A Modification Design of Interlock System of ESPEC PV-212M Oven Rev 9 - Updated

Modification Design of Interlock System of ESPEC PV-212M Oven
A Project Study
Presented to the Faculty of the
College of Engineering and Technical Department
Manuel S. Enverga University Foundation
University Site, Lucena City
In Partial Fulfillment of the Requirement

for the Degree
Bachelor of Science in Electronics Engineering
Expanded Tertiary Education Equivalency and Accreditation Program
by
Alvin Joseph F. Pea
March 2015
INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

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Approval Sheet
This special project entitled:
MODIFICATION DESIGN OF INTERLOCK SYSTEM OF ESPEC PV-212M OVEN
MACHINE
Prepared and submitted by Alvin Joseph F. Pena in partial fulfillment of the requirements for
the degree of Bachelor of Science in Electronics Engineering (ETEEAP Program) has been
presented and passed the Oral Examination.
Engr. Evangeline L. Constantino

Adviser
Approved by the Committee on Oral Examination with a grade of ____ on March 15, 2015
Benilda N. Villenas, PhD

Member
Engr. Erwin Ellazar
Member
Engr. Sherwin Lagrama

Member
Guillermo M. Rago Jr., RCE, Ed.D.
Chairperson
Accepted in partial fulfillment of the requirements for the degree of Bachelor of Science
in Electronics Engineering (ETEEAP Program).
________
Date
Guillermo M. Rago Jr., RCE, Ed.D.

Dean, College of Engineering and Technical Department

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Acknowledgement
First and foremost thanks to our God Almighty for giving me the strength and courage to
accomplish my studies and to everyone who had helped me complete this project study.
I want to thank my loving wife Azeonete, My One and only daughter Audrey, I thank
you for all your support, care, understanding, patience, and love that gave me strength in my
pursuit with this endeavor. To my superior, Rodolfo Tobias for giving me the opportunity to
earned and complete this degree. Furthermore, I would like to thank my mother Felicidad, father
Medardo, siblings Allan, Jason, and Micah for the encouragement and inspiration parted to me as
a source of my strength in fulfilling my dream of finishing my studies.
I also want to thank my project study adviser Engr. Evangeline L. Constantino for the guidance
throughout the various revisions of this research, valued criticism and instructions as well and to
all my classmates in ECE class of 2014-15 on their support and cheerfulness that made this
school electrifying and uncomplicated for each and every one of us.
Lastly I would like to express also my gratitude to those who had given me the
opportunity to complete this project study most especially to our dean Dr. Guillermo Rago, ECE
instructors, Engr. Erwin Ellazar and Engr. Sherwin Lagrama, without your support and advise
these could not be possible.

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Dedication
To my ever-beautiful wife, Azeonete,
To my daughter- Audrey,
To my Pena Family.
I dedicate this manuscript to all of you as you have been and always be my inspiration.

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Table of Contents
Title Page
Approval Sheet...
Acknowledgement..
Dedication..
Table of Contents...
List of Tables.
List of Figures
Abstract..
1
2
3
4
5
7
8
9
UNIT I INTRODUCTION
Background of the Study ..
Objectives of the Study..
Conceptual Framework..
Significance of the Study...
Scope and Delimitation..
Definition of Terms
Acronyms
10
11
11
13
14
14
17
UNIT II- REVIEW OF RELATED LITERATURE AND STUDIES
18
UNIT III METHODS AND PROCEDURE

Research Design
Research Environment...
Procedures ......
Design Concept.
26
26
27
29
UNIT IV- RESULTS AND DISCUSSION

Data Gathering .
32
System Design Modification...
35
Block Diagram.
38
Circuit Design.
38
Material Selection
38
Schematic Diagram..
39
Circuit Diagram
39
Wiring Diagram
44
PCB Layout.
45
System Integration...
45
Specification Requirements
46
Bill of Materials
48
Prototype Fabrication..
49
Installation..
.
51
User Manual ..
53
Cost Benefits Analysis
54
Testing and Evaluation..
56

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Summary of Findings
59
UNIT V CONCLUSIONS AND RECOMMENDATIONS

Conclusions
Recommendations.
61
62
References..
Appendices
A
ESPEC PV-212M Oven Machine
B
PC817 Photocoupler Series..
C
DS1307 Memory.
D
NPN Transistor BC547...
E
MICROCHIP PIC16F87/88 .
F
LM317 Regulator.
G
MICROCHIP 24LC256
H
LCD Pin Diagram
I
Electrical Diagram of Matrix Keypad..
J
1N4007 Rectifier Diode
K
Microprocessor Crystal.
L
Carbon Film Resistor.
M
Tact Switch
N
Respondents Survey Questionnaire.
63
Curriculum Vitae...
89
64
65
66
67
68
69
70
71
72
73
74
75
76
76

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List of Tables
Table No.
1
2
3
4
Title
Likert Scale for Evaluation
Bill of Materials
Survey Results
Page
30
46
48
57

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Figure No.
1
2
3
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5
6
7
8
9
10
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List of Figures
Title
Conceptual Framework Paradigm
ESPEC PV-212M Oven
Operational process flow ESPEC oven
Existing Schematic Diagram
ESPEC Oven Normal Operation
Upgrading Sequence of Interlock System
Flow Chart of the Source Code of the Microcontroller
Block Diagram of Whole System ESPEC Oven
Electronics Components Used
Schematic Diagram of Interlock System
Circuit Diagram of Interlock System
Input Signal ESPEC Oven
Input Keypad Matrix
Input Power Supply
Transistor drive of a Solenoid Valve
Wiring to ESPEC Oven
Printed and Lay-out Components
Etching Procedure of PCB
Soldering Components
Interlock Circuit for PV-212M
Signal Interconnection for PV-212M
Main System for PV-212M
Solenoid Valve and Cylinder for PV-212M
Project Quotation in O.E.M Pricing
ESPEC Interlock system graph analysis
ESPEC Oven Yield Vs Reject
Page
11
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38
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42
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Abstract
Alvin Joseph Pena., A Modification Design of Interlock System of ESPEC PV-212M
Oven Machine, unpublished Project Study for the degree of Bachelor of Science in Electronics
Engineering. College of Engineering, under the Expanded Tertiary Education Equivalency and
Accreditation Program (ETEEAP), Manuel S. Enverga University Foundation, March 2015
ESPEC Oven machine is one of the most commonly used machines in the semiconductor
industry today, due to its efficiency, versatility and reliability. The machine can cure the mold
compound after processing in mold machine to strengthen the plastic by baking the unit.
In this study the researcher aims to prevent bypassed operation of machine when 175
degree unit inside the chamber can be taken out prematurely since the door can be open all the
time if wanted. In this project study the researcher has shown design flaw in existing interlock
through the implementation of the proposed Modification Design of Interlock System the
researcher to prevent bypassed.
The project features an LED module which shows the parameters set in unlocking the
oven, a matrix keypad for the input of the password set by the user and a microcontroller which
would process the data from the LED matrix and oven and display a corresponding output on the
LED module and do a corresponding action in the solenoid valve.
The feasibility of the study was based on the result on the survey conducted on 10
technical respondents. The survey, which used the Likert Scale, had an overall rating of Strongly
Agree. This result showed that based on effectiveness and functionality, the respondents strongly
agree that the project is effective and functional to its objectives.
Keywords: Curing, ESPEC oven, Interlock, Microcontroller, Semiconductor

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Unit I
Introduction
Background of the Study
Post Bake Oven Chamber is used extensively in baking, heat treatment/drying of mold
unit, device requiring clean air conditions. In addition to the standard instrumentation which
offers two-step programming, Class 100 cleanliness is achieved by employing a HEPA filter and
a back-to-front laminar circulation system. The high-performance of ESPEC Oven provides
stable performance even during heat-up or cooling at high temperatures of 150C (+302F).
Espec oven is a major assembly process flow in NXP Semiconductor. It use for
strengthening the mold compound and test the capability of the unit in heat. This is set-up by 5
hours base on revision of our engineer to full complete curing and heat resistance.
The main issue of this problem many supervisors was disregard the process of machine
due to a long 5 hours curing time of the unit so they stop the machine after placid heating and
others no safety lock door during operation. This means they want more output during their shift
and commitment to customer. After unnecessary using method of process which may affect
quality of unit, the possible anxiety that affect is Crack unit and incomplete test in heating for
reliability. So that why the circuit has been design which called Modification of Interlock
System of ESPEC PV-212M Oven Machine that has a special design sequence to avoid the
process of oven and safety user operation.

