Wire Feeding Apparatus with Electromechanical Sensor
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Solution Overview
Problem
Existing solder wire feed devices in automatic soldering systems suffer from mechanical complexity, susceptibility to dirt, and unreliable control due to frictional resistance, leading to inconsistent soldering quality and malfunctions such as solder wire snapping.
Innovation Solution
A feed device with an electromechanical sensor connected to a control unit that measures pressure reaction force electronically, eliminating frictional resistance and providing sensitive, consistent control, integrated within a compact and inexpensive design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a carriage guide with springs is used to control solder wire feed, then the feed rate can be regulated, but the device becomes mechanically complex and space-consuming
Solution Approach 1:
The patent replaces the mechanical carriage guide with springs system with an electromechanical sensor system. The force sensor (e.g., piezo element or Hall sensor) electronically measures the pressure reaction force of the solder wire end, and the control unit processes this signal to regulate the feed rate. This substitution eliminates the complex mechanical guidance structure while achieving reliable feed control through electronic sensing and control.
2Reliability
If a carriage guide with springs is used to control solder wire feed, then the feed rate can be regulated, but the device becomes susceptible to dirt and friction
Solution Approach 1:
The electromechanical sensor system replaces the mechanical carriage guide, eliminating sliding surfaces and contact points that accumulate dirt and generate friction. The force sensor measures pressure reaction force without mechanical contact that would be affected by contamination, and the electronic control system is insensitive to dirt and friction, ensuring consistent feed control over long operating periods.
3Reliability
If carriage springs are used to measure pressure force, then feed movement can be regulated, but the measurement is imprecise and uneven
Solution Approach 1:
The patent replaces the spring-based mechanical force measurement with an electromechanical force sensor. The sensor (such as a piezo element or Hall sensor) provides precise electronic measurement of the pressure reaction force of the solder wire end. The control unit processes this accurate measurement signal to regulate the feed rate, achieving sensitive and consistent control that is not subject to the imprecision and non-reproducibility of mechanical spring forces.
4Reliability
If an electromechanical sensor is rigidly connected to the feed device, then the device becomes spatially compact and less sensitive to external interference
Solution Approach 1:
The electromechanical force sensor is rigidly integrated into the feed device structure, merging the sensing function with the feeding mechanism. This integration makes the device spatially compact and ensures that the sensor moves with the feed device, maintaining accurate measurement of the solder wire end pressure. The rigid connection eliminates relative motion between sensor and feed device, reducing sensitivity to external interference and vibration while maintaining measurement accuracy.
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
Ensures optimal melting of solder wires with minimal thermal load, reducing process times and maintaining consistent soldering quality even with soft or thin wires, by intelligent coordination of wire feed and heat supply.
Implementation Method 1
the sensor unit comprises an electromechanical sensor that is rigidly connected to the feed device and generates an electronic measurement signal as a function of the measured pressure reaction force
Implementation Method 2
a conveying device for linearly feeding a wire along an axial direction
Implementation Method 3
a controllable, in particular controllable, heating device for heating the free end of the wire
Implementation Method 4
the wire end that is free in the conveying direction of the wire hitting a counter surface, absorbing a pressure reaction force acting in the opposite direction to the conveying direction and passing it on in the axial direction along the wire
Data Source
Figure 1~2
AI summary
Feeding device (1) comprises a sensor unit for measuring the pressure reaction force received by the wire with an electromechanical sensor (5) rigidly connected to the feeding device. The sensor unit produces an electronic measuring signal depending on the measured pressure reaction force. The signal is further conveyed to a control and regulating unit. An independent claim is also included for method for operating a feeding device.