Electrical Device Resistance Calibration via Temperature-Dependent Etching
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Solution Overview
Problem
The existing manufacturing processes face challenges in ensuring that the resistance of electrical devices falls within predetermined ranges, leading to increased manufacturing waste and costs due to inefficiencies in precision control.
Innovation Solution
A calibration system comprising a resistance detector, an etching solution container, and a heater is used to adjust the resistance of electrical devices by detecting and heating them at different temperatures, with etching of lead wires if necessary, to achieve precise resistance calibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If improved manufacturing precision is implemented to ensure resistance within predetermined range, then resistance precision is improved, but manufacturing difficulty and cost increase
Solution Approach 1:
The patent applies preliminary action by performing etching on the lead wire before final resistance measurement. The process detects resistance at a first temperature, and if within range, heats to a second temperature for final calibration. This preliminary etching and staged temperature approach allows adjustment before final verification, reducing the need for high initial manufacturing precision while achieving the required resistance tolerance.
2Manufacturing precision
If improved manufacturing precision is implemented to ensure resistance within predetermined range, then resistance precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent implements self-service through an automated calibration system that performs resistance detection, heating, and etching operations automatically. The system uses a resistance detector to measure lead wire resistance, a heater to control temperature, and an etching solution to adjust resistance values. This automation eliminates manual intervention, reduces labor costs, and enables precise resistance calibration without increasing manufacturing complexity or cost.
3Manufacturing precision
If resistance calibration is performed through manual adjustment, then resistance precision can be improved, but productivity decreases and manufacturing waste increases
Solution Approach 1:
The patent applies feedback through an automated calibration system that continuously monitors resistance values and adjusts accordingly. The resistance detector measures the lead wire resistance, compares it against target values, and triggers heating or etching operations as needed. This closed-loop feedback system ensures precise resistance calibration while automating the process, thereby maintaining high productivity and reducing manufacturing waste from manual trial-and-error methods.
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 effectively ensures that the resistance of electrical devices meets predetermined precision requirements, reducing manufacturing waste and costs by iteratively detecting and adjusting the resistance until it falls within the required range.
Implementation Method 1
the electrical device is heated with the heater to a second temperature higher than the first temperature
Implementation Method 2
the lead wire is etched by the etching solution to adjust the resistance of the electrical device
Data Source
AI summary
A calibration system adapted to calibrate a resistance of an electrical device having a lead wire comprises a resistance detector adapted to detect the resistance of the electrical device, a first container containing an etching solution adapted to etch the lead wire, and a heater configured to heat the electrical device. If a first resistance of the electrical device detected by the resistance detector at a first temperature is within a first predetermined range, the electrical device is heated with the heater to a second temperature higher than the first temperature. A second resistance of the electrical device is detected by the resistance detector at the second temperature. If the second resistance is beyond a second predetermined range, the lead wire is etched by the etching solution to adjust the resistance of the electrical device until the second resistance at the second temperature is within the second predetermined range.