Inline Reed Relay with Fixed Metal Pins for Automated SMT Assembly
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Solution Overview
Problem
The existing reed switches on integrated circuit boards are difficult to automate due to the challenge of bending and positioning their fine pins, leading to low production efficiency, high labor costs, and inability to meet market demands for high integration levels.
Innovation Solution
An inline reed relay with integrated reed assemblies and metal pins fixedly connected to a housing, allowing for mechanized automatic welding, where reed switches are connected via metal pins that maintain a fixed shape and position tolerance, enabling efficient integration and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If reed switches are welded manually to guarantee position tolerance, then manufacturing precision is improved, but productivity deteriorates
Solution Approach 1:
Multiple reed switches are integrated into a single inline reed relay module with a common housing and shared mounting pins. This merging allows the entire module to be welded to the circuit board as one unit using automated SMT equipment, achieving both high position tolerance (through precise automated placement) and high productivity (through parallel processing of multiple reed switches simultaneously).
Solution Approach 2:
The reed relay module segments the welding process from the individual reed switches. Instead of welding each reed switch separately, the module presents a standardized pin configuration that can be welded as a single component, enabling automated welding while maintaining position tolerance.
2Productivity
If reed switches are integrated to improve productivity, then manufacturing precision deteriorates due to pin bending
Solution Approach 1:
The reed switches are pre-assembled into a module with their pins already positioned and fixed in the housing before welding. This preliminary action eliminates the need for pin bending during the welding process, as the pins are rigidly held in place by the housing structure, ensuring position tolerance is maintained even when multiple reed switches are integrated.
3Reliability
If manual welding is used to ensure stability, then device complexity increases, but extent of automation deteriorates
Solution Approach 1:
The inline reed relay module provides a universal mounting structure with standardized pins that can be welded using automated SMT equipment. This universal design maintains welding stability through consistent pin positioning and rigid housing support, while enabling full automation by presenting a standard component format that automated equipment can handle and weld reliably.
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 solution improves production efficiency, reduces labor costs, and meets market requirements by allowing multiple reed switches to be integrated and welded automatically, ensuring precise positioning and reduced time and labor.
Implementation Method 1
a coil layer winding the two reed switches and configured to control the two reed switches to open or close
Data Source
AI summary
An inline reed relay comprises at least one reed assembly, at least one pair of metal pins, a housing and a control pin disposed on the housing. The reed assembly comprises at least two reed switches, each having two pins. The metal pins are respectively connected to the two pins of the reed switches. One end of each metal pin extends out of the housing. The inline reed relay allows the reed switches to be integrated through the injection molded housing, and the reed switches are connected to an external circuit board via the metal pins, because the metal pins can be maintained a fixed shape and difficult to deform. The processing size and position tolerances of the inline reed relay can meet the requirements of mechanized automatic welding, thereby improving welding efficiency and production assembly efficiency and reducing labor costs.