Field of invention
The present invention is related to a soldering assembly.
Background of the invention
Soldering is commonly known as a process to join metal contact points and plastic insulated
wires. Presently this process is being done in various ways. Generally being used two ways are
as described herebelow:
1. Conventional soldering- This is also called hand soldering. Operator does this type of
soldering by hand only. If a person solders one sub assembly of metal contact and
insulated wires then sequence of operation will be as follows:
1.1 Operator switches on the soldering iron (Figure-1.1) and waits till bit is heated up to
the desired temperature.
1.2 Then he touches the wire of filler metal (which is called solder wire) with or without
flux with heated bit of soldering Iron and puts one drop of solder one by one on all
the metal contact.(Figure-1.2)
1.3 After this, the Operator puts the insulated wire in to this drop of solder. At the same
time Operator also touches the bit of iron to the end of insulated wire.(Figure-l .2)
1.4 This filler metal contains several elements like Tin, Lead and Silver and various
other elements in very small quantities. Percentage of elements varies depending*
upon the application and requirement of solder joint. In this process 'Flux cored wire'
can be used or Flux can be added manually.
In this process control over some parameters are very important like preheating of metal contact
and insulated wires and quantity of filler metal. These parameters completely depend upon the
skill of Operator. However, detail of various parameters is as foUowsa)
Temperature control of Bit of soldering Iron- Generally, this parameter is being
controlled electronically by controller of soldering iron. The change in temperature
of iron is done as per the requirement. The soldering iron (Figure 1.1) has good
temperature control of bit. It has microprocessor based control over temperature of
bit. A ceramic heater and thermocouple are fitted at the end of hollow bit.
Operator cannot change the temperature of bit because temperature can change
only after inserting a card or password, It depends upon the model/card and
password are not accessible to Operator.
b) Preheating of metal contacts- This parameter is being controlled by operator.
However, time of touching heated bit with metal contact is dependent upon the
skill of operator. More or less time of preheating will change the quality of joint.
c) Quantity of Filler metal (solder) - This is completely dependent upon the skill of
operator and less or more quantity of solder will certainly effect on quality of joint.
d) 'Second time touching of heated bit to the filler metal - This happens when
operator inserts the insulated wire in to the filler metal (solder), but it is not
advisable because it disturbs molecules of solder metal when they are solidifying
and weaken the strength of joints.
It is to be noted that even if everything of set up is provided as per requirement of job, still good
quality soldering will not be ensured. Because the skill of operator and his attitude to make good
quality solder joint affects the overall product result. Various defects may be generated in poor
quality of soldering which can be evaluated visually just after the soldering process, for e.g. dry
soldering, less or more quantity of filler metal and porosity in joint etc. and some defects cannot
be evaluated just after soldering process such as poor pulling strength, failure in various
endurance and environment test etc.
2. Soldering with auto wire feeder- In this type" of soldering, soldering of single wire can be
done at a time. This type of soldering provides some good controls and get better quality,
comparatively with conventional soldering. In this type of soldering, following important
equipments are used:
i) Electronically temperature controlled soldering iron (Figure 2.1) - The operator is
getting a constant temperature (± 10° C) of bit form this controller,
ii) Wire feeder (Figure-2.1) - This equipment is having control of speed of solder
wire and on time of motor of wire feeder. With the help of speed and time, the
operator gets a fix quantity of filler metal (solder wire) for every joint. Wire
feeder has one motor when its starts, two knurled roller rotates and our solder
wire moves in between the rollers as a result, solder wire moves further. There are
two knobs available on the wire feeder- one is to control the speed of motor and
another is to control the on time of motor. With the combination of both controls,
we get correct quantity of solder.
When this device gets electrical input, its motor starts moving and feeding of
solder wire starts and motor will run till preset time only. This unit will get the
input from a control panel. This input goes to control unit of wire feeder, its
controller gives an input to a motor fitted in its control unit. A knurled roller is
fitted with this motor. Our solder wire (Filler metal) passes through two knurled
rollers one rotates freely on its shaft and another roller fitted on motor. When
motor rotates then due to friction created between two rollers and solder wire,
solder wire moves forward toward heated bit after passing through guide unit.
iii) Electronic timer and two counter (Figure-2.2) - This is having a delay timer which
is required to start wire feeder after a delay of preset time. This unit also having
two nos. counters. One counter (counter-1) is for cleaning of bit which stops and
gives a signal to wire feeder- if operator does not reset the counter, after reaching
preset counting. It is presumed that operator will clean the bit than reset the
counter-1.
