Adjustable Wave Solder Nozzle for PCB Dwell Time Control
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Solution Overview
Problem
Wave solder machines with split conveyors face issues of high cost, reduced reliability due to harsh environments, and increased risk of PCB mishandling due to multiple transition points, as well as the need for optimized solder dwell time which is not effectively addressed by a 'one size fits all' approach.
Innovation Solution
An automated adjustable sliding plate in the wave solder nozzle assembly allows for varying the solder wave width, enabling dynamic adjustment of solder dwell time without changing conveyor speeds, and is controlled by a computer system to eliminate human intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed width nozzle is used, then the manufacturing precision is maintained, but the adaptability to different PCB types deteriorates
Solution Approach 1:
The patent applies the dynamics principle by making the nozzle width adjustable through a movable plate mechanism. The nozzle transitions from a fixed structure to a dynamic one where the plate can be positioned at different locations to change the effective nozzle width, enabling adaptation to different PCB types while maintaining a relatively simple overall structure.
Solution Approach 2:
The patent implements universality by designing a single nozzle assembly that can perform multiple functions by adjusting the plate position. This single device can accommodate various PCB widths and solder wave requirements, replacing the need for multiple fixed nozzles for different applications.
2Adaptability or versatility
If a split conveyor is used to adjust dwell time, then the adaptability to different processing speeds is improved, but the reliability deteriorates due to harsh environment and multiple transition points
Solution Approach 1:
The patent extracts the dwell time adjustment function from the conveyor system and relocates it to the nozzle assembly. By making the nozzle width adjustable, the effective solder contact time can be modified without changing conveyor speeds, thereby removing the need for complex split conveyor mechanisms and their associated reliability issues.
3Manufacturing precision
If a fixed nozzle width is used, then the device complexity is minimized, but the manufacturing precision of solder joint quality deteriorates for diverse PCB types
Solution Approach 1:
The patent applies the dynamics principle by making the nozzle width adjustable through a movable plate mechanism. The nozzle transitions from a fixed structure to a dynamic one where the plate can be positioned at different locations to change the effective nozzle width, enabling adaptation to different PCB types while maintaining a relatively simple overall structure.
Data Source
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AI summary
A wave soldering machine includes a housing and a conveyor configured to deliver a printed circuit board through the housing. The wave soldering machine further includes a wave soldering station coupled to the housing. The wave soldering station includes a reservoir of solder material, and a wave solder nozzle assembly configured to create a solder wave. The wave solder nozzle assembly has a nozzle core frame, a solder distribution baffle secured to the nozzle core frame, and a sliding plate that together define a nozzle. The sliding plate is movable with respect to the nozzle core frame between a close proximate position in which the nozzle is configured to produce a reduced width solder wave through the solder distribution baffle and a spaced apart position in which the nozzle is configured to produce an extended width solder wave through the solder distribution baffle.