Resistance Soldering Power Control for Precise Joint Heating Time
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Solution Overview
Problem
Existing resistance soldering systems lack control over the desired time of power delivery to a solder-joint, which affects the consistency and quality of the soldering process, as the time to deliver energy varies based on the electrical connection quality rather than predefined parameters.
Innovation Solution
A resistance soldering system that includes a controller circuit to independently control the desired power level and time, using a silicon-controlled rectifier and transformer to apply a controlled voltage and current to the solder-joint, allowing for user-defined soldering profiles based on joint characteristics, thereby enabling precise control over the soldering process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing resistance soldering systems deliver power to solder-joint, then soldering process is performed, but the time to deliver energy varies based on electrical connection quality rather than being controlled by predefined parameters
Solution Approach 1:
The patent applies parameter changes by transitioning from uncontrolled power delivery to controlled power delivery with independently adjustable power level and time parameters. The controller circuit receives a signal indicating desired power level and desired time, then controls the SCR and transformer to deliver precisely specified energy to the solder-joint, eliminating variability based on connection quality.
Solution Approach 2:
The patent implements feedback through the controller circuit that monitors and adjusts the power delivery process. The controller receives input signals for desired power level and time, controls the SCR firing angle and transformer operation, and ensures the actual delivery matches the predefined parameters, creating a closed-loop control system.
2Manufacturing precision
If existing resistance soldering systems apply power to melt solder-joint, then soldering is achieved, but power level and time are coupled and cannot be independently controlled
Solution Approach 1:
The patent applies segmentation by dividing the control of power delivery into two independent parameters: power level (controlled by SCR firing angle) and time (controlled by controller duration). This segmentation allows each parameter to be optimized independently for precise soldering control without increasing overall system complexity.
Solution Approach 2:
The patent implements dynamics by making the control system adjustable and adaptable. The controller can independently vary power level and time based on different soldering requirements, transforming a static coupled control system into a dynamic decoupled control system that responds to different soldering profiles.
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
This system allows for consistent and precise control over the soldering process by decoupling power level and time, improving the quality and reliability of solder joints by ensuring the desired energy is delivered based on predefined characteristics, rather than relying on connection quality.
Implementation Method 1
using a silicon-controlled rectifier and transformer to apply a controlled voltage and current to the solder-joint
Implementation Method 2
using a silicon-controlled rectifier and transformer to apply a controlled voltage and current to the solder-joint
Implementation Method 3
resistance soldering system that includes a controller circuit to independently control the desired power level and time
Data Source
AI summary
A power delivery system includes a power-input-channel, an AC/DC converter, one or more controller-circuits, a silicon-controlled-rectifier, a transformer, and a pair of output-leads. The power-input-channel receives alternating-current from a power-source. The AC/DC converter converts the alternating-current to a direct-current at a converter-output. The one or more controller-circuits are connected with the converter-output and control a signal indicative of a desired-power-level delivered for a desired-time. The silicon-controlled-rectifier is connected with the power-input-channel and controls an SCR-output-voltage to an SCR-output-channel proportional to the signal. The transformer reduces the SCR-output-voltage from a primary-side to a secondary-voltage on a secondary-side. The pair of output-leads are connected with poles of the secondary-side. A solder-joint is disposed between the pair of output-leads. The one or more controller-circuits determine the signal applied to the silicon-controlled-rectifier required to melt the solder-joint based on the desired-power-level and the desired-time, thereby melting the solder-joint disposed between the pair of output-leads.