2.1 After placing plastic base in a locator operator touches the metal contact with heated
bit of soldering iron and after that, he gently press the metal strip which presses the
micro switch.(Figure -2.3 &2.4)
2.2 Micro switch gives an input to electronic timer and after delay of few seconds, timer
gives an input to wire feeder and then after this, motor of wire feeder starts and wire
comes through a thin tube (wire guide) and one end of wire touches the heated bit of
solder iron to melt the filler metal (i.e. solder wire). The soldering of one wire and
metal contact has been completed and follow the same process sequence for all other
wires. One spool of filler metal (solder wire) is loaded on wire feeder.
In this process, quantity of solder is controlled by 'Auto wire feeder' but still this process
needs skilled operators because of following parametersa)
Time of Pre-heating is controlled by operator- In general, guidance is given to
operator that- Firstly, he will touch the metal contact to heated bit and at the same he
will mildly touch a metal strip which presses a micro switch. This micro switch
gives an input to timer and after preset delay, this timer will give an input to wire
feeder to feed the filler metal (solder wire). But to get more production
knowingly/unknowingly operator c^n press the metal strip before touching the bit to
metal contact, then wire feeder will start before time because delay time has already
been consumed due to change in sequence. Without adequate preheating, solder joint
will not be a good quality joint and may result in various quality problems.
b) Cycle time is more than 'Manual Soldering' which result in less productivity- In this
type of soldering, because of fix time delay to start the wire feeder; cycle time is
more than manual soldering.
c) Control of cycle time controlled by operator- In this type of set up, cycle time of
process is controlled by operator. He can produce the same joint in less time as well
as in more time also. This has experienced that if operator transferred from manual
soldering to soldering with auto wire feeder, psychologically they have mindset that
new set up will take more time which results in less productivity because they are
not getting any signal/input which denotes that the process has been completed.
As described above, good quality soldering with more productivity is not ensured by
either process. Every soldering joint cannot be inspected by machine or man if somehow
inspection made possible even good quality is not ensured. Only visual inspection that may be by
Inspector or machine, but it cannot detect all possible defects because some defects occurs after
some time (may be months/year) and few can be detected in lab. only. In such circumstances, it is
highly impossible to make good quality solder joint with unskilled operator.
Now a days, in any industry who is manufacturing their products with many soldering
joints (metal contact and insulated wires), although they have excellent operator training and
grooming systems but cannot give guarantee for 100% good quality soldering joint. They are
wasting money on a/c of rejection due to soldering. Industries can give training to operator but
can not provide them required skill and attitude. Also it is impossible to depute skilled man
power on all the soldering stations. Consequently, there is a need to have some innovation in this
field which can deskill soldering process up to some extent and with enhance in productivity and
quality.
Objective of the present invention
The main objective of the present invention is to overcome at least one of the above problems.
Another objective of the present invention is to provide a device for soldering.
Still another objective of the present invention is to provide a device for soldering for making
good quality solder joint of metal contact and insulated wire.
Yet another objective of the present invention is to provide a device for soldering on which a less
skilled operator can also work to make good quality solder joints.
Further objective of the present invention is to provide a device for soldering for two soldering of
two joints simultaneously.
Furthermore objective of the present invention is to provide a device for soldering for increasing
production rate.
Another objective of the present invention is to provide a device for soldering which will not
adding the running cost of soldering fixture because no motor or pneumatic or electro pneumatic
actuator would be used for actuation which consume electricity or air
Still another objective of the present invention is to provide a device for soldering which
provides a good visualization of status of various steps through LCD display and LEDs on
control panel.
Yet another objective of the present invention is to provide a device for soldering to standardise
the various parts of set up of soldering station.
Another objective of the present invention is to provide a device for soldering which is cost
efficient and having hassle free operation for a long time with no maintenance, only daily
cleaning is required.
Summary of the invention
The present invention is directed to soldering assembly that substantially obviates one or more
problems due to the limitations and disadvantages of the related art.
Accordingly, the present invention provides a soldering assembly for soldering of two joints
simultaneously.
The Soldering assembly comprises an assembly table, a foot paddle assembly, a platform for
mounting soldering locator, soldering station for mounting soldering iron and soldering iron and
wire feeders mounted on the assembly table and a control panel.
Sequence of operations are as follows:-
1. Checking the type-of filler metal (Solder wire) suitable for insulated wire, rrretal contact
and quality requirement of solder joint.