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Objectives of the Study

The main objective of this study is to enable the researcher to come up with a working
prototype of Auto Interlock circuit. This module shall act as a triggering component on the part
of the ESPEC Oven Machine whenever the machine is used.
The following are the specific objectives:
1. To modify the design of interlock system of ESPEC Oven.
2. To designa circuit of modified design Interlock System.
3. To fabricate a prototype of the designed circuit.
4. To evaluate the prototype in terms of effectiveness, and functionality.
Conceptual Framework of the Study
Figure 1: Conceptual Framework Paradigm

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The researcher chose this framework for the reader to easily understand all the possible
resources that the researcher may use to complete this project, Most of the resources are clearly
stated in this illustration.
The researchers included all the possible materials in creating the project. These were the
basic electronics component used in the circuit like diode, resistor, capacitor, transistor and
Relay. The researcher also needs to focus on some of the advance component which is the
EEPROM and Micro Controller Unit, with the help of a third party who is more familiar in
programming language.
Significance of the Study
The technicians especially the process line sustainance will benefit from this study by
preventing the incomplete process of the machine and quality of the unit. Through this action, it
will be a lesser amount of crack component due to incomplete curing and safety operation.
The study is also beneficial to NXP as a whole. The savings that will be realized in
creating in-house fabrication of the project will have a big impact in the departments cost
savings program. By preventing incomplete curing of unit, the customer will give a high
reputation to the company.
This study would serve as a guide or reference in the conduct of other similar application
that might be needed by technical people or student in their line of work or career, particularly in
manufacturing industries.

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By practicing this study, the researcher would be able to refresh his knowledge about
electronic circuits and components, enhance the skills in the applied aspect of electronics, and
develop the structural approach of creating a technical paper.
Scope and delimitations of the Study
This study deals with the creation of a Modification of Interlock system Circuit wherein
the ESPEC Oven machine will perform when the temperature 150 degree Celsius was stable the
interlock will activate close and after finish 5 hours curing the door will open. If when the
machines stop within the incomplete curing time, the state of interlock close will always activate
only process can access to release the lock by input the password code.
This is the first time that researcher attempt to create a design with micro-controller units
specially in command a ESPEC Oven machine performed a task using a separate circuit board.
In this circuit design the microcontroller unit will use as the main part of the circuit which will be
the controller of all the input signals to perform another design task.
Thus this study is limited for ESPEC Oven Machine which is located on Central
Assembly department at the post mold cure area where the researcher is currently assigned. The
project study will be limited for one unit ESPEC Oven equipment only and after simulation and
evaluation, it will fan out to other existing same equipment that needed to perform the AutoInterlock system.

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Definition of Terms
Buy-off is the process of inspecting a new equipment to be purchased according to the
required specifications prior to the delivery of the equipment to the site of the purchaser.
Capacitor is an electrical device that can store energy in the electric field between a pair
of closely spaced conductors called plates. When voltage is applied to the capacitor, electric
charges of equal magnitude but opposite polarity build up on each plate.
Connector is an electrical connector is a device for joining electrical circuits together. In
computing it can also be known as a physical interface.
Espec PV-212M Oven Machine is the temperature chamber that cures the molding
compound and its also test the capabilities on heat resistance of the unit.
Hardware refers to tangible components of computer system such driver board,
Input/Output board. The hardware component is use to store or process results.
Integrated circuit a miniaturized electronic circuit constructed of individual
semiconductor devices, as well as passive components bonded to a substrate or circuit board.
Interlock is the processes when the machine reaches the set point of
175
Celsius it
will automatic lock the door and it will release after he finish the process.
Light Emitting Diode (LED)
is a semiconductor device that emits incoherent narrow-
spectrum light when electrically biased in the forward direction. This effect is a form of
electroluminescence. The color of the emitted light depends on the composition and condition of
the semiconductor material used, and can be infrared, visible or near-ultraviolet. LEDS are

16
available in different size, shape and color. LEDS may be in color red, yellow, green, orange,
blue and white.
Microcontroller is a computer control system on a single chip. It has many electronic
circuits built into it, which can decode written instructions and convert them into electrical
signals .The microcontroller will then step through these instructions and execute them one by
one. Microcontroller is now changing electronics design. Instead of hard wiring a number of
logic gates together to perform some function we now use instructions to wire the gates
electronically. The list of these instructions given to the microcontrollers is called program.
Poka-yoke is a Japanese term that means "fail-safing" or "mistake- proofing". A pokayoke is any mechanism in a lean manufacturing process that helps an equipment operator avoid
mistakes. Its purpose is to eliminate product defects by preventing, correcting, or drawing
attention to human errors as they occur. The concept was formalised, and the term adopted, by
Shigeo Shingo as part of the Toyota Production System. It was originally described as bakayoke, but as this means "fool-proofing" the name was changed to the milder poka-yoke.
Process Flowis the illustration of one process or procedure where the step by step of the
process is properly defined according to their proper sequence.
PC40 is one of the five Business Fulfillment Groups (BFG) in NXP; also known as
Power department.
Programming Language C is a general-purpose, procedural, imperative computer
programming language developed in the early 1970s by Dennis Ritchie for use on the UNIX
operating system. It has since spread to many other operating systems, and is now one of the

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most widely used programming languages. C also has had a great influence on many other
popular languages.
Resistoris a two-terminal electrical or electronic component that resists an electric current
by producing a voltage drop between its terminals in accordance with Ohms law.
Transistoris a device which utilizes a small charge in current to produce a large change in
voltage, current or power. It may function also as an amplifier or an electronic switch.
Variable resistor consists of a resistance track with connections at both ends and a wiper
which moves along the track as you turn the spindle. The track may be made from carbon,
cermets (ceramic and metal mixture) or a coil of wire (for low resistances).
Acronyms
NXP
Next Experience
BFG
Business Fulfillment Groups
QA
Quality Assurance
MCU
Micro Controller Unit
MPLAB
Microchip PIC Lab
IDE
Integrated Development Environment
PFMEA
Process Failure Mode and Effect Analysis
PCB
Printed Circuit Board

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Unit II
Review of Related Literature and Studies
This section mentioned theories and operation of the electronic components and materials
needed to modify and creating Auto Interlock of a circuit, as well as other technical information
necessitated to be discussed for further understanding of all the target electronic components.
The sources of information are various electronic books and knowledge websites on the Internet.
In NXP Semiconductor particularly in Power Central Assembly the places where all
products had been tested and Curing the molding compound after went in molding machine. This
is the area where the researchers are also assigned.
Espec PV-212MOven
According to ESPEC Corp. (2006) Oven used extensively in baking, heat
treatment/drying of mold unit, devices requiring clean air conditions. In addition to the standard
instrumentation which offers two-step programming, Class 100 cleanliness is achieved by
employing a HEPA filter and a back-to-front laminar circulation system. The high-performance
of ESPEC Oven provides stable performance even during heat-up or cooling at high
temperatures of 150C (+302F).
Circuit
According to Floyd (2010) basically, an electric circuit consists of a voltage source, a
load, and a path for current between the source and the load.

