Solder Machine Alignment Tool for Laser and Wire Feeder Setup
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Solution Overview
Problem
The existing process for aligning a solder wire feeder and a laser in soldering machines is time-consuming and labor-intensive, often requiring a trial and error approach that can take days to complete and necessitates continuous monitoring for weeks.
Innovation Solution
An alignment tool with three movable portions - a base portion, a bracket, and a solder wire alignment portion - that allows for four degrees of freedom, enabling quick and precise alignment of the solder wire feeder and the laser.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a trial and error process is used to align the solder wire feeder and laser, then alignment can be achieved, but the alignment process becomes time-consuming and labor-intensive
Solution Approach 1:
The patent introduces an alignment tool as an intermediary device between the solder wire feeder and the laser. This alignment tool includes alignment features such as alignment holes and alignment slots that facilitate precise alignment without requiring trial and error adjustments. The alignment tool acts as a mediator that guides the relative positioning of the solder wire feeder and laser, thereby achieving accurate alignment quickly and efficiently.
Solution Approach 2:
The alignment tool creates a simplified copy or representation of the alignment relationship between the solder wire feeder and laser. By using alignment features that mirror the desired final alignment configuration, the tool enables operators to achieve correct positioning through direct alignment rather than iterative adjustment, significantly reducing alignment time while maintaining precision.
2Measurement precision
If the solder wire feeder is adjusted in multiple directions to correct misalignment, then alignment can be achieved, but the complexity of the alignment process increases
Solution Approach 1:
The alignment tool serves as an intermediary that simplifies the complex multi-directional adjustment process. Instead of requiring operators to independently adjust the solder wire feeder in X, Y, and Z directions, the alignment tool provides fixed alignment features that guide the positioning, thereby reducing the perceived complexity of the alignment process while achieving the same alignment precision.
Solution Approach 2:
The alignment tool is segmented into distinct portions, each with specific alignment features. The alignment holes in the base portion and alignment slots in the solder wire alignment portion are separate, modular elements that can be independently positioned and secured. This segmentation allows for systematic alignment without requiring complex coordinated adjustments across multiple directions simultaneously.
3Stability of the object's composition
If continuous monitoring is performed to ensure alignment is maintained, then alignment stability can be ensured, but the time and resources required increase
Solution Approach 1:
The alignment tool is designed to be installed beforehand on the soldering machine, with alignment features that are pre-positioned to maintain correct alignment between the solder wire feeder and laser. This preliminary setup eliminates the need for continuous monitoring, as the alignment tool passively maintains alignment stability through its fixed structural relationship with the machine components.
Solution Approach 2:
The alignment tool provides self-maintaining alignment through its fixed installation and rigid alignment features. Once installed, the alignment holes and slots maintain their relative positions without requiring active monitoring or adjustment, allowing the system to self-maintain alignment stability and freeing up time and resources.
Data Source
AI summary
An alignment tool for a solder machine includes a base portion, a bracket and a solder wire alignment portion. Each portion is moveable with respect to the other portions. The base portion includes a laser alignment hole provided on a slope that extends from the base portion. The laser alignment hole is used to align the alignment tool to a laser of the solder machine. A solder wire feeder alignment slot of the solder wire alignment portion is used to align the bracket and the solder wire alignment portion with a solder wire feeder of the solder machine. When each portion of the alignment tool is in a desired position, fasteners of the alignment tool are tightened to secure each portion in the desired position. The alignment tool mirrors a correct alignment between the laser and the solder wire feeder and is usable for subsequent solder machine alignment processes.