Soldering Nozzle Calibration Using Image-Based Wave Detection
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Solution Overview
Problem
Current calibration methods for soldering machines are time-consuming and infrequent, leading to inaccuracies in solder application and potential machine downtime due to lack of frequent monitoring and maintenance, which can result in poor-quality production and undetected equipment deterioration.
Innovation Solution
A method involving machine settings that include nozzle and board target calibration positions, with image-based determination of nozzle and board characteristics, allowing for frequent calibration and maintenance analysis using cameras and sensors to adjust settings and identify maintenance needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional calibration methods using position sensors and conductive needles are used, then calibration accuracy can be achieved, but the calibration process becomes time-consuming and must be performed infrequently
Solution Approach 1:
The patent uses image capture devices to create visual copies of the solder wave and nozzle positions, replacing physical measurement tools like conductive needles and position sensors. The image processing system analyzes these visual copies to determine wave height and position characteristics, enabling rapid calibration without time-consuming physical measurements.
Solution Approach 2:
The patent replaces mechanical calibration systems (conductive needles, position sensors, manual measurement tools) with an optical imaging and image processing system. The image capture device and image processing circuitry automatically measure wave height, nozzle position, and other calibration parameters visually, eliminating the need for mechanical contact and manual intervention.
2Manufacturing precision
If calibration is performed frequently to maintain accuracy, then production quality improves, but machine downtime increases due to repeated calibration interruptions
Solution Approach 1:
The system continuously captures images of the solder wave and nozzle assembly during operation, creating visual records that can be analyzed without stopping production. This allows frequent monitoring and calibration while maintaining continuous manufacturing flow, unlike traditional methods that require machine shutdown.
Solution Approach 2:
The imaging and image processing system operates continuously during soldering production, enabling real-time monitoring and calibration without interrupting the manufacturing process. The system processes images and adjusts parameters on-the-fly, maintaining both production continuity and calibration accuracy.
3Measurement precision
If traditional calibration methods are used, then position and wave height can be measured, but equipment deterioration and maintenance needs remain undetected
Solution Approach 1:
The image capture and processing system serves multiple functions simultaneously: it measures wave height, determines nozzle position, monitors solder flow characteristics, and detects equipment deterioration. This multi-functional system provides both calibration data and maintenance monitoring without requiring separate measurement devices.
Solution Approach 2:
The system continuously captures images, processes them to extract operational parameters, compares these parameters against expected values, and provides feedback for both calibration adjustments and maintenance alerts. This ongoing feedback loop enables early detection of equipment deterioration trends.
4Measurement precision
If multiple nozzles in a multi-wave solder pot are calibrated individually using traditional methods, then each nozzle accuracy can be ensured, but the calibration process becomes extremely time-consuming
Solution Approach 1:
The patent combines the calibration of multiple nozzles into a single integrated imaging process. The image capture device captures all nozzles and their corresponding solder waves simultaneously in one or a few images, and the image processing system analyzes all nozzle positions and wave heights from these combined images, eliminating the need to calibrate each nozzle separately.
Solution Approach 2:
The imaging system creates visual copies of all nozzles and solder waves simultaneously, allowing parallel analysis of multiple nozzle characteristics from a single image set. This replaces the sequential physical measurement process with concurrent visual assessment of all nozzles.
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 approach enables more frequent and accurate calibration, reduces production errors, and allows for timely identification of maintenance requirements, improving production quality and machine efficiency.
Implementation Method 1
obtaining at least one image of the soldering apparatus when the at least one nozzle is positioned according to the nozzle target calibration position
Data Source
AI summary
An example method of calibrating the operation of soldering apparatus for use in a soldering machine, in which the soldering apparatus includes at least one nozzle which is configured to apply solder to an electronics board, in use, involves: providing machine settings to the soldering apparatus, the machine settings including a nozzle target calibration position and at least one solder setting for the at least one nozzle; positioning the at least one nozzle according to the nozzle target calibration position; pumping solder from the at least one nozzle according to the at least one solder setting, when the at least one nozzle is positioned according to the target calibration position; obtaining at least one image of the soldering apparatus when the at least one nozzle is positioned according to the nozzle target calibration position; determining, from the at least one image, at least one nozzle characteristic; and adjusting the machine settings to reduce a difference between the at least one nozzle characteristic determined from the at least one image, and a corresponding expected at least one nozzle characteristic.