U.S. patent application number 10/002876 was filed with the patent office on 2003-05-15 for automated soldering system.
Invention is credited to Hagihara, Yoshihiro, Miyazaki, Mitsuhiko, Yokoyama, Tetsuo.
Application Number | 20030089696 10/002876 |
Document ID | / |
Family ID | 21702960 |
Filed Date | 2003-05-15 |
United States Patent
Application |
20030089696 |
Kind Code |
A1 |
Yokoyama, Tetsuo ; et
al. |
May 15, 2003 |
AUTOMATED SOLDERING SYSTEM
Abstract
An automated soldering system with an intelligent power supply
that can automatically configure the power output to
interchangeable soldering cartridges, where the soldering
cartridges include readable information to allow the power supply
to properly power the cartridge to achieve a desired, entered
operating temperature. The system includes a cartridge with an
identifier that contains information particular to that cartridge,
a reader able to read that information, and an indicator positioned
on a connector into which the cartridge is inserted.
Inventors: |
Yokoyama, Tetsuo; (Osaka,
JP) ; Miyazaki, Mitsuhiko; (Osaka, JP) ;
Hagihara, Yoshihiro; (Osaka, JP) |
Correspondence
Address: |
SQUIRE, SANDERS & DEMPSEY L.L.P.
801 S. Figueroa St., 14th Fl.
Los Angeles
CA
90017-5554
US
|
Family ID: |
21702960 |
Appl. No.: |
10/002876 |
Filed: |
November 14, 2001 |
Current U.S.
Class: |
219/240 ;
219/229; 228/51 |
Current CPC
Class: |
B23K 3/03 20130101; B23K
3/033 20130101 |
Class at
Publication: |
219/240 ;
219/229; 228/51 |
International
Class: |
B23K 003/00; H05B
003/42 |
Claims
What is claimed is:
1. A soldering system comprising: at least one soldering cartridge
having a soldering tip and an identifier to identify the power
requirements of said soldering tip; a power supply to provide power
to said at least one soldering cartridge, said power supply being
capable of generating variable levels of power for different
soldering cartridges; and an identifier reader communicatively
coupled to said power supply and capable of reading said identifier
of said at least one soldering cartridge to obtain and provide
information about the power requirements of said soldering tip to
said power supply.
2. The soldering system of claim 1, further comprising: a power
cable to couple said at least one soldering cartridge to said power
supply.
3. The soldering system of claim 1, wherein said identifier on said
at least one soldering cartridge is a bar code.
4. The soldering system of claim 3, wherein said reader coupled to
said power supply is a bar code reader.
5. The soldering system of claim 1, further comprising: means for
monitoring the temperature of said soldering tip and adjusting the
power output level of said power supply to a preset temperature for
said soldering tip.
6. The soldering system of claim 1, wherein said power supply uses
information from said identifier to determine the appropriate level
of power to be provided to said soldering cartridge.
7. The soldering system of claim 1, wherein said power supply
further comprises: means for retrieving data on said at least one
cartridge based upon information provided by said identifier.
8. The soldering system of claim 1, wherein said power supply
further comprises: means for converting data from said identifier
into instructions for said power supply to control the power output
of said power supply.
9. The soldering system of claim 1, further comprising: an
elongated conductor cable having at least two electrical conductors
extending from a first end to a second end; a connector coupled to
said first end of said conductor cable, said connector adapted to
receive the soldering cartridge; a display element to provide an
indication of an operational parameter of the soldering cartridge;
and an electrical connector coupled to said second end of said
conductor cable, said electrical connector including contacts
attached to respective of said at least two electrical conductors
to couple said power cable to the power supply.
10. A power cable for use in a soldering system to couple a
soldering cartridge to a power supply, said power cable comprising:
an elongated conductor cable having at least two electrical
conductors extending from a first end to a second end; a connector
coupled to said first end of said conductor cable, said connector
adapted to receive the soldering cartridge; a display element to
provide an indication of an operational parameter of the soldering
cartridge; and an electrical connector coupled to said second end
of said conductor cable, said electrical connector including
contacts attached to respective of said at least two electrical
conductors to couple said power cable to the power supply.
