Welding Jig for Planar Magnetic Components
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Solution Overview
Problem
The existing methods for manufacturing planar magnetic components are time-consuming, labor-intensive, and prone to quality issues due to manual soldering and cracking of solder during PIN needle cutting.
Innovation Solution
A welding jig and process that includes a fixed piece with bumps and an elastic piece, allowing for secure placement and simultaneous soldering of PIN needles in a solder pot, eliminating the need for manual soldering and reducing labor costs while preventing solder cracks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual soldering using soldering iron is used, then flexibility and precision are improved, but manufacturing time and labor costs increase significantly
Solution Approach 1:
The patent merges multiple soldering operations into a single automated process. The welding jig holds multiple planar magnetic components in fixed positions, allowing simultaneous soldering of multiple PIN needles at both ends in one operation, replacing sequential manual soldering with a unified automated welding process
Solution Approach 2:
The welding jig serves as an intermediary device that positions components and tools precisely. It includes fixed pieces with positioning holes and elastic pieces that clamp components, enabling automated welding tools to accurately solder multiple PIN needles without manual intervention while maintaining soldering quality
2Manufacturing precision
If only one end of each PIN pin is soldered at a time, then precision is maintained, but production speed decreases
Solution Approach 1:
The welding jig enables simultaneous soldering of both ends of PIN pins and multiple PIN needles in a single operation. The fixed piece positions multiple components with their PIN needles aligned, allowing the welding tool to solder all connections at once rather than sequentially, dramatically reducing production cycle time while maintaining consistent soldering quality through precise positioning
3Length of moving object
If PIN needles are cut after soldering, then length adjustment is achieved, but solder cracks occur on PWB
Solution Approach 1:
The welding jig enables soldering to be performed before the PIN needle cutting operation. Components are positioned and soldered in the jig, then the entire assembly is transferred to a cutting device that trims excess PIN needle length. This preliminary soldering approach prevents solder cracks because the needles are secured to the PWB before cutting, maintaining structural integrity during the length adjustment process
4Productivity
If automated welding jig is used, then productivity increases and labor costs decrease, but device complexity increases
Solution Approach 1:
The welding jig is segmented into modular components: a base structure, multiple fixed pieces with positioning holes, elastic pieces for clamping, and operation ends for tool access. This segmentation allows the complex functionality to be achieved through simple, interchangeable modules that can be easily manufactured, assembled, and maintained, reducing the practical complexity despite increased automation capability
Data Source
AI summary
A welding jig and welding process for planar magnetic components are provided. The welding jig includes a fixed piece and an elastic piece. The fixed piece includes a base and a carrier. The base has an opening, bumps at the bottom of the opening and a pair of operation ends extending from the opening. The carrier is fixed on the base and located in the opening, and has multiple through holes. When the bumps are located respectively in the through holes, an accommodation interval is formed between adjacent pairs of the bumps for the placement of the planar magnetic components. The elastic piece is secured to the fixed piece, and when the planar magnetic components are placed in the accommodation intervals of the fixed piece, the elastic piece covers the planar magnetic components and the planar magnetic components abut against two side edges of the elastic piece.