Wave Soldering Nozzle Monitoring via Test Surface Imaging
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Solution Overview
Problem
Current soldering systems for selective wave soldering lack a reliable method to monitor the shape and position of spray jets and standing waves independently of their diameter, with existing solutions only applicable to thin jets and not allowing for automated monitoring of soldering nozzles.
Innovation Solution
A device using a test surface, such as a tensioned paper web or transparent plate, in conjunction with a digital camera and image processing, to detect and monitor the shape and position of spray jets and standing waves, enabling reliable monitoring regardless of diameter and allowing for automated control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a laser apparatus is used to monitor the spray jet by detecting beam interruption, then the position of thin spray jets can be monitored, but wide spray jets cannot be monitored because they leave the nozzle in fan shape and only presence can be detected
Solution Approach 1:
A test surface is introduced as an intermediary between the spray jet and the camera. The spray jet is brought into contact with the test surface, and its shape and position are imaged on the upper face of the test surface. This intermediary allows the camera to capture the spray jet morphology regardless of the spray jet's diameter, solving the limitation of direct optical detection.
Solution Approach 2:
The spray jet shape and position are copied onto the test surface through contact imaging. Instead of directly observing the spray jet in space, a two-dimensional representation is created on the test surface, which can then be captured by the camera and analyzed through image processing to determine spray jet characteristics.
2Extent of automation
If optical inspection of soldering nozzles is performed manually, then nozzle condition can be assessed, but automated monitoring is not available
Solution Approach 1:
Manual optical inspection is replaced with an automated optical measurement system. A camera captures images of the spray jet imaged on the test surface, and image processing algorithms automatically analyze the spray jet shape and position. This substitution enables consistent, repeatable measurements without human intervention.
Solution Approach 2:
The system provides automated feedback by processing images of the spray jet and determining its shape and position. This feedback mechanism enables continuous monitoring and can trigger alerts or adjustments when spray jet characteristics deviate from expected parameters, ensuring consistent quality control.
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
Enables simple and reliable monitoring of spray jets and standing waves, detecting contamination and clogging, and providing real-time feedback for maintaining optimal nozzle performance, improving the precision and efficiency of the soldering process.
Implementation Method 1
a shape and/or position of the spray jet and/or a shape and/or position of the standing wave can be imaged on the upper face of the test surface by bringing the spray jet and/or the standing wave into contact with the lower face of the test surface
Implementation Method 2
a camera, in particular a digital camera, which is designed to detect the shape and/or position of the spray jet that is imaged on the upper face of the test surface
Data Source
AI summary
The invention relates to a soldering system and a method for wave soldering, having at least one flux nozzle and a device for monitoring a state of a spray jet of the flux nozzle.