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Digital soldering station for WSP80 by Bekcs eKm

Bekcs eKm 29989 34
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  • Digital soldering station for WSP80 by Bekcs eKm

    Hello
    I would like to introduce my first fully self-made construction. My goal was to build at the lowest cost of the station that I could power the Weller WSP80 soldering iron. During the construction I was learning to program in the bascom, I used atmega8. I have plans to make another station, so this one will not be modified anymore.

    When constructing the structure, the most problems with me were measurement of the resistance of the sensor, which is in the range of 20-70 Ohm. Using lm334z, I was able to measure through ADC to the nearest 1/4 Ohm. I used 60W 12V aptly because I only had one at home, so I need about 50 seconds to warm up from 20 to 260 degrees. The temperature can be adjusted in the range of 50 - 450 degrees via a potentiometer connected to the ADC. The display is without backlight but it does not interfere with use. The inscriptions were made in English because I like it better.

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    Digital soldering station for WSP80 by Bekcs eKm Digital soldering station for WSP80 by Bekcs eKm Digital soldering station for WSP80 by Bekcs eKm Digital soldering station for WSP80 by Bekcs eKm Digital soldering station for WSP80 by Bekcs eKm
    Digital soldering station for WSP80 by Bekcs eKm Digital soldering station for WSP80 by Bekcs eKm Digital soldering station for WSP80 by Bekcs eKm Digital soldering station for WSP80 by Bekcs eKm Digital soldering station for WSP80 by Bekcs eKm
    Digital soldering station for WSP80 by Bekcs eKm Digital soldering station for WSP80 by Bekcs eKm Digital soldering station for WSP80 by Bekcs eKm Digital soldering station for WSP80 by Bekcs eKm Digital soldering station for WSP80 by Bekcs eKm
    Digital soldering station for WSP80 by Bekcs eKm Digital soldering station for WSP80 by Bekcs eKm Digital soldering station for WSP80 by Bekcs eKm Digital soldering station for WSP80 by Bekcs eKm Digital soldering station for WSP80 by Bekcs eKm

    Implementation costs:
    Most have already had but you can assume that:

    trafo - PLN 50
    used flask - about PLN 120 (shipping cost)
    housing - PLN 7
    display - PLN 5.49
    atmega8 - PLN 11
    the rest - around PLN 20

    Cool? Ranking DIY
    About Author
    Bekcs eKm
    Level 12  
    Offline 
    Bekcs eKm wrote 93 posts with rating 190. Live in city Poznań. Been with us since 2007 year.
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  • #2 8739495
    Dragas
    Level 26  
    It looks nice, but I do not like one thing, namely making a tile, I mean to arrange the tracks so that there are not as many jumpers, and cutting out the tile, it looks like it would be broken off. As for the appearance of the finished structure, it looks very nice, but is not it just enough to tap it and it will not tip over?

    Regards, Dragas

    PS. can you ask for a schematic and batch to prock, because I've already started learning bascom in the beginner stage, and I would like to see out of curiosity how it is done from the programming side.
  • #3 8739590
    sowalski
    Level 10  
    I like the front panel :D When it comes to the construction itself, I really like it. is the housing stable? Does it heat up too much? My opinion should also replace the metal housing.
  • #4 8740481
    naelektryzowany
    Level 17  
    Good construction, but I have a few comments.

    Tiles ... look for topics on the thermal transfer on the electrode.
    The display in my opinion is too big (but it's a matter of taste ... and sight :) )
    The housing ... is "innovative" but not practical, it takes up a lot of space and it can not be used for other equipment.

    Greetings.
  • #5 8740753
    Dj_Pele
    Level 16  
    Hello
    A friend who is "electrified" and who puts anything on the soldering station, look at other designs of even mass producers, or the handle or upper flat surface is so small that all cigarettes can be put there.
    As for the construction itself, I like the clear and legible display for the tiles, it was possible to do them better but we all learn new methods of implementation so I do not have anything to say how I could do it. The constructor ran away from average thinking and used his own imagination, which in turn is of key importance.
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  • #6 8741446
    Bekcs eKm
    Level 12  
    The tile is not very optimally designed because initially it was to be used only to write a program, but later I did not want to design another one. When writing the program, I had to make some modifications because the pre-established measurement method would not work with such a low resistance.
    Housing contrary to appearances is very stable, there is no possibility that during normal use it has fallen, and even if you lean it is back to the vertical. There is nothing to suggest that the metal casing is better than this, it is made of thick and quite good quality plastic. It does not take up much space, you can put something in it for yourself.