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Language C++
Lovine (2004) noted that there are a number of compilers on the market that allow users
to write programs (code) in different high-level languages. High-level language frees the
programmer from wrestling with and controlling the microcontrollers registers when writing
code and accessing the different aspects of the microcontrollers features and memory.
MPLAB IDE
According to microchip (2003) MPLAB Integrated Development Environment is a free,
integrated toolset for the development of embedded applications employing Microchip's PIC
and PIC microcontrollers. MPLAB IDE runs as a 32-bit application on MS Windows. Is easy
to use and includes a host of free software components for fast application development and
super-charged debugging. MPLAB IDE also serves as a single, unified graphical user interface
for additional Microchip and third party software and hardware development tools. Between
tools is a snap, and upgrading from the free software simulator to hardware debug and
programming tools is done in a flash because MPLAB IDE has the same user interface for all
tools.
PIC16F876A
Microchip (2007) stated that this powerful (200 nanosecond instruction execution) yet
easy-to-program (only 35 single word instructions) CMOS FLASH-based 8-bit microcontroller
packs Microchip's powerful PIC architecture into an 28-pin package and is upwards compatible
with the PIC16C5X, PIC12CXXX and PIC16C7X devices. The PIC16F876A features 256 bytes
of EEPROM data memory, self-programming, an ICD, 2 Comparators, 5 channels of 10-bit
Analog-to-Digital (A/D) converter, 2 capture/compare/PWM functions, the synchronous serial

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port can be configured as either 3-wire Serial Peripheral Interface (SPI) or the 2-wire InterIntegrated Circuit (IC) bus and a Universal Asynchronous Receiver Transmitter (USART). All
of these features make it ideal for more advanced level A/D applications in automotive,
industrial, appliances and consumer applications.
Transistor
The general purpose transistor NPN type and to understand the overall operation of the
transistor amplifier, you must only consider the current in and out of the transistor and through
the various components in the circuit. Therefore, from this point on, only the schematic symbol
for the transistor will be used in the illustrations, and rather than thinking about majority and
minority carriers, we will now start thinking in terms of emitter, base, and collector current.
Before going into the basic transistor amplifier, there are two terms you should be
familiar with: AMPLIFICATION and AMPLIFIER. Amplification is the process of increasing
the strength of a SIGNAL. A signal is just a general term used to refer to any particular current,
voltage, or power in a circuit. An amplifier is the device that provides amplification (the increase
in current, voltage, or power of a signal) without appreciably altering the original signal.
Transistors are frequently used as amplifiers. Some transistor circuits are CURRENT amplifiers,
with a small load resistance; other circuits are designed for VOLTAGE amplification and have a
high load resistance; others amplify POWER.
By inserting one or more resistors in a circuit, different methods of biasing may be
achieved and the emitter-base battery eliminated. In addition to eliminating the battery, some of
these biasing methods compensate for slight variations in transistor characteristics and changes
in transistor conduction resulting from temperature irregularities. (www.tpub.com/electronics,
2005)

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Diode1N4001
According to datasheet.com (2008) the 1N4001 series (or 1N4000 series) is a family of
popular 1.0 amp general purpose silicon rectifier diodes commonly used in AC adapters for
common household appliances. Blocking voltage varies from 50 to 1000 volts. This diode is
made in an axial-lead DO-41 plastic package.
These are fairly low-speed rectifier diodes, being inefficient for square waves of more
than 15 kHz. The series was second sourced by many manufacturers. The 1N4000 series were in
the Motorola Silicon Rectifier Handbook in 1966, as replacements for 1N2609 through 1N2617.
The 1N5400 series were announced in Electrical Design News in 1968, along with the now
lesser known 1.5-ampere 1N5391 series. These devices are widely used and recommended.
Capacitor
From the statement of Floyd (2010) a capacitor is an electrical device that stores
electrical charge and is constructed of two parallel conductive plates separated by an insulating
material called the dielectric.
Ceramic
Alexander (2004) said that the ceramic is a chip of altering layers of metal and ceramic,
depending on their dielectric, whether Class 1 or Class 2, their degree of temperature/capacity
dependence varies. They often have (especially the class 2) high dissipation factor, high
frequency coefficient of dissipation, their capacity depends on applied voltage, and their capacity
changes with aging. However they find massive use in common low-precision coupling and
filtering applications.

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Resistor
Alexander (2004) released the statement that resistor is a two-terminal electronic
component designed to oppose an electric current by producing a voltage drop between its
terminals in proportion to the current, that is, in accordance with Ohm's law: V = IR.
Practical resistors can be made of resistive wire, and various compounds and films, and they can
be integrated into hybrid and printed circuits. Size, and position of leads are relevant to
equipment designers; resistors must be physically large enough not to overheat when dissipating
their power.
Four-band identification is the most commonly used color-coding scheme on all resistors.
It consists of four colored bands that are painted around the body of the resistor. The first two
bands encode the first two significant digits of the resistance value, the third is a power-of-ten
multiplier or number-of-zeroes, and the fourth is the tolerance accuracy, or acceptable error, of
the value. Sometimes a fifth band identifies the thermal coefficient, but this must be
distinguished from the true 5-color system, with 3 significant digits.
PCB Pins
According to answers.com this are the electronic interconnects devices for printed circuit
boards. It has a better signal integrity for high reliability application across a wide range of
industries. Regardless the type and design of a PC board, external signal and power connections
must be made. Printed circuit boards, as well as other electronic components, in many instances
are electronically joined through connectors. The components are typically interconnected to
define a given function.

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Light Emitting Diode

Base on Alexander (2004) a light-emitting diode (LED) as shown in is a semiconductor
device that emits incoherent narrow-spectrum light when electrically biased in the forward
direction. This effect is a form of electroluminescence. LEDs are small extended sources with
extra optics added to the chip, which emit a complex intensity spatial distribution. The color of
the emitted light depends on the composition and condition of the semiconducting material used,
and can be infrared, visible or near-ultraviolet. Rubin Braunstein of the Radio Corporation of
America first reported on infrared emission from gallium arsenide (GaAs) and other
semiconductor alloys in 1955. Experimenters at Texas Instruments, Bob Biard and Gary Pittman,
found in 1961 that gallium arsenide gave off infrared (invisible) light when electric current was
applied. Biard and Pittman were able to establish the priority of their work and received the
patent for the infrared light-emitting diode. Nick Holonyak Jr. of the General Electric Company
developed the first practical visible-spectrum LED in 1962.
The researcher uses the above literature to understand the problems system of interlock
ESPEC oven machine and how does it work in different ways. This will also be needed to
understand the characteristic and behavior of the devices that chosen on the circuit, the possible
problem and circuit conflict may arise when then researcher constructing it.
Microcontroller
A study by Cheng, et Al. (2004) machine vision set up using two cameras as human eyes
and a micro-controller as a human brain to recognize the object. Moreover, with the aid of
artificial intelligence, the machine acted like a regular person and identifies objects. This
machine vision project was implemented on the Robocop robot. In other words, these researches

24
create an "eyes" for the Robocop robot that promoted the study of robotics and artificial
intelligence (AI) researches for the Ohio State University. The study is related to the researchers
proposed study in such a way that it is dealing with the use a micro controller chip as the core
component in the circuit.
Tan, et Al. (2008) replaced a mechanical clock with a much reliable, accurate,
maintenance free and portable service. They used a microcontroller based digital clock using PIC
16F877A and software written in C language. The controller control all the features and the input
frequency taken from a 50HZ clock frequency circuit .To show the time seven segment LED,
four LEDs were used.
This can be considered as related to the researchers proposed study in such a way that
the Microcontroller based Digital also uses a PIC microcontroller using C language LCD display
as the core component in the circuit.
The group of Amon, et.al, (MSEUF, March 2005) also designed a control system
consisting of several sensors with different objectives with GSM module. Each sensor is aimed at
detecting some kind of security breach. Most importantly, the entire system used a
microcontroller that placed in the device to control, to hook up, to power and store information.
The objective is to detect three kinds of security breaches that is light detection, opening a door
and movements. Once any of the sensors is triggered, the GSM module sends SMS message to
the owner of the house or establishment. This authorized person used PIN number to control the
system. The related to the research is utilized the same medium which is the micro controller in
formulating a circuit.
In a study made by Baronia, et. al, (MSEUF, March 2005) entitled A Microcontroller
based Automated Door Lock System, he designed a control system consisting of a

