Solder Bath Level Estimation for Flexible Board Soldering
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Solution Overview
Problem
Existing soldering devices estimate molten solder amounts using limited methods, lacking versatility in determining sufficient solder levels for varying numbers of circuit boards.
Innovation Solution
A soldering device equipped with a detection sensor to measure liquid level height, allowing for estimation of molten solder amounts by comparing detected heights to set levels and calculating remaining solder based on the area of the solder bath, enabling flexible estimation methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a detection sensor is used to measure liquid level height, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical measurement systems with a detection sensor that optically or electrically detects liquid level height. This substitution achieves precise measurement while reducing mechanical complexity, as the sensor provides direct electrical signals for processing without complex mechanical linkages.
2Adaptability or versatility
If multiple estimation methods are implemented, then adaptability is improved, but device complexity increases
Solution Approach 1:
The estimation device is designed with multi-functionality to perform both qualitative assessment (comparing liquid level height to predetermined thresholds) and quantitative calculation (computing remaining solder amount using bath area and height difference). This universal design allows a single device to serve multiple estimation purposes without requiring separate systems.
Solution Approach 2:
The device dynamically adapts its estimation approach based on operational needs, switching between threshold-based qualitative assessment for simple replenishment decisions and formula-based quantitative calculation for precise inventory management. This dynamic flexibility enhances adaptability while maintaining manageable complexity.
3Productivity
If real-time liquid level detection is implemented, then productivity is improved, but use of energy increases
Solution Approach 1:
Instead of continuous monitoring, the detection sensor operates periodically or on-demand to measure liquid level height. This periodic action maintains productivity by providing timely detection information while significantly reducing energy consumption compared to continuous operation, as the sensor activates only when measurement is needed.
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
Enables accurate estimation of molten solder amounts for both predetermined and arbitrary numbers of circuit boards, improving operational efficiency by determining when to replenish or utilize remaining solder, thus enhancing convenience and productivity.
Implementation Method 1
a detection sensor that detects a liquid level height of the molten solder in the solder bath
Data Source
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AI summary
A soldering device according to the present invention includes a detection sensor 128 which can detect a liquid level height of molten solder inside a solder bath. Then, it is determined whether or not a detection height which is the liquid level height of the molten solder detected by the detection sensor is greater than or equal to a first set height which is arbitrarily set. At this time, in a case where the detection height is greater than or equal to the first set height, it is estimated that the amount of molten solder capable of performing a soldering work for a predetermined number or more of boards is stored in the solder bath (first estimation section 160). In addition, the amount of molten solder stored in the solder bath is estimated by multiplying a difference between a detection height which is the liquid level height of the molten solder detected by the detection sensor and a second set height which is preset, by an area inside the solder bath in a horizontal direction (second estimation section 162). As such, according to the present invention, it is possible to estimate the amount of storage of molten solder by using various methods.