11. The power cable of claim 10, wherein said display element is a
light emitting diode.
12. The power cable of claim 10, wherein said display element is
located on said connector.
13. The power cable of claim 10, wherein said display element
further comprises: means for displaying various signals received
from said power supply.
14. The power cable of claim 10, wherein said power cable further
comprises a wire adapted to bi-directionally transfer information
between the soldering cartridge and the power supply.
15. The power cable of claim 10, wherein said power cable further
comprises: a pair of wires capable of transferring current from
said power supply to said soldering cartridge.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention:
[0002] The present invention relates to an automated soldering
system with an intelligent power supply that can automatically
configure the power output to interchangeable soldering cartridges,
where the soldering cartridges include readable information to
allow the power supply to properly power the cartridge to achieve a
desired, entered operating temperature. In particular, the present
invention encompasses the use of an identifier on the cartridges
and a reader coupled to the power supply for immediate recognition
of the type of soldering cartridge to be used. In addition, to
inform the user that the station is operational, a LED indicator
preferably located proximate to the interchangeable cartridge and
activated by the automated soldering system displays various light
signals for the user.
[0003] 2. General Background and State of the Art:
[0004] Soldering stations have been in use for many years. The
typical soldering station includes two components: a soldering iron
composed of either a connector and a cartridge or a handpiece, a
heater and a soldering tip, and a power supply for supplying
current to the soldering iron. The cartridges have a soldering tip,
which is used to solder, located at one end of the cartridge and a
connector at the opposite end which can be inserted into a handle
attached to a power cable extending from the power supply. The
power cable may have many wires capable of carrying power and
information between the power supply and the cartridge.
[0005] Various cartridges have different configurations for the
tip. Because of the varying configurations, the tip temperature
must be optimized for effective soldering. The thermal properties
of the various tip configurations as well as the shape and the size
of the tip will impact the optimal temperature to solder using that
particular tip. Because the tips are integral within the cartridge,
each cartridge becomes unique, its power requirements
distinguishable only by the type of tip. Therefore, traditional
soldering stations, which had only one power output level, did not
optimize the functionality of the different cartridge tips
available in the market. Further, cartridges with varying tip
designs had to be manufactured around the parameters of a
particular power supply. The second generation of soldering
stations allowed the user to adjust the power output of the power
supply using dials and knobs to better define the power required.
These adjustable soldering stations could accommodate a far broader
range of soldering tip configurations as compared to the
traditional soldering stations.
[0006] Each soldering process has an optimum temperature which must
be maintained within set, often specified, limits for proper
soldering. The control dials on the second generation power
supplies can be adjusted to provide the appropriate amount of power
to obtain this optimal temperature. Before heating elements had
sensors built into them, the user would have to measure the tip
temperature using special thermometers, then adjust the control
dials, then measure the temperature, then adjust the control dials,
and so on. Using such an iterative procedure, the user would
fine-tune the actual temperature until it equaled the optimal
temperature. Later technology incorporated sensors within the tip
itself to measure the temperature, thereby eliminating the need for
the time-wasting iterative process. Accordingly, soldering stations
were developed that could utilize information from sensors located
in the cartridge to automatically fine-tune the power output to
reach the optimal temperature.
[0007] The development of cartridge sensors changed the role of the
power supply and the user. The sensors within the cartridge relayed
information back to the power supply, and the power supply
displayed the temperature on a display. However, even these new
technologies encountered serious shortcomings. To begin with, the
temperature sensor was not located near the tip surface used for
soldering. Instead, the temperature sensor was located near the
heating elements inside of the tip. As a result, the sensed
temperature of the heating element within the cartridge did not
reflect the true temperature of the tip. Second, because of the
distance between the sensor and the tip, the temperature gradient
between the sensor and the tip could often be steep. Therefore,
although the automated procedures may have brought the tip
temperature closer to being within range of the optimal tip
temperature, the user still had to make manual adjustments and use
iterative processes to narrow the range until the actual tip
temperature equaled the optimal tip temperature.
