Multi-Head Welding Tool for Simultaneous Cable Soldering
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Solution Overview
Problem
Existing welding systems are inefficient when dealing with multiple cables, requiring a long welding time and low efficiency due to the sequential soldering process.
Innovation Solution
A welding system comprising a welding module with a guiding device and a tooth-shaped welding tool that simultaneously guides and heats multiple welding wires at the joints of cables, allowing for simultaneous welding onto a circuit board, along with a moving module and adjustment devices for precise positioning and improved accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If sequential soldering of multiple cables is performed, then welding precision can be maintained, but welding time increases and productivity decreases
Solution Approach 1:
The patent merges multiple welding operations into a single simultaneous operation by using a welding tool with multiple welding heads that can weld multiple cables at the same time. This combines what were previously sequential operations into one concurrent process, maintaining precision through the guiding device while dramatically improving productivity.
Solution Approach 2:
The welding tool is segmented into multiple independent welding heads, each capable of welding a separate cable. This segmentation allows each head to operate independently on its designated cable while being part of a unified system, enabling simultaneous welding of multiple cables without compromising the precision control of individual welding points.
2Productivity
If multiple welding operations are performed simultaneously, then productivity increases, but device complexity increases
Solution Approach 1:
The welding tool is designed as a universal device with multiple welding heads that can handle multiple cables simultaneously. This multi-functional tool replaces what would otherwise require multiple separate welding operations or tools, increasing productivity while managing complexity through a unified, standardized device design that performs multiple functions.
3Loss of time
If multiple cables are welded at once, then welding time is reduced, but positioning accuracy becomes more difficult to maintain
Solution Approach 1:
The guiding device acts as an intermediary between the multiple cables and the welding heads, providing precise alignment and positioning for each cable. This intermediary structure ensures that even though multiple welding operations occur simultaneously, each welding point maintains the required positioning accuracy through the guiding and alignment functions of the guiding device.
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 system significantly reduces welding time and enhances efficiency by allowing simultaneous welding of multiple cables, improving precision and accuracy through guided and heated welding wires and adjustable components.
Implementation Method 1
The welding tool has a plurality of tooth-shaped welding heads arranged in a row, ends of the plurality of tooth-shaped welding heads are disposed close to the joints of the plurality of cables and configured to simultaneously heat the plurality of welding wires
Data Source
AI summary
A welding system comprises a welding module and a moving module adapted to move the welding module to a predetermined welding position. The welding module includes a guiding device and a welding tool. The guiding device has a plurality of tubular guiding heads arranged in a row, ends of the plurality of tubular guiding heads are disposed close to joints of a plurality of cables so as to guide a plurality of welding wires to the joints of the plurality of cables. The welding tool has a plurality of tooth-shaped welding heads arranged in a row, ends of the plurality of tooth-shaped welding heads are disposed close to the joints of the plurality of cables and configured to simultaneously heat the plurality of welding wires guided to the joints of the plurality of cables, so as to simultaneously weld the joints of the plurality of cables onto a circuit board.