Adjustable Wave Solder Nozzle Throat Width Control
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Solution Overview
Problem
Existing wave solder machines with split conveyors face challenges in cost, repeatability, and reliability due to fixed solder nozzle widths, which limit the adjustment of solder contact time and lead to suboptimal soldering characteristics.
Innovation Solution
An adjustable wave solder nozzle assembly with an electromechanical actuator allows for automated adjustment of the nozzle throat width, enabling varying solder contact lengths without changing conveyor speed, optimized by computer-controlled movement of the second curve plate relative to the first curve plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed width wave solder nozzle is used, then the machine structure is simple, but the solder contact time cannot be adjusted and soldering characteristics are suboptimal
Solution Approach 1:
The wave solder nozzle transitions from a fixed width structure to a dynamically adjustable structure. The second curve plate is made movable relative to the first curve plate through an electromechanical actuator, allowing the throat width to be adjusted automatically based on different PCB requirements, thus optimizing solder contact time and soldering characteristics without requiring a completely new nozzle design for each application.
Solution Approach 2:
The manual width adjustment mechanism is replaced with an electromechanical actuator system controlled by a controller. This substitution enables automated adjustment of the nozzle throat width through electrical signals, improving precision and repeatability while reducing manual intervention, directly addressing the need for optimized soldering characteristics without excessive structural complexity.
2Duration of action of moving object
If a split conveyor configuration is used to adjust solder contact time, then dwell time can be optimized, but machine cost and reliability decrease
Solution Approach 1:
Instead of using a complex split conveyor system to adjust solder contact time, the invention makes the wave solder nozzle throat width dynamically adjustable. By changing the throat width, the solder contact time is optimized directly at the nozzle level, maintaining a simple conveyor system and thereby preserving reliability while achieving the desired dwell time optimization.
Solution Approach 2:
The invention changes the physical parameter of the nozzle throat width to control solder contact time. By adjusting this parameter through the electromechanical actuator, the system achieves optimized soldering characteristics without modifying the conveyor speed or introducing complex mechanical changes to the conveyor system, thus maintaining reliability.
3Reliability
If manual width adjustment is used, then device complexity is low, but repeatability and reliability are poor
Solution Approach 1:
The manual width adjustment mechanism is replaced with an electromechanical actuator system controlled by a controller. This substitution enables automated adjustment of the nozzle throat width through electrical signals, improving precision and repeatability while reducing manual intervention, directly addressing the need for optimized soldering characteristics without excessive structural complexity.
Solution Approach 2:
The controller receives signals and adjusts the electromechanical actuator accordingly to achieve precise throat width positioning. This feedback-controlled system ensures repeatable and reliable adjustment, maintaining consistency across different operating conditions while managing device complexity through intelligent control rather than purely mechanical means.
Data Source
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AI summary
A wave soldering machine includes a housing and a conveyor coupled to the housing. The conveyor is 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 an adjustable wave solder nozzle assembly adapted to create a solder wave. The adjustable wave solder nozzle assembly has a first curve plate and a second curve plate that together define a nozzle. The second curve plate is movable with respect to the first curve plate between a close proximate position in which the second curve plate is proximate the first curve plate and a spaced apart position in which the second curve plate is spaced from the first curve plate to adjust a width of the nozzle.