Wire Alignment Fixture for Circuit Board Welding
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Solution Overview
Problem
Manual alignment of wire cores with wire welding pads on circuit boards is inefficient, and existing fixtures are complex and difficult to operate, leading to potential misalignment during welding.
Innovation Solution
A fixing system comprising a wire clamping device, a base plate, wire fixing members, and a circuit board fixing member, along with moving devices and imaging technology to adjust deviations between wire cores and welding pads, ensuring precise alignment and fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual alignment is used to align wire cores with wire welding pads, then the operation is flexible and easy to adjust, but the alignment efficiency is very low and productivity suffers
Solution Approach 1:
The alignment system is divided into independent functional modules: wire clamping device, circuit board clamping device, imaging device, and moving devices. Each module performs a specific function, allowing automated alignment while maintaining operational flexibility through modular adjustment capabilities.
Solution Approach 2:
The patent replaces manual mechanical alignment with an automated system combining imaging technology (optical field) and controlled mechanical movement. The imaging device captures positions, and moving devices automatically adjust positions based on image analysis, eliminating manual intervention while maintaining adjustability.
2Ease of operation
If existing fixtures are used to fix wires and circuit board, then the structure provides fixing capability, but the fixture structure is complex and difficult to operate
Solution Approach 1:
The clamping system is segmented into separate wire clamping and circuit board clamping devices, each with independent fixing members. This modular approach simplifies the overall structure compared to integrated fixtures while maintaining comprehensive fixing capability for both wires and circuit boards.
Solution Approach 2:
The base plate serves multiple functions: it supports both the wire clamping device and circuit board clamping device, provides a reference plane for alignment, and enables coordinated movement of all components. This multi-functionality reduces the need for separate complex fixture structures.
3Reliability
If existing fixtures are used to fix wires and circuit board, then the structure provides fixing capability, but the operation is difficult and alignment may shift during welding
Solution Approach 1:
The system performs preliminary alignment using the imaging device to capture positions and calculate deviations before welding. The moving devices then adjust the wire clamping device and circuit board clamping device to eliminate deviations, ensuring alignment is established before the welding process begins.
Solution Approach 2:
The imaging device provides continuous feedback on the positions of wire cores and welding pads. The system calculates alignment deviations from captured images and uses this feedback to control the moving devices, automatically adjusting positions to achieve precise alignment and maintain stability during welding.
Data Source
AI summary
A fixing system includes a wire clamping device and a fixture. The wire clamping device is adapted to clamp and fix a plurality of wires. The fixture includes a base plate, a wire fixing member adapted to fix the plurality of wires clamped by the wire clamping device on the base plate, and a circuit board fixing member adapted to fix a circuit board on a front face of the base plate. The wire fixing member and the circuit board fixing member are arranged so as to align cores or conductors of the plurality of wires clamped by the wire clamping device with a plurality of wire welding pads of the circuit board placed on the base plate.