25
microcontroller chip that controls the doors of classrooms and laboratories. The proposal was to
install a circuit and a keypad to control the opening and closing of the door. The authorized
personnel that have the password or number combination that will be encoded into the keypad
can only do this. The study can be related to the researchers proposed study in such a way that
the Automated Door Lock System also uses a microcontroller chip as the core component in the
circuit.
From the study of Albuero and Reganit of Polytechnic University of the Philippines
(March 2004) they designed an apartment digital electric sub metering system using a
microcontroller PIC16F877 and a Liquid Crystal Display that was used in the System. Using a
sub metering system, the consumers comprising of the lessee of commercial unit or the person
renting apartment will be availing the electricity service by means of paying the owner a certain
amount in advance. The electricity will be available as long as the prepaid load is not equal to the
base rate provided by the electricity supplier. The transaction for the electric consumption will be
in a prepayment format. The digital electric meter display kilowatt hour electricity consumption,
remaining prepaid balance and cost per kilowatt hour on its Liquid Crystal Display. Theirs
studies is also related to the researchers proposed study in such a way that the apartment digital
electric sub metering system also uses a PIC microcontroller and LCD display as the core
component in the circuit.
The above studies were chosen by the researcher to emphasize the important
participation of Microcontroller in every design in the modern years. The capability to simplify
the circuit in creating effective solution by means of this small chip can be possible.

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Unit III
Methods and Procedures:
This unit discussed the different methods and procedure that the researcher will be using to
realize the study. It consists of research method, research design, research environment and
procedure.
Research Design
The focus of the study is to develop a prototype auto-interlock circuit wherein the
Research and Development method was applied to establish the positive result. The prototyping
is the engineering term commonly used for trial and error; however the desired output are
visualized and calculated. This was done by the researcher to see the possible weakness of the
design, during the process of trial the researcher has the chance to continuously develop a circuit,
correct the possible mistake and to develop the possible improvement by adding extra features in
the system.
The prototyping method was applied to the project to produce the best results with
regards to the objective of the study. While continuously designing and improving the system to
fit the objective, a trial and error test was conducted every time. This ensures that the circuit
design improves every time a trial was made.
Research Locale
The researcher focus for the solution on process of the machine and safety of user where
the currently happening on NXP semiconductor especially on Power Department. This is the
department where the researcher currently assigned. All of the data gathered from the company
starting from the data where the bypass of the machine and some problem had been seen, like

27
MPMF (Machine Product Monitoring Form), Visual Inspection Log sheet, QA log sheet and the
daily QA PPM reporting where all the non conformance been indicated.
The entire study was conducted at NXP Semiconductor facility, and at school where the
researcher currently studying at Manuel S. Enverga University.
Respondents of the Research
The researcher gathered respondents to complete the study. They are the people who will
help the researcher to make this big project possible. The line engineer is the one whose expert
on the equipment will give the feedback on the risk and the impact of the feasibility study. The
software engineer is the one who will do the programming in the Micro-controller unit. The line
supervisor will make schedule regarding the availability of the machines needed on this project.
The operator and QA personnel will validate the effect of the project once it is implemented.
Procedures
The researcher shall undertake the systematic activities in order to complete this research study.
Data Gathering. To continue this study the researcher will refer to the technical manuals
of the Espec PV-212M Oven Machine. This will also needed a consultation to equipment
engineering to have additional ideas that is not covered by the technical manuals.
The researcher will also gather relevant information in the electronic engineering books
and in the technical Internet sites needed in achieving the objectives of this study.
These tools will help a lot to researcher to deeply understand the project that will going
through.

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System Design Modification. The researcher will create a design modification for the
project based on existing design problem identification, design computation, creating circuit,
installation, and testing the output of the project.
The system would be modified by attaching a keypad matrix and an LCD screen to
prevent unauthorized unlocking of the Oven. The data coming in from the oven and the keypad
matrix would be processed by the microcontroller for accurate and functional result.
Circuit Design. In designing a circuit this will need a corresponding knowledge in basic
electronics and the basic principle of each component. 1.) Understand basic function of the
machine and how function of interlock. 2.) Develop an electronic circuit design based on the
learnings acquired from the research process.3.) The advantage and disadvantage of the project
and its cost.4.) Create a prototype of the electronic circuit that emulates the Espec PV-212M
Oven Machine.
Prototype Fabrication. In this activity, the researcher will create a design circuit by
using EAGLE software and etching solutions used for the fabrication of board by preparing a
developer solution and ferric chloride for etching PCB design.
Evaluation. This activity is the time for the researcher to test the effectiveness of his
circuit design, the aim of researcher is the circuit to activate the interlock within the sequence
when the 175 degree Celsius has been reach the door will close it will open if the process has
been finished.
In this activity will also verify the possible impact on the machine once the circuit had
been installed and during actual simulation. This will also test the affectively and functionality of
the circuit.

29
The evaluation will focus on the criteria of effectiveness and functionality. In proving its
effectiveness and functionality, data will be gathered through a survey which was analyzed
through a modified Likert Scale.
The Questions will be follows;
Effectiveness
1.) Is the machine performing auto-interlock when the machine stable at 175 degree.
2.) Celsius? Is there any occurrence of after the installation of the circuit?
Functionality
1.) No machine hang-ups or breakdown related to auto interlock.
2.) No machine downtime during starting up oven.
The format of a typical five-level Likert item is:

1. Strongly Disagree
2. Disagree
3. Undecided
4. Agree
5. Strongly agree
The results were used to compute for the weighted mean including the formula:

30
WM = (SA*5) + (A*4) + (U*3) + (D*2) + (SD*1)

_________________________________
TNR
Where:
WM = Weighted Mean
TNR = Total Number of Respondents
Table 1
Likert Scale for Evaluation
Rating
Rate
Scale
SA = Strongly agree
4.21 5.00
A = Agree
3.41 4.20
U = Undecided
2.61 3.40
D = Disagree
1.81 2.60
SD = Strongly Disagree
1.00 1.80
Table 1 shows the rating system used on the survey conducted on the new design of
interlock system. Five is the highest rating and zero for the lowest possible rating. This scale will
be used also to interpret the results.
It also presents the interpretation of the weighted mean on each criterion defined. The
researcher used this table as a reference where the weighted mean falls. The personnel based
their rating on how they understand the function as well as their experience with the new
sequence on the interlock system.

31
Design Concepts
The purpose of this project is to design the circuit of Auto-interlock for Espec Oven
Machine. The circuit will execute the correct sequence of interlock which prevent bypassed the
door and procedure of curing time, safety of the user.
The researcher motivation for this project study is the principle of Poka-yoke concept. Its
purpose is to eliminate product defects by preventing, correcting, or drawing attention to human
errors as they occur. This is more of a concept than a procedure. Thus, its implementation is
governed by what people think they can do to prevent errors in their workplace, and not by a set
of step-by-step instructions on how they should do their job. This law is use in a three equivalent
forms depending on which quantity need to determine, whether it current, voltage or resistance.
Ohms Law helps a lot on the researcher, since this law mathematically describes how
voltage, current, and resistance related with each other in a circuit
In circuit design the researchers uses a Thevenins theorem, this theorem provides a
method of simplifying a circuit to a standard equivalent form. In many cases this can be used to
simplify the analysis of complex circuit.
1. Evaluate the actual operation of the prototype through actual connection to the Espec
Oven.
2. Prepare a simple questionnaire analyzing the affectivity, efficiency and safety and this
will be answered by the stakeholders via survey.

