Lead Wire Pull-Out Apparatus Tension Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing ultrasonic vibration bonding process for bonding a lead wire to a substrate faces issues with high tension on thin lead wires due to the large and heavy lead reel, often resulting in wire breakage when pulled out.
Innovation Solution
A lead wire pull-out apparatus with a movable lead bearing and press-down mechanism that reduces tension by distributing the weight of the lead wire across two fixed bearings and a smaller movable bearing, allowing only the weight of the movable bearing to act on the wire during extraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If the lead wire is wound on a large lead reel multiple times, then the lead wire can be supplied continuously, but the tension on the lead wire becomes extremely high causing breakage
Solution Approach 1:
The lead reel is divided into two separate components: a stationary lead reel that holds the wound lead wire and a movable lead bearing that supports the lead wire during payout. This segmentation allows the heavy lead reel to remain fixed while only the lightweight movable bearing moves, significantly reducing the tension on the lead wire from the full weight of the reel to only the weight of the small bearing.
Solution Approach 2:
The movable lead bearing acts as an intermediary between the stationary lead reel and the lead wire payout system. It transfers the support function from the heavy reel to a lightweight component, mediating the tension forces and protecting the thin lead wire from breakage while maintaining continuous supply capability.
2Quantity of substance
If a heavy lead reel is used to wind the lead wire multiple times, then the lead wire storage capacity increases, but the tension and inertia cause lead wire breakage
Solution Approach 1:
The system separates the storage function (stationary lead reel with large capacity) from the payout support function (movable lead bearing). This allows the lead wire storage capacity to be maintained by the large stationary reel while the tension during payout is minimized by the lightweight movable bearing.
Solution Approach 2:
The system transitions from a single-dimensional problem (reel weight affecting wire tension) to a two-dimensional solution by separating the reel into stationary and movable components. The stationary reel provides storage capacity in one dimension while the movable bearing manages tension in another dimension, allowing both requirements to be satisfied simultaneously.
3Productivity
If the lead reel is made large and heavy to accommodate multiple windings, then the lead wire can be pulled out continuously, but the inertia creates extremely high tension
Solution Approach 1:
The lead reel system is segmented into a stationary reel for continuous supply and a movable bearing for stress-free payout. This segmentation enables continuous productivity while eliminating the inertia-induced tension stress that would occur with a single heavy moving reel.
Solution Approach 2:
The movable lead bearing introduces dynamic elements to the system, allowing it to move and adjust during lead wire payout. This dynamic component reduces the effective mass that must be accelerated, thereby reducing inertia forces and tension stress on the lead wire while maintaining continuous payout capability.
Data Source
AI summary
A lead wire pull-out apparatus includes: a lead reel configured to have a lead wire wound thereon; two fixed lead bearings fixed at predetermined positions, on which the lead wire pulled out from the lead reel is slidable; a movable lead bearing arranged between the two fixed lead bearings, the movable lead bearing being movable in a vertical direction and configured such that a lower portion thereof is able to be in contact with the lead wire; and a press-down part configured to press down the movable lead bearing.