works.
This is the "solder bucket" from which the liquified solder is pumped from. This is about 28 lbs. of solder I think...
It took about 1.5 hours to melt the solder and fill the pot from barstock.
The cone shaped nozzle to the right of the pot is the "flux sprayer". It's pumped from a bottle from underneath the KISS 102.
Simple physics: fluid dynamics and gravity. No black magic involved. If you turn on your garden hose really low and hold the end straight up, you will get a similar but shallower bullet nose shape. The Nitrogen does aid a bit in maintaining a "beuatiful" shape as it creates an inert atmosphere where physics can play quietly......
Yes, but the garden hose runs over the side, so the shape and height of the water head are partly dependent on pressure and flow. The solder bubble does not run over the side, so flow rate cannot be a factor. I can see how surface tension alone would let it form a dome shape, but it has to be the nitrogen flow past the nozzle that stretches it into a point. At least that's my guess. The fly in that ointment might be turbulence where the air flow hits the PCB.
Yes, but the garden hose runs over the side, so the shape and height of the water head are partly dependent on pressure and flow. The solder bubble does not run over the side, so flow rate cannot be a factor.
In the video, it looked like the solder head had a channel on one side that the solder would flow down, constantly circulating. But I guess Matt can clear that up for us at some point.
Solder flows up the center of the nozzle and flows down all sides of the nozzle. The versions of nozzles that have a side channel are designed that way to give a directional flow off the nozzle which aids where a wave solder style flow works better fro particular parts. At my work, my wave tech only uses the standard circular nozzles on our '08 KISS102.
Due to surface tension, the vapor pressure of molten metals is fairly low. Plus, Parallax is using a lead-free process. Even if vapors did escape, the toxicity would be low. Knowing Parallax, though, I'm sure that all necessary safety measures have been taken. Besides, they're in California, the bleeding edge of environmental and safety regulation.
Andrew,
Thanks for the explanation. I didn't catch that there is a return flow.
Due to surface tension, the vapor pressure of molten metals is fairly low. Plus, Parallax is using a lead-free process. Even if vapors did escape, the toxicity would be low.
I'm guessing he was thinking more about someone (hopefully accidentally) dipping a finger in it. That was my first thought as well.
@Matt: Do you always leave the solder pot uncovered like that? It doesn't seem too safe
Hi Micro-
You're right - that's not all that safe. However, it's only during the initial filling that it is "open topped" like that. The video that shows that "swiss-cheese" looking thing is actually the lid that fits over the pot. So on a daily basis, yes it's just about completely sealed.
The pot is only open when we initially fill it with the bar stock solder.
And, of course, WBA is the real expert here because he's the one who suggested we take a serious look at this particular machine. It's my understanding (correct me if I'm wrong here WBA) that he and his staff use a KISS 102 just about everyday???
And you're right Phil, some of the earlier photos in this thread show the steps we've taken to get rid of just about every smell and vapor possible.
That's why you see the twin 4" ducts joined to a 6" duct, bushed up to an 8" duct, that's connected to a 650 CFM vent through the roof. The Company insists on having the cleanest and safest work environment possible, and is willing to invest in the quality components and time and training necessary to achieve it.
Our "Trainer" from ACE (Kevin's his name) told us that most companies don't bother to vent at all, since the amount of fumes and smell is really quite minimal - this is especially true if using lead-free technologies. We're lead-free, and we're venting with over-kill.
I'm not an accountant by any stretch, but sometimes it seems like we're spending all our profit on new machines that give us new capabilities and inspirations, that enable new products to be produced right here in the Good Old USA. Gotta love it!
The only drawback for me is that (since I'm kind of a low-man-on-the-totem-pole) my *new product developments* get postponed when company infrastructure and building/technology enhancements are required. My other products in the "pipeline" get side-lined temporarily, until the new machines get installed.
But no, I'm not whining. - We're increasing our capabilities and adding value to what we design and manufacture right here in Rocklin, CA USA.
Oh, and one more thing on the "open solder pot"...
The solder is heated to 300 degrees C.
Kevin (the Trainer) had a nifty pair of gloves (that we now have a pair of). He dipped his entire index finger right into the pot!!! Just to prove that we should use these gloves when changing out, or working with the solder pot while it's still hot.
Pretty good "selling point" for the gloves, I'd say!
@Matt - "low man on the totem pole". The humble attitude is wonderful, but let me make it clear to all forum members - you're the guy who's making a lot of very important things happen. It might be an overstatement to say we'd still be cutting plywood with jigsaws and soldering PCBs with blow torches but Matt's contributions are helping us achieve our goals of having the highest quality manufacturing processes, people and machines. With these improvements we are planning to double our manufacturing throughput starting in August of this year with the finest quality we can deliver.
I'm not an accountant by any stretch, but sometimes it seems like we're spending all our profit on new machines that give us new capabilities and inspirations, that enable new products to be produced right here in the Good Old USA. Gotta love it!