[0008] Another solution to the temperature differentials was the
use of a central processing unit ("CPU") within the power supply to
control the temperature of the heating element located inside of
the tip. A user would measure the actual tip temperature using a
thermometer and then calculate the difference between the actual
tip temperature and the temperature setting on the soldering
station. This difference was input into the CPU, and the CPU
adjusted the power output according to an iterative process or
preprogrammed algorithms. Although the user skill level required to
measure and to calculate the difference was certainly lower than
that required to adjust the dials, the process still expended
valuable time.
[0009] A more significant issue involved the removal of a cartridge
having a given tip configuration from the connector and the
replacement with a cartridge having a different tip configuration.
This occurs because, during the course of soldering in any given
application, the user may need to change the cartridge several
times to have the optimal tip configurations. Every time a
cartridge is replaced, the user must go through the same iterative
procedures discussed above to reach the optimal temperature.
[0010] Inefficient time expenditure is not the only unwanted
consequence of the present state of the art. For example, if the
tip temperature is not adjusted to the proper level, the soldering
iron is operable to solder an application or type of solder even
though the setting is unsuitable for the application or type of
solder. If soldering is performed at an inappropriate temperature,
the electronic component to be soldered may be damaged by the
excessive heat or the solder connection could be weak if the tip
was either not hot enough or too hot. Because several different
cartridges and tips could be utilized during a given soldering
procedure, it is probable that a user may solder an application
without waiting for the tip to reach the optimal temperature. Even
if a CPU is being used to adjust the tip temperature, the
difference between the actual temperature and the optimal
temperature must be input, until the difference is de minimis.
Clearly, performing competent soldering requires the operator to be
skilled in the art of temperature adjustment as well as soldering
technique. When a significant amount of time is spent adjusting the
soldering temperature, the efficiency and cost performance of the
soldering process is reduced. This increases the average cost of
goods and decreases profit margins.
[0011] There is thus a need in the soldering industry to provide an
easier and more automated means of adjusting the tip temperature
for different tips, as well as a reliable mechanism to inform the
operator when the adjustment has been accomplished.
BRIEF SUMMARY OF THE INVENTION
[0012] The present invention is directed to a processor-controlled
automated soldering system and a method for its operation that
determines the characteristics of a particular soldering cartridge
tip, adjusts the output power as appropriate and provides signals
to the operator to assure adjustment has been accomplished. In
particular, the present invention creates an automated system of
cartridge recognition, using reader and identifier technology, to
preset the power output level of the power supply station. The
identifier, which is attached to the cartridge, contains encoded
information about the various properties of the cartridge and its
tip such as for example the offset value of the tip. A reader
associated with the power supply station is able to read the
information from the identifier and communicate it to a CPU within
the power supply station. The power supply station can thus
generate power using the proper offset according to the particular
cartridge tip to be used. Also included in the present invention is
an output device that displays a first light pattern when the
cartridge is not ready to be heated and a different light pattern
when the cartridge is ready to use.
[0013] Accordingly, an automated soldering system is set forth
which includes cartridges capable of storing encoded information in
an identifier, a reader having means to read the information in the
identifier, a CPU adapted to process various data and match
cartridge information with look-up tables, and a power cable having
a connector including means of visually displaying signals received
from the CPU. An intelligent and automated power supply is thus
provided to transmit variable rates of power to power the
cartridge.
[0014] To use and operate the automated soldering system, an
operator first chooses the appropriate cartridge for a given
soldering task, each such cartridge having encoded information
positioned proximate the end opposite the tip. The operator then
sets the desired soldering temperature which is displayed on the
soldering station. The identifier end of the cartridge is inserted
into a reader in the power stations which reads the information
such as the cartridge offset value and transfers it to the CPU.
According to the cartridge offset or various look up tables and
stored data, the CPU determines the corresponding level of power to
be generated to properly heat the respective tip and communicates
this information to the power supply to program its output level.
