Radial Component Lead Bending and Oblique Cutting
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Solution Overview
Problem
The existing through-hole mounting technique for radial electronic components requires bending leads to secure them in place, which is inefficient and often results in components with mismatched pitch being discarded due to manufacturing tolerances, leading to slowed mounting speeds and increased costs.
Innovation Solution
A method involving bending and obliquely cutting the leads of radial electronic components to match or mismatch the pitch of the circuit board holes, allowing for secure insertion and soldering without additional bending, using spacer plates or arms to adjust pitch and cutting members to bevel the leads for easier insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If leads are bent after insertion to secure the component, then the component is held in place, but the mounting process becomes more complex and time-consuming
Solution Approach 1:
The leads are pre-bent before insertion to match the hole pitch, and the component body is pre-positioned on a support surface. This preliminary preparation eliminates the need for post-insertion bending operations, simplifying the overall mounting process while ensuring reliable component retention
2Manufacturing precision
If visual inspection and pitch calibration are performed, then components with wrong pitch are identified and corrected, but the mounting speed is significantly reduced
Solution Approach 1:
Components are pre-sorted by pitch during feeding, and the component body is pre-positioned on a support surface before insertion. This preliminary preparation ensures pitch compatibility is verified in advance, eliminating the need for slow visual inspection and calibration steps during the mounting process
Solution Approach 2:
The manual visual inspection and mechanical pitch calibration system is replaced with an automated mechanical sorting mechanism that separates components by pitch during feeding. This substitution maintains manufacturing precision while dramatically improving mounting speed through automation
3Manufacturing precision
If components with mismatched pitch are discarded, then only properly fitted components are mounted, but material loss increases and costs rise
Solution Approach 1:
Components are pre-sorted by pitch during the feeding process, separating them into different groups. This preliminary sorting enables components with different pitches to be directed to appropriate mounting positions or stored for future use, preventing waste while ensuring pitch compatibility for current mounting operations
Solution Approach 2:
Instead of discarding components with mismatched pitch, the system sorts and recovers them by directing them to separate storage or future mounting operations. This approach maintains manufacturing precision by ensuring proper pitch matching while recovering valuable materials that would otherwise be wasted
4Ease of operation
If the pitch of leads is made different from hole pitch, then insertion is facilitated with friction fit, but additional bending operations are required
Solution Approach 1:
The leads are pre-bent before insertion to create the pitch difference needed for friction fit, and the component body is pre-positioned on a support surface. This preliminary bending eliminates the need for post-insertion bending operations, making insertion easier while avoiding additional complexity in the mounting process
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
Facilitates efficient and cost-effective mounting of radial electronic components by eliminating the need for post-insertion lead bending and addressing pitch mismatches, ensuring secure placement and faster assembly processes.
Implementation Method 1
The bevelled ends of the leads facilitate the insertion of the leads into the holes. The friction between the leads and the edges of the holes keeps the radial electronic component in place in the circuit board
Data Source
Figure 1~2A
Figure 2B~2C
Figure 2D~3A
AI summary
The present invention provides a method and a device for processing a radial electronic component (130, 230). In the invention the radial electronic component (130, 230) is processed by bending a first lead (131, 231) and/or a second lead (132, 232) of the radial electronic component (130, 230) so that the pitch of the leads (131, 132, 231, 232) is different from the pitch of holes in a circuit board, and by cutting the first lead (131, 231) and the second lead (132, 232) obliquely.