Automated SMD Plug Insert Assembly on Circuit Board Panels

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Solution Overview

Problem

Manual soldering of plugs, such as XLR plugs, on circuit boards is error-prone and costly, and existing SMD technology solutions do not provide an efficient and cost-effective alternative for mass production.

Innovation Solution

An automatic SMD assembly process is used to place a plug insert with pins and contact surfaces on a circuit board panel, where the pins and contact surfaces are aligned on the same plane, allowing for automatic soldering and subsequent separation of the circuit board panel, resulting in a cost-effective and efficient production method for various types of plugs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual soldering is used to fix plugs on circuit boards, then flexibility and adaptability are maintained, but production cost increases and error rate rises

Engineering Contradiction:

Improveerror rateVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces manual mechanical soldering operations with an automated SMD (Surface Mount Device) placement and reflow soldering system. The plug insert is designed with contact surfaces that can be automatically positioned and soldered using standard SMD equipment, eliminating manual intervention and its associated errors while reducing labor costs.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the geometric parameters of the plug insert by ensuring all contact surfaces lie on one plane. This planar configuration allows the plug to be treated as a standard SMD component with uniform mounting height, enabling automated placement machines to position it accurately without manual adjustment, thereby reducing errors and production costs.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If automatic SMD process is used to place plug insert, then productivity increases and cost decreases, but manufacturing complexity increases

Engineering Contradiction:

Improveproduction efficiencyVSAvoidmanufacturing process complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The plug insert is segmented into distinct functional elements: pins for electrical connection and contact surfaces for mounting. The contact surfaces are designed as separate solderable pads on a common plane, allowing the automated SMD process to handle placement and soldering as standardized operations, improving productivity while keeping the added complexity manageable through modular design.

Inventive Principle:

Principle #1Segmentation

3Manufacturing precision

If contact surfaces are aligned on one plane, then automatic placement precision improves, but plug insert design complexity increases

Engineering Contradiction:

Improveplacement precisionVSAvoidplug insert design

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The contact surfaces of the plug insert are positioned on a common plane, creating an equipotential mounting surface relative to the circuit board. This ensures that all contact surfaces are at the same height and orientation, allowing automated placement machines to position the component accurately using standard Z-height compensation, thereby improving placement precision while limiting design complexity through geometric simplification.

Inventive Principle:

Principle #12Equipotentiality

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 process enables the automatic and cost-effective production of plugs like XLR, RJ45, and USB plugs, reducing errors and production costs by utilizing an SMD fitment device for precise alignment and soldering, while allowing for minimal plug casing dimensions.

Implementation Method 1

A plug insert with at least one pin and at least one plug contact surface is placed by means of an automatic SMD fitment device in one of the openings

Methodology Applied

Scientific EffectSMD (Surface Mount Device) technology:

Implementation Method 2

The contact surfaces are automatically soldered to one of the contact surfaces of the circuit board

Methodology Applied

Scientific EffectSoldering: Soldering

Data Source

PatentUS9172159B2Process for the production of a plug and a plug

Publication Date: 2015.10.27 SENNHEISER ELECTRONICS GMBH & CO KG

AI summary

A process for the production of a plug, in which a circuit board panel with openings is provided for forming a circuit board. A plug insert, having a plurality of pins and a plurality of plug contact surfaces, is then placed in one of the openings, by means of an automatic SMD fitment device, in such a way that at least one pin of the plug rests on the circuit board panel, and at least two plug contact surfaces, which are electrically connected to the pins, rest on the circuit board, with the contact surfaces of the plug being on one plane. The plug contact surfaces are then automatically soldered to at least one of the contact surfaces of the circuit board.