32
3. Gather 5-10 persons consisting of a cross functional team, this will be from production,
engineering and from quality.
4. Perform needed modification or simplification in the prototype, as necessary.
5. Finalize and document the prototype circuit.
The researcher will be needed a statistical method use to tabulate the results of evaluation
was the so called Five Point Likert Scale Method. This method is the most appropriate approach
to evaluate the project effectiveness in a way of evaluation.
Unit IV
Results and Discussions

33
The content of this unit discusses the different steps for the realization of this project
study. It also provides the presentation and interpretation of the data gathered on how the
researcher conducted her method, design modification, analysis, procedure and the outcome of
the modified design of interlock system of ESPEC PV-212M Oven machine.
Data Gathering
The data gathered was fully studied to identify the sources of opportunities. Facts
obtained had to be formulated to determine the baseline prospect of this project study.
ESPEC PV-212M oven machine. The researcher gathered the following data shown in
Figure 2 and was fully studied to identify the source of opportunity. Below figures shows the
actual machine and electrical lay-out of ESPEC Oven PV-212M where the researcher focus the
interlock system to improve the safety of the user when using the machine.
Figure 2: ESPEC PV-212M Oven Machine

Existing process flow chart. In Figure 3 illustrate the process flow chart of ESPEC PV212M Oven.

34
Start Mode
End Mode
Rising up TempStabilization of temp 175
Door will unlock
Operational Complete
5hrs End
Start 5hrs
Door will Lock

Take note: When
machine stop while in
middle of 5hrs curing
process the door unlock.
Figure 3: Operational process flow ESPEC oven

On figure 3 shown the operational process flow of ESPEC oven to the line production
output is the most important because of the commitment in customer because of highly demand
in output the process of the ESPEC oven was been ignore because of long curing time process it
also note even in the middle of 5hrs the interlock will be unlock by stop the machine so the unit
can take out prematurely which maybe affect to the unit because of this the researcher study to
modify the existing interlock system and lessen the bypassed of the curing time of a oven.
Existing Schematic Diagram. Shown in figure 4 is the existing schematic diagram of

ESPEC Oven wherein built in automatic interlock in the system has been the researchers
problem every time theres a fluctuation in power the interlock has been release can be bypassed
so it may possible the process tech didnt know if the unit has been cured. To prevent
unnecessary bypassed is to change the system of the interlock by using microcontroller.

35
Figure 4: Existing Schematic Diagram
Data in figure 5 shows that the most critical curing of the unit stable in 175 degree
Celsius unit inside the chamber can be take out prematurely, since door can be open all times if
wanted because of the unnecessary procedure so why the line process technician didnt know if
the cycle was done.

36
Figure 5: ESPEC Oven Normal Operation
System Design Modification

The Researcher focused on the modification of the interlock system of ESPEC PV-212M
to improve the sequence by design using a microcontroller.
Proposed Process Flow. In this figured 6 shows the process improvement sequence of
interlock system and also include the flow chart of programming.

37
Start Mode
Stabilization of temp 175Start

Rising up Temp
5hrs
1
End Mode
Door will unlock
5hrs End
Door will Lock
Operational Complete
Door Lock Steadily
End Mode
Door will unlockEnter
Password
Only Process Tech can access
Figure 6: Upgrading Sequence of Interlock System

It explains the additional flow system to prevent bypass shows in no. 1. A new sequence
appear once theres an error encountered. The door will be locked and only the process
technician who has access to the door would be able to unlock and investigate the error happened
with this the researcher comes up an idea by using a microcontroller to improve the sequence of
interlock system and also added features to the machine.
System Flow Chart. On Figure 7 the flow chart process of microcontroller where the
researcher created a program on how will execute the system of interlock. The researcher also
used MPLAB software to create a program to improve the sequence of the interlock system.

38
Start
Machine:
Temp:
Count
No
Is
Machine Ok
Yes
No
Is
Temp 175
Yes
Lock Solenoid
Count = Count +1
Delay=10000ms
No
No
Is
Count
Is the Machine Turn Off?
Yes
Open Solenoid
END
Enter Password
No
Is Password Correct?
Yes

39
Figure 7: Flow Chart of the Source Code of the Microcontroller

Block Diagram. As illustrated in Figure 8, the first section is the power supply. An input
signal of 220 volts AC is applied to the power supply which will give source across the system of
ESPEC PV-212M Oven. The ESPEC Oven section is the main body chamber wherethey process
the unit carried out accordingly (e.g. temperature and time) and also for test reliability of heating
the unit.
Power Supply
ESPEC OVENModification Interlock System Interlock
Figure 8: Block Diagram of Whole System ESPEC Oven

In this section where the researcher focused on the Modification Interlock System by
interfacing the signal to the ESPEC oven machine and take control of microcontroller. The Final
section Interlock, a type of electromechanical used by a 5/2 way valve solenoid and piston
cylinder that perform to be lock and unlock the door.
Circuit Design
The development of proposed project study covers the hardware and wiring connection of
the modified design.

40
Material Selection. During the circuit development of this project study, included were
the selection of the precise component and materials shown in figure 9 which are electronic
standard and are readily available in the market. These materials are the essence of this project
study since it will define how reliable and efficient this project would be.
Transistor BC547
LED 5mm
Ceramic
1N4007 Diode
LM 317
Conn
ector
Photo
C Socket
coupler
Relay 5volts
Crystal Oscillator
Electrolytic
Coin Cell
Trimmer Resistor
Fixed Resistor
Tact Switch
DS1307
24LS2
PIC16F88-I/P
56P
LCD Display
Matrix Keyboard

41
Figure 9: Electronics Components Used

Schematic Diagram. Figure 10 illustrates the prototype circuit which were specially
designed for ESPEC Oven to create a systematically sequence of interlock door by using a
programmable circuit which called microcontroller.
Figure 10: Schematic Diagram of Interlock System

Circuit Diagram. The circuit diagrams below shows the computation per parts of the
schematic diagram, based on the input, output and processing of the project.

42
Figure 11: Circuit Diagram of Interlock System

43
Input: ESPEC OVEN
Figure 12: Input Signal ESPEC Oven

Input Section the internal infrared LED with 15mA, we could assure that the
phototransistor will be in the saturate state (ON), because the minimum current to make the
phototransistor on is about 10mA. The following circuit is use optocoupler to interfacing the
Idiode = 15 mA (0.015 A), VLED = 2 Volt to interfacing the microcontroller in I/O shown in Figure
12.
R1 = (Vcc VLED) / IB = (24 2) / 0.015 = 1466.66 Ohm, use 1.8k Ohm resistor
P = (Vcc VLED) x IB = (24 2) x 0.015 = 0.33 watt, use 0.25 Watt resistor

44
And the output of optocoupler in collector have a resistor of 10k ohms pull-up to stable the
signal gave to microcontroller port.
INPUT: KEYPAD MATRIX
Figure 13: Input Keypad Matrix
Keypad Pin
Connects to Arduino Pin...
D9
D8
D7
D6
D5
D4
D3
D2
The matrices are actually an interface technique. It can be used to interface inputs like
the PC keyboard keys, but also to control multiple outputs like LEDs. According to this
technique, the I/O are divided into two sections: the columns and the rows.

45
INPUT: POWER SUPPLY
Figure 14: Input Power Supply
The LM317 is an adjustable voltage regulator which can output a range of voltages (1.5
to 37V) based on the resistors R1 and R2. Normally the value of R1 is 240, the recommended
value by the manufacturer. However, the value of R1 may be any value from 100 to 1000.
The resistor R2 then is the chief resistor which allows for the swings in different voltage outputs.
The formula is below.
Using the voltage divider theorem to compute for the output, R1=240 and R2=720
will produce an output voltage of exactly 5V, being that VOUT= 1.25V * (1+ R2/R1) = 1.25V *
(1 + 720/240) = 5V.

