Soldering Iron Tip State Detection Using Gas Flow and Pressure
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Solution Overview
Problem
Existing methods for soldering devices cannot accurately determine the state of the iron tip during the soldering process, limiting real-time monitoring and feedback.
Innovation Solution
A method involving a gas supply system that measures the flow rate and pressure of gas flowing through the iron tip, using a constant total flow rate and comparing measured physical quantities to reference values to determine the state of the iron tip, including its contact with objects and the melting of solder pieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If air pressure measurement is used to detect solder joint failure after soldering, then soldering failure can be detected, but real-time monitoring of iron tip state during soldering cannot be achieved
Solution Approach 1:
The patent introduces gas supply before and during the soldering process to enable real-time monitoring of the iron tip state. By supplying gas through the iron tip's internal passage and measuring flow rate or pressure changes during the soldering process itself (rather than after), the system can detect the iron tip's contact state with the workpiece and solder melting state in real-time, preventing the time loss associated with post-soldering detection methods.
2Measurement precision
If post-soldering air passage detection is used to determine soldering completion, then soldering completion can be confirmed, but the state of iron tip during soldering processing cannot be determined
Solution Approach 1:
The patent implements a feedback mechanism by continuously measuring gas flow rate or pressure during the soldering process and using this information to determine the iron tip's state. The gas supply system provides real-time feedback about whether the iron tip is in contact with the workpiece and whether solder is melting, preserving information that would otherwise be lost with post-soldering detection methods.
3Loss of time
If gas flow rate and pressure measurement is implemented during soldering, then real-time iron tip state determination is achieved, but device complexity increases
Solution Approach 1:
The patent makes the gas supply system multi-functional by using it for both protecting the solder joint from oxidation and monitoring the iron tip state through flow rate or pressure measurement. This eliminates the need for separate monitoring equipment, reducing overall device complexity while achieving real-time monitoring capability.
4Device complexity
If gas supply portion is integrated into the iron tip structure, then compact design is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent integrates the gas supply passage within the iron tip's internal structure, nesting the gas flow path inside the existing iron tip geometry. This nested design achieves compact integration without significantly complicating manufacturing, as the gas passage can be formed as a simple internal channel during iron tip fabrication.
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
Enables immediate and accurate determination of the iron tip's state, allowing for continuous monitoring and improving the precision of soldering processes by assessing changes in flow rate and pressure.
Implementation Method 1
a total flow rate of the gas flowing through the gas supply portion is constant, a physical quantity of the gas flowing within the gas supply portion is measured
Implementation Method 2
an iron tip that includes a solder hole into which a solder piece is supplied and that heats and melts the solder piece in the solder hole
Implementation Method 3
heats and melts the solder piece in the solder hole
Data Source
Figure 1
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Figure 4~5
AI summary
By a method of determining the state of an iron tip according to the present invention, in a soldering device including: an iron tip that includes a solder hole into which a solder piece is supplied and that heats and melts the solder piece in the solder hole; a gas supply source that supplies a gas; and a gas supply portion that makes the gas supply source communicate with the solder hole and that supplies the gas from the gas supply source into the solder hole, the total flow rate of the gas flowing through the gas supply portion or a supply pressure is constant, a physical quantity of the gas flowing within the gas supply portion is measured and the measured physical quantity is compared with a previously provided reference value or table such that the state of the iron tip is determined. In this way, it is possible to constantly accurately determine the state of the iron tip.