PCB Contact Pin Insertion Angle Measurement and Correction
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Solution Overview
Problem
Existing methods for fitting printed circuit boards with contact pins fail to consistently maintain a constant circumference of wobble, leading to faulty insertions and rejection of boards when tolerance limits are exceeded, without providing a means to prevent or correct such faults during the production process.
Innovation Solution
A device and method that utilize a sensor assembly with at least two sensors arranged at different heights above the printed circuit board to measure the angle of insertion between the contact pin and the board, allowing for real-time adjustment of the insertion device to ensure accurate positioning within predetermined tolerance limits, thereby preventing faulty insertions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If random matrix testing is used to check contact pin positions, then faulty insertions are detected, but production efficiency is reduced due to rejection of boards exceeding tolerance limits without opportunity for correction
Solution Approach 1:
The measuring device performs angle measurements during the insertion process itself, before the insertion is completed. This preliminary detection allows the system to identify potential faults early, enabling corrective action before the board is fully processed and rejected, thereby maintaining both reliability and productivity
Solution Approach 2:
The system continuously monitors the angle of insertion in real-time and provides feedback to the control system. When deviations from the predetermined angle are detected, the system can immediately adjust the insertion parameters or alert operators, creating a closed-loop control system that prevents faulty insertions rather than merely detecting them after the fact
2Productivity
If no real-time measurement is performed, then production proceeds quickly, but angle deviations go undetected until final testing
Solution Approach 1:
The measuring device operates continuously during the insertion process, with sensors constantly monitoring the angle of insertion as contact pins are being inserted. This continuous measurement occurs without interrupting the production flow, maintaining productivity while ensuring precise angle detection throughout the entire insertion sequence
Solution Approach 2:
The system replaces traditional mechanical measurement methods with optical or electromagnetic sensors that can measure angle deviations non-contactly and in real-time. This substitution enables precise measurement without adding mechanical complexity or slowing down the insertion process
3Reliability
If angle measurement is implemented during insertion, then faulty insertions are prevented, but device complexity increases
Solution Approach 1:
The measuring device is integrated into the existing insertion machine structure, allowing the same system to perform both insertion and measurement functions. The sensors and evaluation systems are incorporated into the insertion device's control architecture, enabling multi-functionality without requiring completely separate measurement equipment
Solution Approach 2:
The system uses intermediate sensors that detect angle deviations without requiring direct physical contact with the contact pins or printed circuit board. These sensors act as intermediaries, converting physical angle measurements into electrical signals that can be processed by the control system, thereby simplifying the overall measurement implementation
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 early detection and correction of angle deviations, preventing faults and ensuring that contact pins are inserted within specified tolerance limits, thereby reducing board rejection and improving production efficiency.
Implementation Method 1
The angle of insertion between the contact pin and the printed circuit board can be determined from the relative speed between the printed circuit board and the sensor assembly, as well as from the time difference for the sensors to detect the contact pins
Data Source
AI summary
A device for fitting printed circuit boards (5) with contact pins (7), comprising at least one insertion device (1) for inserting at least one contact pin (7) into a printed circuit board (5), at least one measuring device (3) for measuring the angle of insertion (θ) between the at least one inserted contact pin (7) and the printed circuit board (5), wherein the measuring device (3) comprises a sensor assembly (9) having at least two sensors (11) arranged at different heights above the printed circuit board (5) in such a way that the contact pins (7) can be detected by the sensors (11). At least one of the sensor assemblies (9) and the printed circuit board (5) are capable of being displaced in a plane parallel to the printed circuit board (5). The angle of insertion (θ), between the contact pin (7) and the printed circuit board (5), is determined using the relative speed between the printed circuit board (5) and the sensor assembly (9) and from the time difference for the sensors (11) to detect the contact pins (7). The measuring device (3) may connect to the insertion device (1) in such a way that a resulting measurement, taken by the measuring device (3), may be transmitted to the insertion device (1), which is capable of readjustment in response to the transmitted resulting measurement.