Soldering Iron Tip State Detection Using Gas Flow Measurement
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Solution Overview
Problem
Existing methods for determining the state of an iron tip in soldering devices cannot detect the state during the soldering process, only after completion, making it difficult to assess the soldering process in real-time.
Innovation Solution
A method involving a gas supply system that measures the flow rate and pressure of gas flowing through the iron tip, comparing it to reference values to determine the state of the iron tip, including the contact with an object, input of solder, melting, and flow of solder, using a constant total flow rate and physical quantity measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If air pressure measurement is used to detect solder joint state after soldering, then the solder joint failure can be detected, but the iron tip state during soldering cannot be determined
Solution Approach 1:
The patent introduces gas flow rate as an intermediary parameter to indirectly measure the iron tip state. By measuring the flow rate of gas passing through the iron tip, the system can determine the iron tip state (clogged, normal, melted solder) without directly observing the iron tip interior, thus resolving the contradiction between detecting solder joint state and losing iron tip state information during soldering
2Reliability
If post-soldering detection methods are used, then solder joint failures can be identified, but real-time monitoring of soldering process cannot be achieved
Solution Approach 1:
The patent performs preliminary measurement of gas flow rate before and during soldering to predict and determine the iron tip state in advance. By measuring the gas flow rate continuously during the soldering process, the system can determine whether the iron tip is clogged or functioning normally in real-time, enabling timely intervention before soldering failures occur
3Extent of automation
If gas flow rate measurement is implemented, then iron tip state can be determined in real-time, but the measurement system complexity increases
Solution Approach 1:
The patent replaces complex direct observation or mechanical inspection methods with gas flow rate measurement. By using a simple flow rate sensor to measure the gas passing through the iron tip, the system achieves automated real-time monitoring of iron tip state without requiring complex mechanical or optical measurement systems
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 state during soldering, allowing for continuous monitoring of the soldering process and improving the reliability of solder joint formation.
Implementation Method 1
a flow rate or a pressure of a gas flowing through the branch pipe or a supply pipe to the solder hole is metered
Implementation Method 2
a total flow rate of the gas flowing through the gas supply portion is constant
Implementation Method 3
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
Data Source
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.