Automatic Solder Nozzle Exchange for Mixed-Component Assemblies
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Point-to-point soldering systems require frequent nozzle changes for different components, leading to production delays and manual intervention, as each nozzle size is typically used for specific components, causing inefficiencies in mixed technology assemblies.
Innovation Solution
A soldering system with a nozzle exchange unit that allows for automatic or programmed switching of nozzles during the soldering operation, enabling the use of multiple nozzle sizes without manual intervention, facilitated by a robot that can detach and attach nozzles from a storage unit based on component dimensions and space availability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual nozzle changes are performed for different component sizes, then soldering precision for specific components is maintained, but production time increases and productivity decreases
Solution Approach 1:
The system changes the nozzle parameters (size, shape) automatically based on component requirements. The controller selects appropriate nozzles from the exchange unit based on component pitch and thermal mass, enabling precise soldering for each component type without manual intervention, thus resolving the contradiction between maintaining precision and improving productivity
Solution Approach 2:
The nozzle exchange unit enables dynamic adaptation of nozzle configuration during the soldering process. The system transitions from static single-nozzle setups to dynamic multi-nozzle configurations, allowing automatic switching between different nozzle types (e.g., from small pitch nozzles to large pitch nozzles) based on real-time component requirements, thereby maintaining precision while eliminating manual changeover time
2Adaptability or versatility
If multiple nozzles are stored in the nozzle exchange unit, then adaptability to different component types is improved, but device complexity increases
Solution Approach 1:
The nozzle exchange unit serves multiple functions: storing multiple nozzles, automatically selecting appropriate nozzles based on component characteristics, and facilitating rapid nozzle changes. This multi-functional design consolidates what would otherwise require separate manual operations, improving adaptability while managing system complexity through integration
Solution Approach 2:
The system performs self-service by automatically selecting and exchanging nozzles based on component requirements without operator intervention. The controller determines the appropriate nozzle based on component pitch and thermal mass, and the exchange unit executes the change automatically, reducing the need for complex manual operation interfaces while maintaining high adaptability
3Device complexity
If a single nozzle is used on the solder pot, then device simplicity is maintained, but the ability to handle mixed technology assemblies is limited
Solution Approach 1:
The soldering system is segmented into a stationary solder pot and a detachable nozzle assembly. This segmentation allows the nozzle (which requires frequent changes for mixed technology assemblies) to be independently exchanged without affecting the solder pot structure. The nozzle coupling mechanism enables clean separation and reattachment, maintaining solder pot simplicity while achieving high adaptability through nozzle interchangeability
Data Source
AI summary
A soldering system comprising a solder pot and a nozzle exchange unit. The solder pot is configured to detachably couple to a solder nozzle during a soldering operation. The nozzle exchange unit is arranged to: store a plurality of solder nozzles; detach a first nozzle from the nozzle coupling; and attach a stored second nozzle to the nozzle coupling.