Busbar Assembly With Aligned Lead Apertures for Automated Soldering
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Solution Overview
Problem
Existing electronics assembly processes are inefficient and costly due to manual labor, necessitating automation of construction and joining steps to reduce manufacturing time and cost.
Innovation Solution
A busbar assembly comprising first and second busbars with aligned lead apertures and an insulation layer, along with a protuberance extending through the apertures, allowing simultaneous alignment and electronic coupling of component leads with both busbars, facilitated by a lead solder guide for efficient wave soldering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual labor is used for assembly processes, then flexibility and adaptability are maintained, but manufacturing time and cost increase
Solution Approach 1:
The busbar assembly is divided into multiple busbars (first busbar, second busbar) with separate lead apertures, allowing individual leads to be inserted and soldered independently. This segmentation enables automated assembly processes to handle each lead-busbar connection separately, improving manufacturing efficiency while maintaining process manageability
Solution Approach 2:
The busbar assembly design with multiple aligned lead apertures and extension elements serves multiple functions: it provides electrical connection points for multiple leads, enables simultaneous alignment and soldering operations, and facilitates automated assembly. This multi-functionality allows a single assembly structure to support both manual and automated manufacturing approaches
2Productivity
If multiple separate assembly steps are used for joining leads to busbars, then precision is maintained, but manufacturing time increases
Solution Approach 1:
Multiple lead apertures in the first and second busbars are aligned to create a common insertion path for leads. This merging of alignment features allows multiple leads to be positioned and soldered in a single automated operation, increasing assembly speed while maintaining precision through the fixed geometric relationship between aligned apertures
Solution Approach 2:
The lead apertures are pre-aligned and positioned in the busbars before the assembly process. This preliminary positioning of apertures ensures that when leads are inserted, they automatically achieve precise alignment with the busbars, eliminating the need for complex real-time alignment adjustments during automated assembly
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates efficient and automated assembly of electronic components by reducing manual labor, enhancing manufacturing efficiency and cost-effectiveness through simultaneous soldering of leads to busbars and printed circuit boards.
Implementation Method 1
electronically coupling the portion of the first lead with the first busbar and electronically coupling the portion of the second lead with the second busbar
Data Source
AI summary
A busbar assembly comprises a first busbar having a first surface and a second surface opposite the first surface and having a first lead aperture formed therein. The busbar assembly also comprises a second busbar positioned adjacently to the first busbar and having a third surface and a fourth surface opposite the third surface and having a second lead aperture formed therein. The first busbar comprises an extension element extending from the second surface. The first lead aperture is formed through the extension element. The extension element has a portion thereof extending through the second lead aperture.