Vision-Guided Wire Welding Head for Precise Pad Alignment
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Solution Overview
Problem
The miniaturization of communication products makes it difficult to ensure accurate alignment of small-diameter wires with welding pads, leading to positioning errors in existing welding systems that rely on fixtures for alignment.
Innovation Solution
A welding system with a moving device capable of movement in at least two directions, equipped with a welding head and a visual device for precise alignment and clamping of wires to welding pads, allowing the welding head to be moved to a clamping position aligned with the wire and then to a welding position aligned with the pad under visual guidance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a fixture is used to clamp and align the wire and welding pad, then alignment is provided, but positioning accuracy deteriorates due to miniaturization of wire diameter
Solution Approach 1:
The patent replaces the mechanical fixture-based alignment system with a vision-guided positioning system. The visual device captures images of the wire and welding pad, and the control unit processes these images to calculate precise positioning coordinates, substituting mechanical alignment with optical-mechanical integration to achieve higher positioning accuracy for miniaturized wires
Solution Approach 2:
The patent uses visual imaging to create a digital copy or representation of the wire and welding pad positions. The visual device captures the actual positions, and the control unit processes these visual copies to determine precise welding coordinates, enabling accurate positioning without physical contact or mechanical fixtures
2Volume of moving object
If the wire diameter is reduced for miniaturization, then product size is reduced, but alignment accuracy deteriorates
Solution Approach 1:
The patent replaces mechanical fixture-based alignment with a vision-guided system that can accurately detect and position miniaturized wires. The visual device captures high-resolution images of the small-diameter wires, and the control unit processes these images to achieve precise positioning coordinates, enabling accurate welding despite the reduced wire diameter
Solution Approach 2:
The patent changes the measurement parameters by using visual detection instead of mechanical measurement. The visual device can detect position with high precision at the pixel level, and the control unit converts these visual parameters into precise positioning coordinates, maintaining alignment accuracy even when wire diameter parameters are reduced
Data Source
AI summary
A welding system for welding a wire to a welding pad includes a moving device movable in at least two directions, a welding head mounted on the moving device and a visual devise. The welding head is adapted to clamp the wire. The visual device guides the moving device to move the welding head to a predetermined position. In operation, the moving device moves the welding head to a clamping position aligned with the wire, and moves the clamped wire to a welding position aligned with the welding pad under the guidance of the visual device.