46
Output Section by using 5 Volt power supply and solenoid coil with 24 Volt and 60mA
operating current shown in Figure 15.
OUTPUT: ESPEC OVEN
Figure 15: Transistor drive of a Solenoid Valve

RC = 0 Ohm can be directly drive to coil
IB = IC / hFE = .1 A / 450 = 0.0002
R16, R17 = (VPORT VBE) / IB = (4.2 0.7) / 0.0002 = 17500 Ohm, use 5K1 Ohm resistor
P = (VPORT VBE) x IB = (4.2 0.7) x 0.0002 = 0.0007 watt, use 0.25 Watt resistor

47
Wiring Diagram. On figure 16 shows on how to be connect the wiring from the machine
of ESPEC Oven to Modification Design of system interlock circuit.

48
Output Signal
Input Signal

49
Figure 16: Wiring to ESPEC Oven
2 condition signal
The wiring diagram shows the connections of the prototype to the ESPEC Oven. The first
connection established was that of the microcontroller and the oven. That was the first input. The
second was that of the keypad matrix which is then connected to the microcontroller and has an
output in the LCD module. This set up will control the solenoid valve which acts as the main
switch to the oven door.
PCB Layout. This shows the layout of the components on the presentesized PCB. The
task was done using CAD software for component layout called EAGLE software. This was to
ensure that all the wirings are done and that proper spacing for each component is made.
Figure 17: Printed and Lay-out Components

System Integration. Interfacing system show, theres a two condition signal before the
interlock must be functionone is Machine Operation and two is Stable 175 degree Celsius
once the signal are satisfy. The microcontroller who take action to lock the door base on the
program in IC while in production running the LCD display show the time and other minor
activities if there any error encounter into door lock. The matrix keypad will access to unlock the

50
door if there errors encounter and only process technician who have access door to investigate
what happen and why the process stops.
The list of specific requirement of each electronics component has been searched through
the internet and other existing items used in the line but the researcher exhaust all avenues at
arriving the correct specification of materials to be used in attaining success on these project
study, have also search at RS catalogue and Alexan to obtain the high end product commonly
used in the industry today. The list is composed of the main components used in the proposed
project study as shown in table 2.
Table 2:

51
Component
PC817
Transistor
BC547 NPN
Silicon
LED
Resistor
Specific Requirement
Forward current IF 50 mA
Collector-emitter voltage V CEO 35 V
Emitter-collector voltage V ECO 6 V
Collector current IC 50 mA
Collector power dissipation P C 150 mW
BaseEmitter Saturation Voltage
(IC = 10 mA, IB = 0.5 mA)
CollectorEmitter Voltage ( 45V)
CollectorBase Voltage (50V)
EmitterBase Voltage (6.0)
Size 3mm (Red, Green and Yellow)
Fixed Resistor watt
Model Required
Brand
DIL-Package
Sharp
TO-92
Motorolla
3mm
Avago
Technologies
603
Vishay
Molded
Bourns
Trimmer
Resistor
10K Ohms
LCD
LCD Display
Ceramic
.1uf, 22nf and 104nf
Polyester
Vishay
Electrolytic
470uf /63v
TH Aluminum
Nichicon
X-tal Oscillator
10Mhz and 32.768Khz
Through Hole
Micro X-tal
Relay
5volts/2amp contact
PCB Mount
Nais
LM 317
Adjust Voltage Regulator
TO-220
On Semi
Coin Cell
3volts
Coin
Maxwell
1n4007
Rectifier Diode
DO-41
On Semi
Matrix Keyboard
Keyboard
Alexan
LCD Display
LCD
Alexan
PIC16F88 P/I
PIC Microcontroller 20mhz 256B

7168 B Flash, 368 B Ram, 12c 18-Pin PDIP
DS1307
24LC256P
Maximum Operating Supply Voltage 5.5v

User RAM 56B
Function: Clock
Maximum Operating Supply Voltage 5.5v
Memory size 256kbit
Programming Voltage 3.3v, 5v
Alexan
PDIP
Microchip
PDIP
Maxim
PDIP
Microchip
Presensitized Board
Prototype Board
PCB
Alexan
Tact Switch
SPST-NO 50ma @ 12Vdc
Switch
Alps

52
Bill of Materials
Enumerated in Table 3 are the materials costing table for Auto Interlock system of
ESPEC Oven. Project prototype and development cannot be completed without the total cost on
all items that will be used and must be approved by the product team. A list of resource
Requirements and those project partners that can support these requirements will be
created during the definition stage of the project. Any additional funding requirements will be
identified as soon as possible and will require approval from MTs before becoming available.
After generating PR at SPEED system the total incurred amount is the total cost of the project
and is equivalent to 1,688.409 pesos. This figure denotes the initial investment cost for the
prototype circuit and will be charged to special projects cost in Power department.
Table 3:
Bill of Materials
Part Number
Description
Quantity (pc)
Electrical Supply
Price (PhP/pc)
708-5483
Photocoupler
RS
PHP 25.582
545-2232
BC547
RS
PHP 4.43
806-6373
Resistor
32
RS
PHP 11.10
247-1498
LED 3mm
RS
PHP 10.314
Matrix Keyboard
Alexan
PHP 80.00
805-1362
LM317
RS
PHP 13.512
117-372
Ceramic
RS
PHP 8.00
440-6597
Electrolytic
RS
PHP 30.24
649-1187
1N4007
RS
PHP 2.708
LCD Display
Alexan
PHP 175.00

53
600-7760
IC Socket
RS
PHP 15.00
PCB
Presensitized
Alexan
PHP 180.00
623-0487
PIC16F88-I/P
RS
PHP 212.43
786-0745
DS1307N
RS
PHP 237.975
667-8242
24LC256
RS
PHP 77.112
425-6049
Tact Switch
RS
PHP 38.00
Prototype Fabrication
Using the EAGLE 6.0 software the researcher able to design the modified interlock
system circuit and the parts placement on the PCB by auto routing the board design or manage
desire position of the components. The software has a lot update components and term user
friendly.
Figure 18: Etching Procedure of PCB

54
In Figure 18 shown, After making a design of the circuit in eagle software the researcher
prepare a etching PCB where the design will be appear a form of circuit to the PCB Board. The
first step will be expose the fluorescent lamp by 8 minutes to marked the design to the PCB next
is the developer solution where the PCB will dissolve the rendering area of PCB and appear the
desire circuit and last is the ferric chloride dissolved the copper and appear a last form of circuit
PCB after Exposure and Etching the board next step is soldering the components where the
researcher assemblies one by one to complete the components shown in Figure 19.
Figure 19: Soldering Components

After a long procedure the board has been finalize which will use for installation of
Interlock system PV-212M Oven for improve capability of the machine shown Figure 20.
Figure 20: Interlock Circuit for PV-212M

55
Installation. This section showed the installation of the prototype into the PV-212 oven
by defining the connection of each input and illustrating the process of each connection. Figure
21 shows the main signal connection from the oven. Tha data coming from this connection is the
temperatureand the status of being locked or unlocked.
Figure 21: Signal Interconnection for PV-212M
Figure 22 showed the main system, wherein the relays used to unlock and lock the oven
are located. A connection from the output of the prototype, which is like a pulse, switches the
relay on or off. This was the main focus of the prototype; that is to prevent any unauthorized
unlock of the relays.

56
Figure 22: Main System for PV-212M

The main lock latch, showed in Figure 23, was what kept the door closed and was
controlled by the microcontroller to open only if the correct pin was inputted into the keypad of
the prototype. The results are shown on the LCD module.
Figure 23: Solenoid Valve and Cylinder for PV-212M
Users Manual
1. Press on to power the ESPEC PV-212M Oven.
2. Run the machine by press start button means the machine is operational which will

57
trigger the 1st condition of the signal goes to microcontroller. (The setting was already
set-up base of revision of our engineering process.)
3. While the oven is running the temperature rising which will be stable at 175 degree.
4. When the temp stable at 175 degree the 2nd condition will trigger and the timer of the
ESPEC oven start in 5hrs parallel to the circuit of microcontroller.
5. The door will be lock until the curing time is not finish.
6. When the 5hrs are finish the door will be unlock base on the program of microcontroller
which will be safe of the unit and prevent bypassed operation.
7. End of process.

