Automatic Solder Nozzle Exchange for Mixed-Component Assembly
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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 detachment and attachment of nozzles during the soldering operation, enabling seamless switching between different nozzle sizes without manual intervention, using a robot to manage nozzle exchange based on component dimensions and space availability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual nozzle exchange is used for different component sizes, then soldering precision is maintained, but production time increases and productivity decreases
Solution Approach 1:
The system dynamically exchanges nozzles based on real-time soldering requirements. A nozzle exchange unit automatically replaces nozzles of different sizes during the soldering process, allowing the system to adapt its configuration dynamically rather than being static. This resolves the contradiction by enabling precision maintenance through appropriate nozzle selection while improving productivity through automated exchange that eliminates manual intervention time.
Solution Approach 2:
The system changes the nozzle parameter (size/diameter) according to the specific soldering requirements for different components. By having multiple nozzles with different parameters stored in the exchange unit and selecting the appropriate one based on component pitch and size, the system maintains optimal soldering precision for each specific task while the automated exchange process prevents productivity loss.
2Adaptability or versatility
If multiple nozzles are stored for different components, then adaptability improves, but device complexity increases
Solution Approach 1:
The nozzle exchange unit serves multiple functions: it stores multiple nozzles of different sizes, automatically selects the appropriate nozzle based on component requirements, and performs the exchange operation. This multi-functional design improves adaptability to different components while managing device complexity by consolidating storage, selection, and exchange functions into a single integrated unit rather than separate systems.
Solution Approach 2:
The system performs self-service by automatically selecting and exchanging nozzles based on the soldering requirements without external manual intervention. The control system monitors component pitch and size, determines the appropriate nozzle, and executes the exchange autonomously. This self-service capability enhances adaptability while preventing complexity increase by eliminating the need for manual nozzle selection and exchange procedures.
3Productivity
If automated nozzle exchange is implemented, then productivity improves, but ease of operation decreases
Solution Approach 1:
The system extracts the complex automated nozzle exchange function from the overall operation, isolating it in a dedicated exchange unit. This allows the main soldering operation to remain simple and easy to operate, while the complex exchange function is handled separately by the automated system. The extraction principle resolves the contradiction by enabling high productivity through automation without burdening the operator with complex operational procedures.
Data Source
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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.