Coaxial Optical Solder Controller for Compact Precision Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional non-contact soldering devices are bulky, complex, and prone to accuracy issues due to separate optical and soldering components, which complicates adjustments and reduces precision, especially when used on mobile systems like robot arms.
Innovation Solution
Integration of an optical guiding assembly, sensor, and feedback controller into a system controller, creating a coaxial optical path that reduces the device's volume and weight, stabilizes the system, and separates dynamic and static components to enhance accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the sensing light beam is collected coaxially, then the optical path and light spot adjustment is complicated, but the volume of optical components is reduced
Solution Approach 1:
The patent integrates the optical guiding assembly, sensor, and feedback controller into a unified system controller, merging previously separate components. This integration simplifies the overall structure and reduces the volume of optical components while maintaining coaxial optical path alignment, thereby resolving the contradiction between reduced volume and adjustment complexity.
Solution Approach 2:
The patent introduces an optical guiding assembly as an intermediary component that facilitates coaxial collection of the sensing light beam. This intermediary structure enables simplified optical path management and reduces adjustment complexity while maintaining compact dimensions.
2Device complexity
If the sensing light beam is collected non-coaxially, then the adjustment is simpler, but the volume of optical components increases
Solution Approach 1:
The integration of optical guiding assembly, sensor, and feedback controller into a unified system controller reduces the overall volume of optical components. The merged structure enables non-coaxial light beam collection with simplified adjustment while maintaining compact dimensions, resolving the contradiction between adjustment simplicity and volume reduction.
3Ease of repair
If the light source and soldering module are independently installed, then the maintenance is easier, but the accuracy is reduced due to tolerance and assembling problems
Solution Approach 1:
The patent integrates the optical guiding assembly, sensor, and feedback controller into a unified system controller, reducing the number of independent components. This integration minimizes assembly interfaces and tolerance accumulation, thereby improving soldering accuracy while maintaining ease of maintenance through modular design.
4Adaptability or versatility
If the soldering module is installed on a mobile vehicle, then the flexibility is improved, but the optical path system requires frequent adjustment due to positional movement
Solution Approach 1:
The patent integrates the optical guiding assembly, sensor, and feedback controller into a unified system controller that moves as a single rigid body with the soldering module. This integration eliminates relative movement between components, preventing optical path misalignment and eliminating the need for frequent adjustments during mobile operation.
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
The integrated system controller results in a more compact and accurate solder device with reduced instability and load on mobile systems, improving the precision and ease of maintenance.
Implementation Method 1
The light source emits waveband light. The waveband light is guided to a to-be-soldered area by the solder module for heating to perform a solder operation.
Implementation Method 2
The sensor is disposed on another side of the optical guiding assembly relative to the solder module for receiving a sensing light beam and generating a sensing signal according to a sensing result of the sensing light beam.
Data Source
AI summary
A system controller includes a light source, an optical guiding assembly, a sensor and a feedback controller, and is applied to perform a solder operation with a solder module. The light source emits waveband light guided to a to-be-soldered area for heating. The optical guiding assembly is disposed between the light source and the solder module, and the waveband light is guided to the solder module by the optical guiding assembly. The sensor is disposed on another side of the optical guiding assembly for receiving a sensing light beam and then generating a sensing signal. The sensing light beam is guided to the sensor by the optical guiding assembly. The feedback controller is connected with the sensor and the light source for receiving the sensing signal and then controlling the light source. The system controller is a static part, and the solder module is a dynamic part.