58
Cost Benefit Analysis.

On figure 24 shown the actual price quotation from the O.E.M way to expensive versus
to the in house fabrication of prototype.
Project Quotation
Cost!!!!
US $ 14,838 per unit
or Php 771,576
In house Fabrication
Cost of PHP 1688.409 VS
O.E.M. PHP 771,576
Figure 24: Project Quotation in O.E.M pricing.

Base of the pricing of O.E.M vs. in house fabrication it prove a big dissimilar value of
project cost. This project will add to cost saving program of NXP Semiconductor. The researcher
is confident enough on the capability of his circuit design and its contribution. It may bring when
it will be fanned out to all ESPEC Oven in APP Cabuyao.

59
Testing and Evaluation

On figure 25 shows after installing with the new modified interlock system the sequence
improve.
Figure 25: ESPEC Interlock system graph analysis

Figure 25 shows the rise of process heating. The door interlock will not activate until the
set point of temperature has been not stable. After stable at 175 degree Celsius and curing time is
in process the door activate close once the 5hrs elapse the door will open. The researcher show
the modified interlock was effectively and functionality base on the design circuit.

60
600000.00
500000.00
400000.00
Yield per Month
300000.00
Reject Per Month
200000.00
100000.00
0.00
1
Figure 26: ESPEC Oven Yield Vs Reject

Oct-14
44678
3.00
11169.
58
Nov-14
45346
8.00
11336.
70
Dec-14
57342
9.00
14335.
73
Jan-15
55363
8.00
2768.1
9
Feb-15
56272
1.00
1688.1
6
Survey Results. Table 4 illustrates the summary of ratings from respondents which were
composed of 12personnels from different departments of Power BFG; they were operators,
technical operators, line maintenance technicians, preventive maintenance technicians,
preventive maintenance engineer, industrial engineering technician and automation technician.
The operators who closely knew the daily routine of the machine, preventive maintenance and
line technicians who knew the technical aspect and performance of the machine and to validate
the efficiency of the project were the industrial and automation technicians.

61
Table 4
Survey Results
Auto Interlock PV-212M Oven
Survey Questionnaire
S
A
N D
A
SD
A
Tot
al
Weighte
d Mean
Effectiveness
1. The machine is performing automatic

interlock every time the machine is in
operation.
2. Auto interlock didnt stop while in operation
3. The keypad system was effective in
providing security for the lock system.
4. The machine was effective in locking the
oven at 175 degrees Celsius.
5. The machine was effective in preventing
unauthorized unlock in the oven.
12
4.583333
6
1
0
9
5
1
0
0
0
0
12
12
4.416667
4.75
12
4.75
1
1
12
4.916667
12
4.583333
12
4.5
1
0
7
12
4.833333
12
4.5
12
4.75
1
1
Functionality
1. No machine hung-ups or breakdown related

to auto interlock.
2. No machine downtime during stabilization of
heating.
3. The machine did not unlock at a different
password.
4. The machine password input system did not
experience any hang-ups related to data
interfacing.
5. The machine served its function as an AutoInterlock System at 175 degrees Celsius
temperature in the oven.
Most of the respondents had a positive response on the survey, it is a proof that the
researcher meets the four major concerns in this circuit design which are; the effectiveness by
knowing the respondents observation regarding the design, efficiency by gathering their
feedback deemed at the circuits effect to the machine performance, maintainability by giving
their insights on how to maintain the machine when trouble comes related to the automatic

62
Interlock circuit and safety on how to address the respondents security concerns with regards to
the project. By giving their positive responses on the survey, the researcher is confident enough
on the capability of his circuit design and its contribution to NXP in terms of efficiency,
maintainability, safety and cost savings it may bring when it will be fanned out to all ESPEC
Oven in APP Cabuyao.
Summary of Findings
After the implementation of the Modified Design of Interlock System of ESPEC PV212M oven several improvements were realized.
1. Based on the modification of the existing design, the prototype improved the Oven
operations by prohibiting unauthorized unlock once it reaches 175 degrees Celsius.
2. The circuit design, which involved designing of the schematic diagram and wiring
diagram, featured the parts needed for the system to be effective and to function well. This
improvement was realized through the respondents survey result. This result was analyzed after
a brief demonstration to the respondents on the operation of the system. The main improvement
realized in the system was the decrease in the reject yield as soon as the circuit design of the
prototype was implemented.
3. In Fabrication of the modified interlock system, a trial and error was made to allow the
production of the most applicable PCB Design. This allowed the best outcome for the main
circuit, thus improving the effectiveness and functionality of the whole system.

63
4. Evaluation of the finished project gave the average results of Strongly Agree on the
Likert questions as to how effective and functional the system is.
During testing of the modified interlock system to attain the sequence of interlock the
researcher conduct test trial in line production as many as do if the design circuit will be problem
base on result the circuit has meet the condition sequence. Judgment criteria have been set and
the standardization of this procedure is ongoing and will be deliberated by Central Line
production where the ESPEC Oven lay.

64
Unit V
Conclusions and Recommendations
Conclusions
The main goal of the project study is to produce safe quality of the product and also to the
user through the installation of Modification of Interlock system on ESPEC PV-212M Oven
which will activate during stabilization of heating process. The researcher learned many things
along the way during the creation of his design and concluded the following observations;
1.
The original design of the interlock system of ESPEC oven was modified
effectively to prevent unauthorized unlocking.
2.
A circuit was designed for the main objective which is to create a modified
interlock system of an ESPEC oven. This design allowed the best outcome from
the prototype as it was designed specifically for the oven.
3.
The designed circuit was fabricated into a prototype using the most appropriate
materials and components that made it effective and functional in avoiding
unauthorized unlocking of the system.
4.
Through a survey that was conducted to a group of respondents that witnessed the
operation of the prototype, the effectiveness and functionality was rated and
evaluated. The results of the evaluation were that the prototype was effective and
functional in avoiding unauthorized unlocking.

65
Recommendations
After validating all the findings and conclusion and measured system study the researcher
recommended the following:
1. In the modification of the design circuit the researcher highly recommend conducting
series of studies, gathering information and do not hesitate to ask the experts. With this
information you will be able to design a circuit based on the ability to prevent
unauthorized unlocking.
2. In the development of circuit design, the researchers recommends the use of EAGLE 6.0
software because of friendly use and draw a schematic and printed circuit board of a
3.
project.
In the fabrication of the prototype, the researcher uses an olden procedure using a
chemical of ferric chloride to etch the PCB. It also recommends use of pre-sensitized
board, a modern type procedure that can easily to design the circuit fast.
4. In evaluating the effectiveness and functionality of the project, the researcher
recommends that the modified of interlock system applied to the NXP Semiconductor
Cabuyao Laguna where the address issue in Central Area Station.

66
References:
Alexander, C. K. (2004). Fundamentals of Electric Circuit. McGraw-Hill Inc.
Boylestad, R. L., & Nashelsky, L. (2002). Electronic Device and Circuit Theory (4th ed.).
(pp.
147-216)
Floyd, T. L. (2010). Principles of Electric Circuits (9th ed.). ( pp 452- 485)

Gibilisco, S. (2006) Electricity and Electronics, Second Edition. Singapore: McGraw Hill
Book Company.
Grob, B. (2007). Basic Electronics. ( page 59) Schultz Hill Inc.
John, L. (2004). PIC Robotics a Beginners Guide to Robotics Projects Using the PIC Micro.
( pp 200-210 ) The McGraw-Hill Companies.
Lojek, B. (2006). History of semiconductor engineering,
( pp. 212215 ) Springer.
Wu, F. (2004). "Theory of resistor networks: The two-point resistance".