    Quote:
    Tiles ... look for topics on the thermal transfer on the electrode.

    So what exactly do you think is wrong in this tile?



    Scheme after modifications on the board:
    Digital soldering station for WSP80 by Bekcs eKm


    I have to improve the program and if I want it, I will place the batch.
  • #7 8741680
    szandi
    Level 11  
    Would a colleague describe the temperature measurement itself more accurately?
  • #8 8741702
    szympek;)
    Level 20  
    Very nice but ... Well, there are always some but 1. Is my monitor spoiled or there are some black stripes on the front panel ??? 2.Plastik.Transformator, heatsinks etc. in a plastic housing ?? and without a fan. There are ventilation holes ?? That's cool.
  • #9 8741878
    marchello
    Level 15  
    where did you get the socket to connect the flask? I hunt myself and can not find anywhere.
  • #10 8742350
    nico41
    Level 13  
    A colleague of the marchello what to socket in TME in the search engine type din socket . The construction that we see is. The front panel is a matter of taste, while the tile is not a fairy tale, it is rather horror.
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  • #11 8742371
    plahenryk
    Level 16  
    The most important are the first constructions, congratulations. I would adjust the temperature on the buttons and not on the potentiometer. The program is probably not a problem. I see that you took the temperature measurement as simply as possible. Is there a thermistor resistance table somewhere in the soldering iron or did you have a temperature resistance characteristic yourself?
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  • #12 8742670
    FoxTech
    Level 20  
    nico41 wrote:
    (...) while the tile is not a fairy tale, it is rather horror.


    Do not overdo it, the fact that it is not fancy pamper does not mean anything yet. This is an amateur construction and, as the author himself wrote:

    Bekcs eKm wrote:
    The board is not very optimally designed because initially it was to be used only to write a program, but later I did not want to design another one. When writing the program, I had to make some modifications because the pre-established way of measurement did not work (...)


    The only thing you can pay attention to is how to make the jumpers on the soldering side - instead of the twisted pair it is best to use a kynar which is insulated made of Teflon so that it does not run off the wire during soldering.

    Interestingly, no one paid any attention to the temperature stabilization algorithm, which is the most important in the case of soldering stations, everyone is looking only for unimportant aesthetic piercings to which he could attach.
  • #13 8742753
    naelektryzowany
    Level 17  
    Bekcs eKm wrote:


    Quote:
    Tiles ... look for topics on the thermal transfer on the electrode.

    So what exactly do you think is wrong in this tile?

    I do not mean that the tile is made badly. It is only made it the old method, so I encourage you even to the thermal transfer. After a few attempts, the tiles will be like :) from the factory.

    greetings
  • #14 8742851
    omicronNs
    Level 21  
    In the flasks are rather thermocouples and not thermistors.
  • #15 8743384
    FoxTech
    Level 20  
    omicronNs wrote:
    In the flasks are rather thermocouples and not thermistors.

    Weller temperature sensors are PTC thermistors.
  • #16 8744360
    Bekcs eKm
    Level 12  
    The temperature measurement is based on the calculation of the linear function based on the ADC values at 100 and 300 degrees. I measured the tip temperature and every 50 degrees from 50 to 450 I wrote the ADC value in the table.

    Digital soldering station for WSP80 by Bekcs eKm

    Unfortunately, it does not have a more accurate meter to perform a more accurate calibration. As can also be seen, the resistance measurement method gives a low resolution.
    When it comes to regulating the temperature, I did not want to immediately take the PID and just if the temperature is lower than the set temperature, the heater is turned on. For the transformer used, this is, in my opinion, sufficient and as soon as the temperature measurement has been mastered with greater accuracy, and PID will build a more extensive station.

    The tile is made by the thermal transfer method, it was designed in eagle, and the paths look like that because I like it more so :P

    szympek;) wrote:
    2.Plastik.Transformator, heatsinks etc. in a plastic housing ?? and without a fan. There are ventilation holes?

    The system does not heat up too much, the stabilizer does not even require a heat sink. The vents are but just in case I'll probably get some more.
  • #17 8750388
    Przemek Elektro
    Level 16  
    Bekcs eKm wrote:
    The temperature measurement is based on the calculation of the linear function based on the ADC values at 100 and 300 degrees. I measured the tip temperature and every 50 degrees from 50 to 450 I wrote the ADC value in the table.

