Luminescent Braze Preforms for Automated Detection
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Solution Overview
Problem
Automating brazing procedures is challenging due to the difficulty in confirming whether braze preforms are assembled onto components before heating, often resulting in detection only during post-brazing tests or field use, and existing solutions like visual inspection or sophisticated sensors are costly and prone to contamination.
Innovation Solution
A braze preform with a luminescent material, such as a neon blue ink, is applied to the filler metal, which luminesces under UV light, allowing for detection using a sensor system, reducing the risk of contamination and enabling automated verification of preform presence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual inspection by operator is used to confirm braze preform assembly, then detection accuracy is improved, but labor cost and time consumption increase
Solution Approach 1:
The patent applies luminescent material to the braze preform that changes its optical properties under UV light, making it highly visible and distinguishable from the component. This allows automated optical sensors to easily detect the presence and position of the preform without requiring human visual inspection, thereby improving detection accuracy while reducing time consumption.
2Extent of automation
If sophisticated optical or mass sensors are used to detect braze preforms, then detection automation is improved, but equipment cost and complexity increase
Solution Approach 1:
The luminescent material provides a simple, high-contrast visual signal under UV illumination that can be detected by basic optical sensors. This approach achieves effective automation using inexpensive, simple light sources and sensors rather than requiring sophisticated or complex detection equipment, thereby improving automation extent while minimizing device complexity.
3Measurement precision
If luminescent ink is applied to braze preform, then detection capability is improved, but risk of contamination during brazing increases
Solution Approach 1:
The luminescent material is applied only to specific areas of the braze preform that are visible during assembly inspection, rather than coating the entire preform uniformly. This localized application reduces the amount of material that could potentially contaminate the brazing zone while maintaining sufficient detection capability for automated verification.
Solution Approach 2:
The luminescent material is designed to be non-critical and easily replaceable. Even if some material falls into the brazing zone, it does not compromise the integrity of the joint or require rework. The focus is on achieving detection capability with minimal material application, treating the luminescent coating as a temporary, non-critical feature.
4Productivity
If braze preform assembly is automated, then productivity is improved, but ability to verify assembly before brazing deteriorates
Solution Approach 1:
The luminescent material is applied to the braze preform in advance during manufacturing, before the automated assembly process. This preliminary marking enables verification systems to confirm proper preform placement and orientation on the component before the brazing operation begins, ensuring assembly reliability while maintaining automated high-speed production.
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
The solution ensures reliable detection of braze preforms without human visual inspection, preventing contamination and enabling automated brazing processes, resulting in stronger, defect-free joints that meet high-strength and leak-testing standards.
Implementation Method 1
a luminescent material that can luminesce when exposed to a special light
Implementation Method 2
The optical brightener is the active material that causes the luminescence under a black UV light
Implementation Method 3
The substantially thin coating of the luminescent material may provide a relatively small amount of the luminescent ink and correspondingly a relatively small amount of non-filler metal material which may reduce the likelihood of braze joint contamination
Data Source
AI summary
A braze preform is provided that includes a filler metal and a luminescent material that covers at least a portion of the filler metal and that can luminesce when exposed to a black light. The luminescent material may include a luminescent ink and a solvent that are mixed together before being applied to filler metal. Presence of the braze preform may be determined using automated equipment by detecting luminescence of the braze preform with a sensor. A decision may be made on whether to advance a parts assembly for brazing based on the determination of presence or absence of the braze preform on such parts assembly.