Electronic Detonator Ignitor PCB Microcontroller Capacitor Shroud
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Solution Overview
Problem
The manual hand-dipping method for applying pyrotechnic composition to resistive elements in electronic detonators is hazardous and difficult to control, leading to inefficiencies in ignitor performance and increased costs due to waste.
Innovation Solution
A microcontroller and capacitor configuration on a printed circuit board with a shroud containing pyrotechnic composition, where the resistive element radiates heat to ignite the primary charge, allowing for precise and automated application of the pyrotechnic composition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual hand-dipping method is used to apply pyrotechnic composition, then worker can directly apply material, but worker safety deteriorates due to hazardous exposure
Solution Approach 1:
The patent introduces an automated dipping apparatus as an intermediary between the worker and pyrotechnic composition. The apparatus includes a robotic arm with a dipping head that automatically dips resistive elements into pyrotechnic composition reservoirs, eliminating direct worker contact with hazardous materials while maintaining manufacturing capability
Solution Approach 2:
The patent replaces manual mechanical dipping operations with an automated robotic system. The robotic arm performs precise dipping motions controlled by a computer system, substituting human mechanical actions with automated mechanical and computational control to improve safety
2Ease of manufacture
If manual hand-dipping method is used, then application process is simple, but manufacturing precision deteriorates due to difficulty in controlling amount applied
Solution Approach 1:
The patent incorporates sensors and computer control systems that monitor the dipping process in real-time. The system measures parameters such as dipping depth, speed, and pyrotechnic composition application amount, providing feedback to adjust operations to maintain precise and consistent application quantities across all resistive elements
Solution Approach 2:
The patent employs a dynamic automated dipping system where the robotic arm can adjust dipping depth, speed, and angle during the process. This dynamic control allows precise regulation of pyrotechnic composition application, ensuring consistent coating thickness and quantity while maintaining manufacturing efficiency
3Reliability
If too much pyrotechnic composition is applied, then ignitor reliability improves, but material waste increases leading to higher costs
Solution Approach 1:
The patent uses computer-controlled parameters for the automated dipping process, precisely controlling dipping depth, speed, and residence time in the pyrotechnic composition. This parameter optimization ensures sufficient coating for reliable ignition while minimizing excess material application, reducing waste and costs
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
This configuration enhances safety by reducing worker exposure, allows for precise application of pyrotechnic material, and improves ignitor efficiency with a smaller quantity needed, thereby reducing costs.
Implementation Method 1
a resistive element extending between the conductive traces and configured to radiate heat when current passes therethrough
Data Source
AI summary
An ignitor for an electronic detonator, the ignitor including a microcontroller and a capacitor mounted on a printed circuit board (PCB) and electrically connected to one another, the microcontroller configured to discharge the capacitor in response to an actuation signal received by the microcontroller, a pair of conductive traces extending from the capacitor, a resistive element extending between the conductive traces and configured to radiate heat in response to current flowing therethrough, and a shroud disposed over the resistive element, the shroud containing a pyrotechnic composition that at least partially covers the resistive element.