67
Appendices
Appendix A
ESPEC PV-212M Oven

68
Appendix B
PC817 Series

69
Appendix C
DS1307

70
Appendix D
BC547

71
Appendix E
PIC16F7/88

72
Appendix F
LM317 Regulator

73
Appendix G
24LC265

74
Appendix H
LCD Display

75
Appendix I
Matrix Keyboard

76
Appendix J
1N4007

77
Appendix K
Crystal Oscillator

78
Appendix L
Carbon Film Resistor

79
Appendix M
Tact Switch

80
Appendix N

81

82

83

84

85

86

87

88

89

90

91

92
Curriculum Vitae
ALVIN JOSEPH FLORES PEA

471 San Fernando Malvar Batangas City
Cell no: 09159688120/09065144478
CAREER AIM I am therefore looking for a position, one that will build on my
skills and experiences in Electronics and related fields and allow
me scope for upward movements.
EDUCATION
College
Secondary
Technological University of the Philippines

Ayala Boulevard, Ermita, Manila
Course: Electronics Engineering Technology
2002-2005
Las Pias National High School, LPC.
1998-2002
WORKING EXPERIENCE
Oct. 15, 2004 - Mar. 27, 2005
AMKOR TECHNOLOGY PHILIPPINES P3/P4
SIP Department (FOL Wirebond)
OJT-Technician trained in KNS 8026
RESPONSIBILTY
Supporting manufacturing through maintaining, line sustaining activities.
Set-up Conversion and Change Capillary.
Calibration like Bond Force, clamp, magazine and etc...
Log every set-up and trouble shoot of the machine.
Monitoring downtime machines.
Installed GASO Units to KNS 8026 Wirebonder machines.
Aug. 13, 2005- Oct. 13, 2007
PHILIPS SEMICONDUCTOR PHILIPPINES
Preventive Maintenance (FOL & EOL)
Technician I
RESPONSIBILTY
Responsible for maintenance activity such lubrication, overhaul machine, change spare
parts of the machine if ever defective and trouble shoot and follow our checklist PM
Calibration of the Machines (FCM-Flip Chip Mounting, EAGLE 60, Datacon APM)

93
Handle PM Documentation (PM Masterplan, PM Database etc)

ESD Ground installation and monitoring
Monitoring downtime machine
Supporting to the PROJECT (Auto Shut off Pressure, UV Curing w/ PLC NAIS Control,
ACS)
Supporting line sustaining activities specialties in EAGLE 60 Wirebonder
Oct. 13, 2007 Oct. 13, 2008

NXP Semiconductor Founded by Philips
Equipment Technician (FOL Wirebond & Diebond)
Technician I
RESPONSIBILITY:
Supporting manufacturing through maintaining, line sustaining activity
Log every set-up and downtime machine when start-up of the shift
Do set-up and calibration of the machine
Oct. 14, 2008 Present
NXP Semiconductor Founded by Philips
Automation Technician (Electrical Board Repair)
Technician II
RESPONSIBILITY:
Repairing a circuit board like power supply, monitor LCD, Parset Cabinet, Temp.
Controller, Driver motor, Rack panel, etc.
Installed CCTV or ACS monitoring LAN cable
Set-up a computer desktop installed application/reformat OS and can also make a backup of the harddisk and also to the machine by using NORTON GHOST
Every log when repaired & updating cost reduction & support major downtime machine
offline & online.
Member of ESD committee(Maintenance of continuous Checker)
Creating a prototype project for the better performance of the machine & can design own
circuit by using EAGLE software and Create a PCB design by using presentisized board
(ALEXAN)
INTEREST/SKILL
Knowledge in PLC Programming (Omron, KV builder Keyence)
Knowledge in Electropneumatics
Electronics Circuit Design (EAGLE / Livewire Software)
Digital Electronics Techniques
Industrial and Process Control Calibration and Maintenance Instruments.

94
TRAININGS ATTENDED:
ELECTROPNEUMATICS CONTROL
Conducted: Oct. 4, 5, 20 & 21, 2005
Place: Philips Semiconductors Cabuyao
Instructor: Arwin F. Habaa
CERTIFICATE by: DUALTECH CENTER
ASM EAGLE 60 WIREBONDER
Conducted: July 21, 22, 2005
Place: ASM Agency (Alabang Madrigal Business Park)
Instructor: Sir Roque
CERTIFICATE by: ASM (Automation Assembly Machine)
PRESENTATION SKILLS
Conducted: Oct. 11, 2005
Place: Philips Semiconductor Cabuyao
Instructor: Connie F. Kahanap
CERTIFICATE by: Philips Semiconductor
SENSOR/STEPPER MOTOR
Conducted: Sep. 26, 27, 2005
Place: Philips Semiconductors Philippines
Instructor: Sir. Philip Demagante
QUANTUM FCQ-Flip Chip Quantum (Programming)
Conducted: Sep. 21-23, 2005
Place: Philips Semiconductors Philippines
Instructor: Mr. Teddy
CERTIFICATE by: Philips Semiconductors Philippines
FPMEA (Failure Process Monitoring and Effective Analysis)
Conducted:
Place: Admin Building
Instructor: Ms. Kaye Diao
CERTIFICATE by: NXP Semiconductor Philippines
Training ESD ASEMEP (Electro Static Discharge Technical)
Conducted: June 25, 2010
Place: Alabang Business Cyberzone
Instructor: Member of ESD Committee

95
PERSONAL
Age 29
Nationality: Filipino
Civil Status: Married
Height: 58
Weight: 176lbs
Good Health
Willing and eager to learn
CHARACTER REFERENCES
Junifer Padrique
(Engineering Equipment in Backend)
NXP Semiconductor Philippines
POWER Department
09192658298
Mr. Reynold Pantaleon
(MEE Engineering)
Philips Semiconductors Philippines
SIPS Department
816-2617 loc. 2437
Mr. Romeo G. Mendoza
Electronics Department Head
Technological University of the Philippines
College of Industrial Technology
Electronics Department
302-7750 loc. 206
__Alvin Joseph Pena__

Signature over printed name

96

A Modification Design of Interlock System of ESPEC PV-212M Oven Rev 9 - Updated

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Modification Design of Interlock System of ESPEC PV-212M Oven

In Partial Fulfillment of the Requirement

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

Engr. Evangeline L. Constantino

Benilda N. Villenas, PhD

Engr. Sherwin Lagrama

Guillermo M. Rago Jr., RCE, Ed.D.

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

To my ever-beautiful wife, Azeonete,

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

UNIT II- REVIEW OF RELATED LITERATURE AND STUDIES

UNIT III METHODS AND PROCEDURE

UNIT IV- RESULTS AND DISCUSSION

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

UNIT V CONCLUSIONS AND RECOMMENDATIONS

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

Objectives of the Study

Conceptual Framework of the Study

Figure 1: Conceptual Framework Paradigm

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

is a semiconductor device that emits incoherent narrow-

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

Business Fulfillment Groups

Micro Controller Unit

Microchip PIC Lab

Integrated Development Environment

Process Failure Mode and Effect Analysis

Printed Circuit Board

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

Light Emitting Diode

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

The format of a typical five-level Likert item is:

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

WM = (SA*5) + (A*4) + (U*3) + (D*2) + (SD*1)

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

Figure 2: ESPEC PV-212M Oven Machine

INTERLOCK SYSTEM OF ESPEC PV-212M OVEN MACHINE

Rising up TempStabilization of temp 175

Door will unlock

Door will Lock

Figure 3: Operational process flow ESPEC oven

Existing Schematic Diagram. Shown in figure 4 is the existing schematic diagram of

WM = (SA5) + (A4) + (U3) + (D2) + (SD*1)