Solder Paste Supply Nozzle Control via Air Chamber Pressure Decay
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Solution Overview
Problem
Existing viscous fluid supply devices face challenges in accurately detecting the remaining amount of viscous fluid, leading to inefficiencies in work related to circuit boards due to interference from the color or material of the solder cup, requiring multiple photoelectric sensors that increase costs and reduce detection accuracy.
Innovation Solution
A device that includes a housing with a movable member, an ejection nozzle, a pressure adjusting device, and a control system with a pressure sensor to estimate the remaining viscous fluid by measuring the time it takes for the pressure inside the air chamber to decrease, allowing for precise determination of the fluid amount.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Difficulty of detecting and measuring
If photoelectric sensors are used to detect the remaining amount of viscous fluid, then detection capability is provided, but detection accuracy deteriorates due to interference from the color or material of the solder cup
Solution Approach 1:
The patent introduces an intermediary mechanism (pressure detection system) between the viscous fluid and the detection system. Instead of directly detecting the fluid level using photoelectric sensors that are affected by the solder cup's color and material, the system uses pressure changes in the air chamber as an intermediate parameter to indirectly measure the remaining fluid amount, thereby eliminating the interference from the solder cup's optical properties
Solution Approach 2:
The patent replaces the optical detection system (photoelectric sensors) with a mechanical pressure detection system. By substituting the optical field with a mechanical pressure field, the system avoids the limitations of optical detection caused by the solder cup's color and material, achieving more reliable and accurate measurements
2Measurement precision
If multiple photoelectric sensors are arranged to obtain detailed information on remaining fluid amount, then measurement precision is improved, but device complexity and manufacturing costs increase
Solution Approach 1:
The patent makes the pressure detection system multi-functional by using it for both monitoring the remaining fluid amount and controlling the supply process. A single pressure sensor serves multiple purposes: measuring fluid level, determining when to stop supply, and providing feedback for process control, thereby eliminating the need for multiple specialized sensors
Solution Approach 2:
The patent changes the detection parameter from optical properties (which require multiple sensors for accurate measurement) to pressure (which can be accurately measured with a single sensor). By transforming the measurement parameter, the system achieves detailed information about remaining fluid levels using only one pressure sensor, significantly reducing device complexity
3Productivity
If pressure is applied to move the movable member for fluid supply, then productivity is improved, but energy consumption increases
Solution Approach 1:
The patent implements periodic action by applying pressure in cycles rather than continuously. The pressure is applied to move the movable member for fluid supply, then released to allow return movement, creating a rhythmic push-pull motion that improves productivity while reducing overall energy consumption compared to continuous pressure application
Solution Approach 2:
The patent makes the pressure application dynamic by adjusting it based on real-time feedback from the pressure sensor. The system applies pressure only when and where needed to move the movable member, rather than maintaining constant pressure, thereby optimizing the balance between productivity and energy consumption
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 solution enhances the accuracy of viscous fluid detection, improves work efficiency by providing detailed information on remaining fluid levels, and reduces the need for multiple sensors, thus lowering manufacturing costs and improving usability.
Implementation Method 1
a pressure sensor configured to detect whether the pressure inside the air chamber has reached a specified set pressure
Implementation Method 2
a time measuring control section configured to measure a required time from starting to decrease the pressure inside the air pressure using the pressure adjusting device to when the pressure sensor detects that the pressure inside the air chamber has been reduced to the set pressure
Implementation Method 3
a movable member arranged inside the housing in a state maintaining airtightness and so as to be movable in accordance with a pressure level inside an air chamber
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
In solder printer 10, solder supply device 50 uses positive and negative pressure supply device 70 to apply pressure inside air chamber 58 to move solder cup 51 inside outer tube 53, such that solder paste is supplied from supply nozzle 59 (S1 to S4). Controller 101, when supply of solder paste from supply nozzle 59 is stopped, performs drive control of positive and negative pressure supply device 70 to decrease the pressure inside air chamber 58 (S5), and uses timer 74 to measure the time required (S7) from the starting of decreasing the pressure inside the air chamber (S5) to when the pressure inside air chamber 58 has reached a set pressure (S6: yes). Because this required time corresponds to the movement amount of solder cup 51 from the start of supply of the solder paste to when supply is stopped, controller 101 using the measured required time to estimate the remaining amount of the solder paste in detail with good accuracy (S11).