Micromini TIG Welding FET Terminals with Grounded Earth Clamp Jig
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Solution Overview
Problem
Conventional methods for welding terminals of field effect transistors (FETs) and bus bars, such as resistance welding and laser welding, face challenges like high current surges, breakage of electronic components, and increased costs due to complex setups and low resistance values, making it difficult to apply micro spot TIG welding effectively in small control apparatuses.
Innovation Solution
The method involves using a micromini TIG welder with an earth clamp jig to sandwich and ground the terminals and bus bars, controlling the welding arc to prevent breakage and ensuring a stable join by setting terminals to an identical potential, thereby reducing the risk of voltage differences and improving the strength of the weld.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If resistance welding is used to weld FET terminals and bus bars, then the welding strength is improved, but the electronic component may be broken by current surge
Solution Approach 1:
The patent applies preliminary action by grounding the FET terminal before the welding arc is generated. The earth clamp jig is positioned to contact the terminal in advance, ensuring that when the arc fires, the terminal is already at ground potential, preventing voltage differences from causing current surge that could break the electronic component.
2Device complexity
If micro spot TIG welding is used to weld high current components, then the device complexity is reduced, but the electronic component may be broken by flying arc to other terminals
Solution Approach 1:
The patent applies equipotentiality by bringing all FET terminals to the same ground potential using the earth clamp jig before welding. This eliminates voltage differences between terminals, so even if the welding arc flies to other terminals, no harmful current will flow through the electronic component, maintaining reliability while using simple micro spot TIG welding equipment.
3Manufacturing precision
If conventional welding methods are used for small control apparatus, then the manufacturing precision is maintained, but the productivity is reduced due to difficulty in applying micro spot TIG welding
Solution Approach 1:
The patent applies preliminary action by pre-positioning the earth clamp jig to ground the terminal before welding begins. This simple preparatory step enables the use of micro spot TIG welding with precise arc control, improving productivity by allowing welding in previously difficult-to-access configurations while maintaining manufacturing precision through controlled arc placement.
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 prevents breakage of electronic components, reduces costs by minimizing the need for additional equipment and man-hours, and achieves high-strength, low-resistance welds suitable for high-current applications, enabling mass production of EPS control units.
Implementation Method 1
welding arc from a first electrode of a micromini TIG welder
Implementation Method 2
by melting and joining by a welding arc
Implementation Method 3
earth clamp jig serving as a second electrode so that the one of the plurality of terminals... and the circuit conductor to be welded are grounded
Data Source
AI summary
A method of welding a circuit conductor and one of a plurality of terminals of an electronic component of a control apparatus by melting and joining by a welding arc from a first electrode of a micromini TIG welder, the method includes: using the electronic component including the terminals which are apart from each other; and arc-welding while only the one of the plurality of the terminals of the electronic component of the control apparatus which is to be welded and the circuit conductor to be welded are sandwiched by an earth clamp jig serving as a second electrode so that the one of the plurality of the terminals of the electronic component of the control apparatus which is to be welded and the circuit conductor to be welded are grounded.