I gotta agree: it's a great way to build for the future. In my own little company, if I've got enough left over for beer (for me) and shrimp (for Browser), the rest goes to new equipment. 'Just ordered a MakerBot Thing-o-Matic. 'Not sure what I'll do with it yet (or where I'll put it); but I said the same about the laser cutter. 'Couldn't live without it now!
'Just ordered a MakerBot Thing-o-Matic. 'Not sure what I'll do with it yet (or where I'll put it); but I said the same about the laser cutter. 'Couldn't live without it now!
'Just ordered a MakerBot Thing-o-Matic. 'Not sure what I'll do with it yet (or where I'll put it); but I said the same about the laser cutter. 'Couldn't live without it now!
-Phil
Make a Propeller control board for it, for starters!
Matt, yes, we run our KISS 102 nearly everyday with a variety of product. We have a lead free pot and a tin/lead pot and use both about the same amount. (tin/lead won't go away for a long time)
Comments
These Bars are not exactly usable for "fine work", but once they're melted, they'll become the medium for the "little silver fountain"...
-Matt
-Matt
The video is correct, but only after the "bulk" of the pot is initially filled.
When the level drops, then the spool feed "tops it off" as necessary - kind of a cool way to accomplish the initial task of filling from scratch - otherwise it would take a lot of spools to fill a pot with molten solder this size!
-Matt
What's the alloy composition of the solder you'll be using?
-Phil
The bubble on a wave solder machine is something to be seen, but that video of the molten solder head is awesome.
Hey! No cutting in line, chief!
-Phil
No tornados, but not much sun either. It'll all rust within a year.
I wish they knew about some of these nice solutions (using nitrogen) in the 70's. I used to operate a wave solder machine and "the generation of dross" was dealt with all day long added up to 45 minutes to my work day while I cleaned and generally "uncontaminated" the machine for the next work day.
This is the "solder bucket" from which the liquified solder is pumped from. This is about 28 lbs. of solder I think...
It took about 1.5 hours to melt the solder and fill the pot from barstock.
The cone shaped nozzle to the right of the pot is the "flux sprayer". It's pumped from a bottle from underneath the KISS 102.
-Matt
-Matt
Here's part of the way in which the shape of the "fountain" is controlled...
-Matt
-Phil
-Phil
In the video, it looked like the solder head had a channel on one side that the solder would flow down, constantly circulating. But I guess Matt can clear that up for us at some point.
Due to surface tension, the vapor pressure of molten metals is fairly low. Plus, Parallax is using a lead-free process. Even if vapors did escape, the toxicity would be low. Knowing Parallax, though, I'm sure that all necessary safety measures have been taken. Besides, they're in California, the bleeding edge of environmental and safety regulation.
Andrew,
Thanks for the explanation. I didn't catch that there is a return flow.
-Phil
I'm guessing he was thinking more about someone (hopefully accidentally) dipping a finger in it. That was my first thought as well.
Hi Micro-
You're right - that's not all that safe. However, it's only during the initial filling that it is "open topped" like that. The video that shows that "swiss-cheese" looking thing is actually the lid that fits over the pot. So on a daily basis, yes it's just about completely sealed.
The pot is only open when we initially fill it with the bar stock solder.
And, of course, WBA is the real expert here because he's the one who suggested we take a serious look at this particular machine. It's my understanding (correct me if I'm wrong here WBA) that he and his staff use a KISS 102 just about everyday???
And you're right Phil, some of the earlier photos in this thread show the steps we've taken to get rid of just about every smell and vapor possible.
That's why you see the twin 4" ducts joined to a 6" duct, bushed up to an 8" duct, that's connected to a 650 CFM vent through the roof. The Company insists on having the cleanest and safest work environment possible, and is willing to invest in the quality components and time and training necessary to achieve it.
Our "Trainer" from ACE (Kevin's his name) told us that most companies don't bother to vent at all, since the amount of fumes and smell is really quite minimal - this is especially true if using lead-free technologies. We're lead-free, and we're venting with over-kill.
I'm not an accountant by any stretch, but sometimes it seems like we're spending all our profit on new machines that give us new capabilities and inspirations, that enable new products to be produced right here in the Good Old USA. Gotta love it!
The only drawback for me is that (since I'm kind of a low-man-on-the-totem-pole) my *new product developments* get postponed when company infrastructure and building/technology enhancements are required. My other products in the "pipeline" get side-lined temporarily, until the new machines get installed.
But no, I'm not whining. - We're increasing our capabilities and adding value to what we design and manufacture right here in Rocklin, CA USA.
-Matt
The solder is heated to 300 degrees C.
Kevin (the Trainer) had a nifty pair of gloves (that we now have a pair of). He dipped his entire index finger right into the pot!!! Just to prove that we should use these gloves when changing out, or working with the solder pot while it's still hot.
Pretty good "selling point" for the gloves, I'd say!
-Matt
Thanks for making it happen, Matt!
Ken Gracey
-Phil
I am so jealous. I want both of those!!!!
Make a Propeller control board for it, for starters!
Ken Gracey