Automated Wire Soldering With Vision Feedback for Length Consistency
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Solution Overview
Problem
Manual soldering of electrical device leads or pins is inefficient and unsuitable for mass production, as it requires manual operation and lacks precision for consistent soldering quality and length.
Innovation Solution
An automatic soldering system comprising a carrier, a robot, a solder paste container, and a heater, along with vision detection and cutting mechanisms, to automate the soldering process, ensuring consistent soldering quality and length, and incorporating a cleaning brush and waste recycling bin for efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual soldering is used, then operation flexibility is maintained, but productivity is very low and unsuitable for mass production
Solution Approach 1:
The patent replaces the manual mechanical soldering operation with an automated robot system. The robot gripper automatically holds the electrical product, moves it to the soldering station, and positions it for soldering, eliminating manual labor and significantly improving productivity for mass production
Solution Approach 2:
The system enables self-service automation where the robot automatically performs the complete soldering cycle including picking up the product, positioning it, heating the solder paste, and moving the product away after soldering, without requiring continuous human intervention
2Manufacturing precision
If manual soldering is used, then equipment complexity is low, but manufacturing precision of soldering length and quality is inconsistent
Solution Approach 1:
The patent incorporates a vision detection system that uses a camera to detect the soldering length and quality in real-time. The detected information is fed back to the control system, which adjusts the robot's movements and heating parameters to maintain consistent soldering precision throughout mass production
Solution Approach 2:
The system dynamically adjusts the robot's gripper position, movement speed, and the heater's temperature based on real-time feedback from the vision system and process requirements, enabling precise control of soldering length and quality while maintaining system adaptability
3Productivity
If automated soldering system is implemented, then productivity increases for mass production, but device complexity increases
Solution Approach 1:
The patent divides the automated soldering system into distinct functional modules: a robot module for product handling, a heating module for solder paste melting, and a vision detection module for quality control. This segmentation allows each module to be optimized independently while working together to achieve high productivity in mass production
Solution Approach 2:
The robot gripper serves multiple functions: holding the electrical product during transport, positioning it precisely at the soldering station, and moving it away after soldering. This multi-functionality reduces the need for separate dedicated components, managing system complexity while maintaining high productivity
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 system significantly increases efficiency and precision in soldering multiple wires by automating the process, ensuring consistent soldering quality and length, and facilitating easy recycling of waste, making it suitable for mass production.
Implementation Method 1
a heater configured to heat the solder paste and melt the solder paste into a liquid
Implementation Method 2
heat the solder paste and melt the solder paste into a liquid
Data Source
AI summary
A wire automatic soldering system includes a carrier adapted to load an electrical product to be soldered, a robot adapted to grip and move the carrier on which the electrical product is loaded, a solder paste container containing a solder paste, and a heater configured to heat the solder paste and melt the solder paste into a liquid. The robot moves a plurality of wires of the electrical product into the solder paste container to solder the wires together with the solder paste.