Fixture for Fine Wire Laser Soldering Tension Control
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Solution Overview
Problem
The complex process of soldering fine wires onto circuit boards requires highly skilled and time-consuming manual operations, leading to inconsistent solder quality and high costs due to the lack of suitable fixtures for robotic positioning and manipulation.
Innovation Solution
A fixture assembly that includes a holding and support structure with wire securing and tensioning features, allowing for precise alignment, tension control, and adjustment, enabling robotic assistance in the laser soldering process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual soldering operations are performed by well-trained operators, then soldering quality can be achieved, but the process is time-consuming and expensive
Solution Approach 1:
The patent replaces manual mechanical soldering operations with an automated system comprising a robotic positioning system for precise wire placement, a laser soldering device for automated soldering, and a specialized fixture for wire support and alignment. This substitution eliminates the need for well-trained manual operators while maintaining soldering quality and significantly improving productivity through automation.
2Manufacturing precision
If manual wire manipulation is performed with force feedback control, then proper alignment can be achieved, but the operation becomes complex and difficult to automate
Solution Approach 1:
The patent introduces a specialized fixture as an intermediary device that includes wire support members, alignment features, and positioning mechanisms. This fixture simplifies the wire manipulation process by providing physical guidance and support structures that automatically maintain wire alignment during the soldering process, eliminating the need for complex force feedback control while enabling robotic automation.
3Productivity
If robotic positioning is attempted for fine wires, then productivity can be improved, but positioning precision is insufficient without proper support fixtures
Solution Approach 1:
The patent implements preliminary action by providing pre-positioned wire support members and alignment features in the fixture before the robotic positioning and soldering operations begin. These pre-configured support structures guide the fine wires into correct positions and maintain them during the automated process, enabling robotic systems to achieve the necessary positioning precision without complex control algorithms.
4Ease of operation
If fine wires are manipulated without tension control, then the process is simpler, but wire alignment and positioning become difficult
Solution Approach 1:
The patent applies local quality by incorporating specific tension control features at critical locations in the fixture, such as wire support members and clamping points, rather than applying tension control throughout the entire wire. These localized tension control elements maintain wire alignment and positioning precision only where needed during manipulation and soldering, simplifying the overall operation while achieving the required precision.
Data Source
AI summary
A fixture assembly for use with fine wire laser soldering. The fixture includes a holding and support fixture and a wire securing and tensioning fixture. The holding and support fixture has a wire holding member and a retention member. The wire holding member and the retention member cooperate with wires prior to the wires being soldered. The wire securing fixture has wire tensioning projections and wire retention members. The wire tensioning projections and wire retention members cooperate with the wires to provide tension to the wire prior to the wires being soldered.