Synchronous Selective Soldering for Continuous Conveyor Throughput
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Solution Overview
Problem
Traditional multiple station selective soldering machines require stopping the conveyance of workpieces at each station, leading to reduced throughput capacity, increased complexity and cost, and limited workpiece length due to the need for additional components like stop pins and sensors.
Innovation Solution
A method and system for applying solder to a workpiece while it is continuously moving, using a conveyor and multiple selective soldering nozzles that track the movement of the workpiece, allowing for synchronized application of flux, heat, and solder without stopping the workpiece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If workpieces are stopped at each station for soldering, then soldering precision can be maintained, but throughput capacity is reduced
Solution Approach 1:
The patent implements a dynamic conveyor system that can adjust its speed to match the soldering process requirements. The conveyor motor speed is controlled to synchronize with the nozzle movement, allowing the workpiece to move at variable speeds rather than being completely stopped. This dynamic speed adjustment maintains soldering precision while minimizing interruption time, thereby improving throughput capacity compared to traditional stop-and-go systems.
Solution Approach 2:
The patent enables continuous conveyance of workpieces through the soldering station without complete stops. The conveyor system operates continuously, and the soldering nozzle moves synchronously with the workpiece, maintaining relative positioning accuracy. This continuous operation eliminates the idle time associated with stopping and starting the conveyor, significantly improving throughput capacity while maintaining soldering precision through coordinated motion control.
2Manufacturing precision
If multiple components are added to stop workpieces at each station, then soldering can be performed, but device complexity and cost increase
Solution Approach 1:
The patent combines the conveyor function with the positioning function into a single integrated system. Instead of using separate stop pins, sensors, and conveyor control mechanisms, the invention uses a unified conveyor motor control system that coordinates the conveyor speed with the nozzle movement. This merging of functions reduces the number of components needed, simplifies the machine structure, and lowers cost while maintaining soldering capability.
Solution Approach 2:
The conveyor system is designed to perform multiple functions: it transports workpieces through the machine, positions workpieces for soldering, and synchronizes with the nozzle movement. This multi-functional conveyor eliminates the need for dedicated stopping and positioning components, reducing device complexity and cost while maintaining full soldering capability across different workpiece types and stations.
3Manufacturing precision
If workpieces are stopped at each station, then soldering can be completed, but processing time is increased
Solution Approach 1:
The patent implements continuous conveyance of workpieces through the soldering station without complete stops. The conveyor operates continuously, and the soldering nozzle moves synchronously with the workpiece to maintain precise relative positioning throughout the soldering process. This eliminates the time lost during stopping and starting operations, significantly reducing total processing time while ensuring soldering is completed accurately.
4Manufacturing precision
If stations are spaced apart to accommodate stop components, then work can be performed, but machine footprint increases
Solution Approach 1:
The patent merges the conveyor and positioning functions into a single integrated system, eliminating the need for separate stop components that require spacing between stations. The synchronized motion control allows workpieces to be processed at closer station intervals, reducing the overall machine footprint while maintaining full work capability through coordinated nozzle and conveyor movement.
Data Source
AI summary
Methods and apparatus for applying molten solder are disclosed. A system for applying solder to a workpiece includes a conveyor for moving a first workpiece along a machine direction, and a first selective soldering nozzle to apply solder to the first workpiece while the first workpiece is moving along the machine direction. The system can also include a flux application area to apply flux to bottoms of workpieces, a heating area to heat the bottoms of the workpieces, and a conveyor to convey the workpieces. The workpiece can constantly move through multiple areas, such as a flux application area, a heating area, and a selective soldering area. As such, two or more areas can operate on the workpiece simultaneously and while the workpiece is moving. The method includes applying solder from the first selective soldering nozzle to the first workpiece while the first workpiece is moving along the machine direction.