Soldering Method with RF Temperature Feedback Control
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Solution Overview
Problem
In soldering processes, the quality of soldered connections between units is difficult to control due to non-uniform heat distribution and varying heat capacities of soldering partners, leading to potential issues like shrinkage holes and poor electrical and thermal contacts.
Innovation Solution
A soldering method utilizing a soldering machine with a heating chamber equipped with a heating unit, temperature measuring units, radio frequency transmitters, and a control unit to monitor and control temperature profiles of each set of components, ensuring precise energy delivery and maintaining consistent temperature profiles throughout the soldering cycle, even in a vacuum or reducing atmosphere.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional soldering furnace is used to solder multiple units, then productivity is improved by soldering many units simultaneously, but manufacturing precision deteriorates due to non-uniform heat distribution and varying heat capacities
Solution Approach 1:
The system divides the soldering process into individually controllable segments by assigning a separate temperature measuring unit and control algorithm to each set of components. This segmentation allows each unit to be monitored and controlled independently, ensuring uniform soldering quality across all units simultaneously processed in the furnace.
Solution Approach 2:
The system implements real-time feedback control by continuously measuring the temperature of each set of components during the soldering cycle and using this information to adjust the heating power. The control unit receives temperature data from measuring units and dynamically modifies heating parameters to maintain uniform temperature profiles across all units, resolving the non-uniform heat distribution problem.
2Manufacturing precision
If individual temperature control for each set of components is implemented, then manufacturing precision is improved by controlling temperature profiles of individual sets, but device complexity increases due to multiple temperature measuring units and control systems
Solution Approach 1:
The control unit is designed as a universal multi-functional system that can simultaneously manage multiple temperature measuring units and control multiple heating zones. This centralized control architecture allows the system to handle individual temperature control for each set of components without proportionally increasing overall system complexity, as the control unit performs multiple functions integrated in a single device.
3Manufacturing precision
If real-time temperature monitoring and control is implemented during the soldering cycle, then manufacturing precision is improved by preventing shrinkage holes and ensuring quality connections, but use of energy increases due to continuous measurement and adaptive heating
Solution Approach 1:
The system employs dynamic control of the heating unit, continuously adjusting the heating power based on real-time temperature measurements from each set of components. This dynamic adaptation allows the system to apply energy only when and where needed during the soldering cycle, maintaining high manufacturing precision while optimizing energy consumption by avoiding unnecessary heating once target temperatures are achieved.
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 method allows for continuous monitoring and control of temperature profiles, preventing shrinkage holes and ensuring high-quality soldered connections with improved electrical and thermal contacts by adapting energy delivery based on real-time temperature data.
Implementation Method 1
a heating unit operable to provide energy... for pre-heating or soldering, the sets of components are heated by the energy provided by the heating unit
Implementation Method 2
the radio frequency (RF) transmitter is operable to transmit temperature information on the temperature of the respective temperature measuring unit to the receiving unit
Data Source
AI summary
A soldering method is provided. According to the method at least two sets of components are heated and soldered by heating. Each set includes a first soldering partner, a second soldering partner, and a solder. During the soldering process, the individual temperatures of each one of the sets are transmitted by a radio frequency transmitter to a receiving and control unit. The control unit controls the heating of the sets depending on the transmitted individual temperatures.