Even though the power supply has received instructions to supply
power, it will not initiate power generation until a closed circuit
is established, which indicates that the cartridge has been
properly inserted into the connector of the power cable.
[0015] An LED indicator located on the connector blinks on and off
if the power supply is on and a cartridge has not been inserted
into the reader. Once a cartridge is inserted into the reader and
its information is obtained, the LED indicator turns on to indicate
that the power supply is calibrated.
[0016] If the cartridge is disconnected from the connector of the
power cable, the resulting open circuit will cause the power supply
to reset and the LED indicator located on the connector blinks on
and off. To reinitiate power generation, the procedure detailed
above must be followed with the same or a different cartridge.
[0017] The above described and many other features and attendant
advantages of the present invention will become apparent from a
consideration of the following detailed description in conjunction
with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] A detailed description of the invention will be made with
reference to the accompanying drawings wherein:
[0019] FIG. 1 shows a perspective view of the soldering system
including a cartridge assembly, power supply, a reader and a power
cable coupling the cartridge to the power supply;
[0020] FIG. 2 is a block diagram indicating the flow of information
within the soldering system of FIG. 1;
[0021] FIG. 3 depicts the cartridge, handle assembly and connector
of the power cable;
[0022] FIG. 4 is a side and partial cross-sectional view of the
connector;
[0023] FIG. 5 is a frontal view of the reader on the power
supply;
[0024] FIG. 6 is a side view of the reader of the power supply;
[0025] FIG. 7 is a cross-sectional view of the reader depicting the
sensors and switch inside of the power supply;
[0026] FIG. 8 shows a cartridge just before it is inserted into a
cross-sectional view of the reader; and
[0027] FIG. 9 shows a cartridge inserted into a cross-sectional
view of the reader.
DETAILED DESCRIPTION OF THE INVENTION
[0028] FIG. 1 depicts a perspective view of an automated soldering
system 10 according to the present invention. The automated
soldering system 10 includes a power supply 12 that supplies
current and power to a soldering cartridge 20 through a power cable
14 terminating at a connector 16. The power cable 14 couples the
cartridge 20, inserted into the connector 16 located at the
proximal end of the power cable 14, with the power supply 12.
Inside the power cable 14 are numerous individual wires, each
coated with insulation, bundled together and wrapped with a plastic
or rubber sheath. Attached to the distal end of the power cable 14
is an electrical connector 28 that has pins (not shown), each
associated with a wire inside of the power cable 14. The electrical
connector 28 connects to a coupling jack 26 located on the power
supply 12. The end opposite the electrical connector 28 is adapted
to receive a cartridge assembly 18, which includes a handle 22 and
the cartridge 20. The power supply 12 contains a reader 24 equipped
to read and decode information provided by an identifier (as
described below) on the cartridge 20.
[0029] FIG. 2, a block diagram of the preferred embodiment, depicts
the particular components within the power supply 12 of the
automated soldering station 10. The power supply 12 includes a
central processing unit or CPU 30, a temperature display 32,
temperature set point dials 34, and a power generator 36 in
addition to the reader such as a bar code reader 24.
[0030] As illustrated in FIG. 3, the cartridge assembly 18 includes
the handle 22 which removably slides onto the cartridge 20. The
cartridge 20 has three main visible components: a tip 42, a
cylindrically shaped housing 44 and a contact area 46 which
includes electrical contacts 48 and 50 separated from the housing
44 and from each other by cylindrical insulators 52. As depicted in
FIG. 3, this cartridge 20 also includes an identifier, which is
depicted as being a bar code 38. Within the cartridge 20, wires
connected at one end to respective terminals on the inside of the
electrical contacts 48, 50 extend through the housing 44 to a
heating wire within a heating element or a sensor insider of the
tip 42.
[0031] The bar code 38 provides a readable code or information
about the particular cartridge 20. In the preferred embodiment, the
bar code 38 provides at least an offset value or a product
identification number for the particular cartridge 20. The reader
24 is able to read the stat information from the identifier 38 and
transmits it to the CPU 30. The CPU 30 has various look-up tables
that store many cartridge identification numbers and corresponding
power generation levels.
