Resistive Heating Wire Termination for Fine Connector Pin Soldering
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Solution Overview
Problem
Conventional wire termination methods are labor-intensive, time-consuming, and error-prone, especially in medical applications where numerous fine wires need to be connected to electrical connectors, often resulting in defective connectors due to human error and the complexity of small wire sizes.
Innovation Solution
A wire termination system utilizing a heat applicator device that applies resistive heating to connector pins within an electrical connector, allowing wires to be soldered efficiently and automatically, reducing human error and increasing efficiency by using a heat applicator device to melt solder within the connector pins, forming a secure electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual soldering is used to connect wires to connector pins, then connection reliability can be achieved, but labor intensity and time consumption increase significantly
Solution Approach 1:
The system uses automated wire feeders and soldering machines that automatically feed wires, position them, apply solder, and complete connections without manual intervention for each wire, transforming the manual soldering process into an automated self-service system
Solution Approach 2:
The patent replaces manual mechanical soldering operations with automated mechanical systems including robotic positioning, automated wire feeding mechanisms, and controlled solder application systems that perform all connection tasks automatically
2Ease of manufacture
If technicians manually solder numerous fine wires to electrical connectors, then connections can be formed, but error rates approach 25% due to human error
Solution Approach 1:
The system incorporates vision systems and sensors that detect wire positions, connector pin locations, and connection quality in real-time, providing feedback to the control system to automatically correct positioning errors and verify successful connections
Solution Approach 2:
The patent replaces human manual soldering operations with automated systems that eliminate human error, using robotic positioning and automated soldering machines to consistently achieve high connection accuracy
3Ease of manufacture
If conventional soldering devices are used for each individual wire, then connections can be made, but material waste and discarded materials increase significantly
Solution Approach 1:
The system merges multiple soldering operations into a single automated machine that can handle multiple wires simultaneously or in rapid sequence, consolidating soldering resources and reducing overall material consumption
Solution Approach 2:
The automated system implements precise solder application control that minimizes excess solder, and the system design allows for recovery and recycling of solder materials, reducing material waste
4Ease of manufacture
If technicians manually position and solder each wire to corresponding connector pins, then proper connections can be established, but the process becomes extremely time-consuming
Solution Approach 1:
The system performs preliminary actions by pre-positioning wires, pre-heating soldering tools, and pre-programming connection sequences before actual soldering begins, reducing the time required for each connection operation
Solution Approach 2:
The automated system maintains continuous operation with multiple wires being positioned, soldered, and cooled in overlapping time sequences, eliminating idle time between operations and maximizing productive action throughout the 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
The system significantly reduces human error, increases efficiency, and minimizes material waste by automating the wire termination process, enabling faster and more reliable connections even in complex configurations with numerous small wires.
Implementation Method 1
a heat applicator device to apply resistive heating to a specific connector pin of an electrical connector
Data Source
AI summary
A wire termination system includes a heat applicator device to apply resistive heating to a specific connector pin of an electrical connector for the soldering of a wire to the connector pin. In operation, a wire of a cable is inserted into an interior cavity of the connector pin and resistive heating is applied to the connector pin resulting in the melting of solder contained within the interior cavity. Upon stoppage of the resistive heating by the heat applicator device, the solder within the interior cavity of the connector pin solidifies about the wire to form an electrical connection between the wire and the connector pin. The heat applicator device may then be repositioned to apply resistive heating to each additional connector pin of the electrical connector until all wires of the cable are soldered to their corresponding connector pins on the electrical connector.