DigiKey - Portable Fume Extractor - The Byte Sized Engineer | DigiKey
The creator, Zach, aims to make his soldering setup mobile by building a portable fume extractor. He starts by examining a standard fume extractor, noting its simplicity and the need for a suitable fan. After testing various power solutions, including a 9V battery and a drill battery adapter, he decides on using a USB-C power delivery breakout board to power a 12V fan. This board allows the fan to run efficiently by requesting the correct voltage from a USB-C power source. Zach designs a 3D-printed enclosure to house the components, ensuring it integrates seamlessly with the iFixit soldering station. He also adds a brass sponge holder for cleaning the soldering tip. The final product is a compact, portable soldering station with a built-in fume extractor, powered by a USB-C source, making it convenient for on-the-go projects.
Key Points:
- Use a USB-C power delivery breakout board to power a 12V fan efficiently.
- Design a 3D-printed enclosure to integrate the fume extractor with a soldering station.
- Ensure the setup is powered by a USB-C source for portability and convenience.
- Incorporate a brass sponge holder for soldering tip maintenance.
- Test and troubleshoot power delivery to ensure the fan operates at the correct voltage.
Details:
1. 🔧 Setting the Scene: Soldering Adventures
- The narrator frequently encounters large projects like giant boxing robots and large format laser cutters, which are impractical to move to a conventional workbench, necessitating a mobile soldering setup.
- The primary challenge in creating a mobile soldering station is the dependence on wall outlets for essential tools such as soldering irons and fume extractors.
- A viable solution for portable soldering was achieved by acquiring a USB-C powered soldering iron from Digi-Key, compatible with a battery bank, providing the needed mobility.
- Despite the success with the soldering iron, the lack of a commercially available portable fume extractor remains a significant obstacle in achieving a fully mobile setup.
- Further exploration into custom solutions or DIY approaches for portable fume extraction could address this gap, potentially enhancing the practicality of mobile soldering.
2. 💨 Portable Fume Extractor: The Design Process
- The existing fume extractor design is simple, consisting of a fan similar to a regular computer fan with a protective grill.
- The initial fan considered was too small, leading to the decision to use a 120 mm fan that runs on 12 volts, which is similar in size to the fan used in a desktop version.
- A matching carbon filter was selected to fit the 120 mm fan, both components sourced from the Digi-Key website.
- Key challenges identified include powering the fan and enclosing the components for portable use.
- The need for a portable fume extractor arises from the demand for mobile soldering solutions, where traditional, stationary fume extractors are impractical.
- The choice of a 120 mm fan was driven by the need for adequate airflow while maintaining portability.
- Efforts were made to ensure that the selected components are readily available and cost-effective.
3. 🔋 Powering the Mobile Setup: Battery Challenges
- Using a single cell lipo battery with 3.7 volts requires a boost converter for 12-volt applications, which adds complexity. This solution is lightweight but demands careful voltage management.
- A regular 9-volt battery can run a 12-volt fan at a slower RPM, making it less effective, and requires frequent recharging and swapping, leading to inconvenience and potential downtime.
- An 18-volt drill battery with an adapter provides a more robust solution, allowing for easy recharging and usage. However, it necessitates the use of a buck converter to safely reduce voltage to 12 volts, ensuring equipment longevity without damage.
- The implementation of a buck converter is crucial for converting 18 volts to 12 volts safely, maintaining the reliability and safety of the equipment. This method guarantees proper voltage levels, preventing overheating and component failure.
4. 🔌 USB-C Power Solution: Overcoming Hurdles
- The USB-C breakout board used initially lacks power delivery circuitry, limiting power to 5 volts, which is insufficient for a 12-volt fan, resulting in reduced RPM.
- A USB-C PD (Power Delivery) breakout board is utilized, allowing for voltage selection via solder bridges, enabling the necessary 12-volt output for the fan.
- Initial failed attempts to power the fan were due to incorrect device plug-in order, supplying only 5 volts instead of the desired 12 volts.
- Correcting the device plug-in sequence by connecting the fan before other devices resolved the voltage issue, highlighting the importance of correct plug-in order for USB-C power delivery implementation.
- The experience underscores a potential flaw in the USB-C PD spec implementation, emphasizing the need for awareness of device connection order to achieve desired power levels.
- A custom case design using 3D modeling software is necessary to organize and secure the setup, preventing exposed wires and ensuring a safer, more efficient arrangement.
5. 🖥️ Designing the 3D Enclosure: Bringing it Together
- Integrate components into a single unit rather than separate parts to enhance design cohesiveness.
- Utilize 3D models of existing components, such as the iFixit soldering station, to accurately plan the enclosure design.
- Position the fan at a 30° angle and incorporate a USBC power delivery board with a clear placement strategy.
- Design snap-together parts for the 3D printed enclosure, including a hexagon grid for the fan grill.
- Ensure practical component access by leaving cutouts for USB connections and secure the fan with designated screw holes.
- Adapt the enclosure design to match the product's curves using projection and offset techniques for seamless integration.
- Address design functionality issues, such as lacking a soldering tip cleaner, by adding a brass sponge holder that clicks into accessory knobs.
- Use the shell command to hollow out components for the brass sponge holder, ensuring it fits snugly into the design.
- Finalize the design by creating a keyhole cutout to secure the holder onto the unit.
6. 🛠️ Assembling and Testing: Portable Success
- The assembly process included tasks such as soldering wires to a breakout board, indicating a focus on detailed hardware assembly.
- Transitioning from a non-portable setup to creating a portable soldering station was highlighted as a key improvement.
- The completed portable soldering station includes a fume extractor, which adds a safety feature that is crucial for user health.
- The soldering station features an LED indicator to signal when the iron is heated, enhancing usability and user experience.
- The assembly involves multiple components such as a metal grill for protection, carbon filter, and a brass sponge holder, which contribute to the functionality and safety of the device.
- The successful creation of a portable soldering station with integrated features demonstrates an improvement in convenience and safety for mobile or space-constrained environments.
7. ⚙️ Future Projects and Reflections
- The use of a portable soldering station with a fume extractor is planned for the next project, indicating a focus on efficient and safe working conditions.
- The project involves building a custom macroad using a specific PCB, highlighting a hands-on approach to electronics design.
- A USBC power delivery breakout board is crucial to the project, enabling the use of a 12-volt fan and enhancing power management capabilities.
- The USBC power delivery breakout board shares similarities with a previously used power supply, but includes additional features, suggesting iterative improvement and enhanced functionality in design.