Wave Solder Nozzle Exit Wing Actuation for Precise Solder Flow

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Solution Overview

Problem

Existing wave soldering machines require manual adjustment of exit wings, which is difficult and risky for operators, as it involves tilting the wings to control solder flow within a molten solder pot.

Innovation Solution

A wave soldering machine with a wave solder nozzle assembly that includes a rotatable exit wing adjustable by a linear actuator and linkage system, allowing for real-time control of the exit wing's orientation and thus the solder flow, eliminating the need for manual intervention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If manual adjustment of exit wing is used, then device complexity is reduced, but operational safety deteriorates and manufacturing precision worsens

Engineering Contradiction:

Improvestructure complexityVSAvoidoperational safety

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent replaces the manual mechanical adjustment system with an automated electromechanical system. A linear actuator is introduced to automatically adjust the exit wing angle, eliminating the need for operators to manually reach into the molten solder pot. This substitution of manual mechanical operation with automated actuation resolves the safety contradiction by removing operators from the hazardous zone while maintaining precise control over the exit wing position.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Device complexity

If manual adjustment of exit wing is used, then device complexity is reduced, but manufacturing precision deteriorates

Engineering Contradiction:

Improvestructure complexityVSAvoidsolder flow control precision

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent replaces imprecise manual adjustment with an automated linear actuator system that provides consistent, repeatable positioning of the exit wing. The actuator can be controlled to achieve precise angular positions, ensuring uniform solder flow control. This eliminates the variability and imprecision inherent in manual adjustment, resolving the manufacturing precision contradiction.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If automated linear actuator is used, then operational safety is improved, but device complexity increases

Engineering Contradiction:

Improveoperational safetyVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent introduces a linear actuator as an intermediary device between the control system and the exit wing. This actuator serves as a mediator that automatically performs the adjustment function, protecting operators from direct exposure to molten solder while maintaining precise control. The actuator is positioned outside the hazardous zone and transmits its effect to the exit wing through a mechanical linkage, thus improving safety while adding only the necessary level of automation complexity.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Manufacturing precision

If automated linear actuator is used, then manufacturing precision is improved, but device complexity increases

Engineering Contradiction:

Improvesolder flow control precisionVSAvoidstructure complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces manual mechanical adjustment with an automated linear actuator system that provides precise, repeatable positioning of the exit wing. The actuator can be controlled to achieve consistent angular positions, ensuring uniform solder flow control across multiple operations. This automation eliminates the variability inherent in manual adjustment, improving manufacturing precision while adding only the necessary level of system complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

The automated adjustment of the exit wing's orientation enables precise control over solder flow, enhancing operational safety and efficiency by reducing the risks associated with manual adjustments and improving the consistency of the soldering process.

Implementation Method 1

a linear actuator connected to the exit wing and configured to adjust an orientation of the exit wing with respect to the nozzle core frame

Methodology Applied

Scientific EffectLinear actuator mechanism: Linear Motor

Implementation Method 2

The exit wing is rotatable about a hinge with respect to the nozzle core frame to adjust a flow of a solder wave

Methodology Applied

Scientific EffectHinge rotation mechanism: Hinge

Data Source

PatentEP4196306B1Wave solder nozzle with automated exit wing

Publication Date: 2025.06.04 ILLINOIS TOOL WORKS INC

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AI summary

A wave soldering machine includes a housing and a conveyor configured to deliver a printed circuit board through the housing. The wave soldering machine further includes a wave soldering station coupled to the housing. The wave soldering station includes a reservoir of solder material, and a wave solder nozzle assembly (36) configured to create a solder wave. The wave solder nozzle assembly (36) has a nozzle core frame (40) and an exit wing (52), the exit wing (52) being rotatable about a hinge (54) with respect to the nozzle core frame (40) to adjust a flow of a solder wave. A linear actuator (56) is connected via a linkage (58, 62, 64, 70, 74) to the exit wing (52) to allow the linear actuator (56) to adjust an orientation of the exit wing (52) with respect to the nozzle core frame (40).