    As can also be seen, the resistance measurement method gives a low resolution.


    You could make a measuring bridge on this thermistor and give a differential amplifier made on an operational amplifier. Then you would adjust the signal going to the ADC so that you can use the whole range of the transducer, the measurement resolution would increase.

    I do not understand the behavior in this forum a bit.
    The device was designed from the beginning to the end by the author, it is fully finished and enclosed in the casing. Structures like this should be highly rated. Sometimes someone will take pictures of their semi-prototype made on a universal board based on a diagram downloaded from the net, lying on the desk without any housing and everyone just applauds him. Stop clinging to a crooked solder or bad insulation in the cable, because it does not have the slightest effect on the operation of the system.
    Author, bravo. You've made a layout yourself that will definitely serve you the next few years. You have learned something, you can see what can be improved. Keep it up! :D
  • #18 8751227
    janchar
    Level 14  
    Bekcs eKm wrote:

    Implementation costs:
    Most have already had but you can assume that:

    trafo - PLN 50
    used flask - about PLN 120 (shipping cost)
    housing - PLN 7
    display - PLN 5.49
    atmega8 - PLN 11
    the rest - about PLN 20


    You probably are happy with your work, but can you explain to me what is the highest quality of your station from the station for a price of around PLN 50? I checked the prices on the well-known portal all ....
  • #19 8751262
    bartosz789
    Level 30  
    Satisfaction that it happened to her alone?
  • #20 8754608
    szympek;)
    Level 20  
    Experience priceless and for all the others ... and besides buying for all ... for PLN 50 you will not buy a digital soldering station
  • #21 8760048
    Mad Bekon
    Level 23  
    I am very interested in what real hysteresis you have around the set working point with this type of control?
  • #22 8763911
    Bekcs eKm
    Level 12  
    Mad Bekon wrote:
    I am very interested in what real hysteresis you have about the set operating point for this type of control?

    At 320 degrees the temperature if the soldering iron lies on the stand varies between 317 and 322 degrees, and during soldering 313 - 324, for 260 degrees 258 - 263 and 256 - 263. Unfortunately, the measurement resolution is only 2-3 degrees.


    Przemek Elektro wrote:
    You could make a measuring bridge on this thermistor and give a differential amplifier made on an operational amplifier. Then you would adjust the signal going to the ADC so that you can use the whole range of the transducer, the measurement resolution would increase.

    At the next station he will try to do this, we will see with which effect :P
  • #23 8825339
    Niuniek_84
    Level 23  
    Hello,

    The project is very interesting.

    Can I use soldering irons with a PT100 sensor ??

    greetings
    Piotr
  • #24 8830894
    Bekcs eKm
    Level 12  
    After modifying the software there should be no problem with PT100 support, in the next version of my station I will try to add the possibility of handling PT100.
  • #25 8830975
    Niuniek_84
    Level 23  
    It would be perfect if it would be :)

    Unfortunately, uP are black magic for me, and every modification puts a lot of doubt on me.

    The design is very nice, probably many people would be happy to hear that other soldering flasks can be used.
  • #26 8999196
    marchello
    Level 15  
    Is it possible to connect a WSP80 weller to a station with a thermocouple temperature sensor?
  • #27 9012935
    Bekcs eKm
    Level 12  
    If the station only supports thermocouples, you can not.
  • #28 10543904
    sq3dwe
    Level 16  
    Bekcs eKm do you already have a well-developed hex file? If you allow it, I would like to replicate your project with the use of laminarka.Pozdrawiam Rysiek.
  • #29 10545299
    Bekcs eKm
    Level 12  
    It works well enough that I did not want to change anything. I do not even have the source code anymore, but the hex file can, of course, be uploaded. How would it be used in a laminator?
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Topic summary

A user introduced their self-made digital soldering station designed to power a Weller WSP80 soldering iron, utilizing an ATmega8 microcontroller programmed in Bascom. The construction faced challenges, particularly in measuring the low resistance of the sensor (20-70 Ohm) using an LM334Z for accurate ADC readings. The station heats up from 20 to 260 degrees Celsius in approximately 50 seconds, with adjustable temperature settings ranging from 50 to 450 degrees via a potentiometer. Feedback from other users included suggestions for improving the PCB layout, housing stability, and temperature measurement accuracy. Discussions also covered the use of different temperature sensors, including PT100 and thermocouples, and the importance of temperature stabilization algorithms in soldering stations. The author plans to enhance the design in future iterations.
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