[0032] To inform the CPU 30 that the user wants to use the
soldering station 10, the identifier end of the cartridge assembly
18 is inserted in the reader 24. In response to the information
provided by the reader 24, the CPU 30 compares the cartridge
information with data stored in the look-up tables. If the CPU 30
does not recognize the cartridge 20, a LED indicator 40 will
display a corresponding signal to inform the user to reinsert a
known cartridge 20. If the CPU 30 recognizes the cartridge 20, the
CPU 30 directs the power supply 12 to begin a power generation
sequence and the LED indicator 40 will display a signal indicating
recognition of the cartridge 20. The power supply 12 provides a
variable current and/or manipulates the number of current pulses in
a given period to appropriately energize the cartridge. An
indicator on the power supply 12 will display a signal
corresponding to the recognition by the CPU 30 that the cartridge
has been appropriately energized to the point where the tip has
reached its optimal temperature.
[0033] To ensure safety and conserve energy, the power generator 36
will not transmit current to the cartridge 20 until the circuit
including the power supply 12, the connector 16 and the cartridge
20 is closed. The complete insertion of the cartridge 20 into the
connector 16 will close the circuit and trigger a flow of current
from the power generator 36 to the cartridge 20 through the power
cable 14. A heating element within the tip 42 of the cartridge 20
generates heat. A temperature sensor inside the tip 42 of the
cartridge 20 will transmit temperature data to the CPU 30 through
the power cable 14. The temperature display 32 on the power supply
12 will show the desired tip temperature. The user can adjust the
desired tip temperature using the set point dials 34 to provide a
signal to the CPU 30 if the user desires a specific temperature and
the offset information obtained by the reader 24 from the cartridge
20 provides the offset information to adjust the CPU 30 to adjust
the output to the cartridge 20.
[0034] Once the cartridge 20 has been inserted into the reader 24,
the LED indicator 40 will be continuously lit to provide a visual
cue to the operator. The light signal informs the user that the
power supply 12 is programmed for the soldering cartridge 20 and
the power supply 12 is in use. If the user removes the cartridge 20
from the connector 16, the CPU 30 will recognize that the circuit
has been broken and reset the power generator 36. The LED indicator
40 will blink on and off and current will not flow through the
connector 16 until the user reinitiates the sequence described
above, i.e. inserting an identifiable cartridge 20 into the reader
24 and then inserting the same cartridge 20 into the connector 16.
The same steps must be followed if the user wants to reuse a
removed cartridge 20 or replace it with a new cartridge 20 during
the course of soldering in any application.
[0035] The tip 42 of the cartridge 20 can come in many shapes and
sizes to accommodate the various demands of soldering technique.
Inside the tip 42 is a heating mechanism that is known in the art.
Heating mechanisms also contain various temperature sensors in
addition to many heating elements. When the cartridge 20 receives
power from the connector 16, the cartridge 20 will become hot from
the heat generated within the tip 42. The housing 44 of the
cartridge 20 protects the wires (not shown) connecting the
electrical contacts 48 and 50 in the contact area 46 of the
cartridge 20 to heating mechanisms inside the tip 42.
[0036] The type and location of the identifier such as the bar code
38 on the cartridge 20 will depend on parameters particular to the
technology used. In the preferred embodiment, the identifier is the
bar code 38. The bar code 38 is preferably located near the distal
end of the housing 44 to minimize the harmful effects from the heat
generated inside the tip 42. In alternative embodiments, the
constraints of the particular technology used for the identifier
may require a different placement. Moreover, the identifier could
utilize other technologies such as optical scanning, magnetism,
RFID, memory devices, or other contact and contact-less means to
transfer information to an appropriate reader associated with the
power supply 12.
[0037] It should be noted that a user could insert either the
cartridge 20 by itself or the cartridge assembly 18 into the reader
24 in the preferred embodiment. However, as a practical matter and
for safety reasons, it is preferable if the user does not
physically touch the cartridge 20. This prevents contamination of
the cartridge 20 with oils and moisture from human contact. It is
preferred if the user grips the handle 22 to manipulate the
cartridge 20.
[0038] The LED indicator 40 is not restricted to its limitations in
the preferred embodiment. In the preferred embodiment, the LED
indicator 40 includes a light emitting diode ("LED") (as described
below) located within the connector 16. In alternative embodiments,
the LED indicator 40 can include various colored diodes, where each
color and each color pattern has an associated meaning. For
example, a green light could mean that the cartridge 20 is ready to
use, whereas a red light could mean that the CPU 30 has not
recognized the identifier 38 and/or that the power supply 12 has
not begun transmission of power to the connector 16. It is also
contemplated that various blinking and other on/off patterns could
be used to display information. Also, it is not absolutely
necessary to use diodes in the LED indicator 40. Other light
producing mechanisms such as fiber optics can be used to display
light patterns. The location of the LED indicator 40 does not
necessarily need to be within the connector 16, as long as the LED
indicator 40 is located someplace on the soldering system 10 where
it is visible to the operator, the exact location is variable.
[0039] FIG. 4 depicts a cross-sectional view and a side view of the
connector 16 of the power cable 14. The connector 16 has a
cylindrical sleeve 62 which slopes inward to seal against the
insulator of the power cable 14. A cord bush 60 may be inserted
between the cylindrical sleeve 62 and the insulator of power cable
14 to ensure that the power cable 14 is not easily removable from
the connector 16. A first wire 76 from within the power cable 14 is
connected to a LED 64. Additional wires 78 and 80 connect to the
pair of wiping contacts 68 that supply current to electrical
contacts 48 and 50 on the cartridge 20. The LED 64 is positioned
within an indicator window 66. The LED 64 and the LED indicator
window 66 form the LED indicator 40. The LED 64 turns on and off
according to the signals sent from the CPU 30. The cylindrical
sleeve 62 extends past the LED 64 to an end 70 defining a
cylindrical opening 72 adapted to accept the contact area 46 of the
cartridge assembly 20. The cylindrical sleeve 62 is preferably made
of a hard, non-flexible material designed to insulate the outside
grip area.
[0040] FIGS. 5, 6, and 7 depict a front view, side view and
cross-sectional view of the reader 24 respectively. The reader 24
includes an opening 90 into which a cartridge assembly 18 is
inserted. The internal components of the reader 24, which are best
illustrated in FIG. 7, include a plurality of sensors 92 and a tip
sensor switch 94 mounted in an assembly 96. In the exemplary
embodiment, the sensors 92 are simple bar code detectors, one
sensor for each potential line of bar code. In alternative
embodiments, only one sensor may be necessary or the sensors may
use different technology, such as optical scanners, magnetics,
RFID, memory devices, or other contact and contact-less means to
receive information from the identifier. The tip sensor switch 94
detects whether the cartridge assembly 18 has been fully inserted
into the reader 24 and triggers the actuation of sensors 92.
[0041] As shown in FIGS. 8 and 9, the contact area 46 of cartridge
20 of the cartridge assembly 18 is inserted into the reader 24
opening 90 until the end of the cartridge 20 triggers the tip
sensor switch 94. Once the tip sensor switch 94 is activated as
depicted in FIG. 9, the sensors 92 begin transmitting information
to the CPU 30. If the cartridge assembly 18 is removed, the tip
sensor switch 94 is deactivated, which further deactivates the
sensors 92.
[0042] In the preferred embodiment, the reader 24 is located in the
power supply 12. However, in alternative embodiments, the reader 24
can be located anywhere within the soldering system 10 as long as
there is a means of communication for the data received by the
reader 24 and transmitted to the CPU of the power supply 12.
[0043] Having thus described different embodiments of the
invention, other variations and embodiments that do not depart from
the spirit of the invention will become readily apparent to those
skilled in the art. The scope of the present invention is thus not
limited to any one particular embodiment, but is instead set forth
in the appended claims and the legal equivalents thereof.
* * * * *