2. Switching on Controllers of soldering iron, wire feeders and control panel.
3. Checking the set temperature of soldering irons.
4. Putting base with metal contact in locator.
5. Pressing foot paddle. Cable pulling both soldering irons downwards.
6. Pressesing one limit switch and it gives a signal to control panel and confirming that
Soldering iron has reached on its desired position and one LED glows. Two metal
contacts exposed in base touches with both heated bits and at the same time placing
insulated wires at its required location by operator. Then ends of insulated wires are
touched with heated bits. As soon as the limit switch gives the signal to control panel,
delay to start wire feeder starts.
7. After preset delay time, control panel gives output signal to wire feeder.
8. Motor of wire feeder starts running and wire comes forward and touches to heated bit,
metal contact and end of insulated wires simultaneously and required quantity of filler
metal (Solder wire) melts and makes the required joint.
9. Releasing the foot paddle.
10. Giving a suitable time for solidifying the filler metal.
11. After few seconds three beeps sound comes from panel and one LED glows (to confirm
that the job has been completed and soldered sub assembly is taken out from the locator.
One count of good joint increases in counter (Displayed in control panel)
The same invention can also be used for the soldering of double base. In this process, sliding
aside the locator is done & than another base will come under the soldering bits. All steps for
soldering of another base and wires are repeated as mentioned for single base soldering process.
The present invention provides a good quality solder joint, a less skilled operator can also work
to make good quality solder joints. It increases production rate and also not adding the running
cost of soldering fixture because no motor or pneumatic or electro pneumatic actuator is used for
actuation which consumes electricity or air. It also provides a good visualization of status of
8
various steps through LCD display and LEDs on control panel. This soldering device also
standardizes the various parts of set up of soldering station, which is cost efficient and having
hassle free operation for a long time with no maintenance, only daily cleaning is required.
Additional advantages, objects, and features of the invention will be set forth in part in the
description which follows and in part will become apparent to those having ordinary skill in the
art upon examination of the examination of the following or may be learned from practice of the
invention may be realized and attained by the structure particularly pointed out in the written
description as well as the accompanying drawings
Brief description of tlie accompanying drawings
Further aspects and advantages of the present invention will be readily understood from the
following detailed description with reference to the accompanying figures of the drawings.
The figures together with a detailed description below, are incorporated in and form part of
the specification, and serve to further illustrate the embodiments and explain various
principles and advantages but not limiting the scope of the invention. In the accompanying
drawings,
Figure 1.1-1.2 illustrates a conventional soldering process.
Figures 2.1-2.5 illustrates a soldering process with auto wire feeder
Figures 3.1 & 3.2 shows an exploded view of a Soldering assembly according to an embodiment
of the present invention.
Figures 3.3 shows an exploded view of a Soldering cable according to an embodiment of the
present invention.
Figures 3.4 shows an exploded view of a foot pedal assembly according to an embodiment of the
present invention.
Figures 4.1 illustrate a fixture for a soldering locator according to an embodiment of the present
invention.
Figures 4.1(a) illustrate a fixture for soldering locator for double base according to an
embodiment of the present invention.
Skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and
have not necessarily been drawn to scale. For example, the dimensions of some of the elements
J
in the drawings may be exaggerated relative to other elements to help to improve understanding
of embodiments of the present invention.
10
Detailed Description of tlie present invention
While the invention is susceptible to various modifications and alternative fonns, specific
embodiment thereof has been shown by way of example in the drawings and will be described in
detail below. It should be understood, however that it is not intended to limit the invention to the
particular forms disclosed, but on the contrary, the invention is to cover all modifications,
equivalents, and alternative falling within the spirit and the scope of the invention as defined by
the appended claims.
Before describing in detail embodiments it may be observed that the novelty and inventive step
that are in accordance with the present invention reside in the Soldering assembly accordingly,
the drawings are showing only those specific details that are pertinent to understanding the
embodiments of the present invention so as not to obscure the disclosure with details that will be
readily apparent to those of ordinary skill in the art having benefit of the description herein.
The terms "comprises", "comprising", or any other variations thereof, are intended to cover a
non-exclusive inclusion, such that a setup, device that comprises a list of components does not
include only those components but may include other components not expressly listed or
inherent to such setup or device. In other words, one or more elements in a system or apparatus
proceeded by "comprises... a" does not, without more constraints, preclude the existence of
other elements or additional elements in the system or apparatus.
Referring to figure 3.1, The present invention relates to a Soldering assembly. The said assembly
comprises an assembly table, a foot paddle assembly, a platform(Base plate) for mounting
soldering locator, fixtures for mounting soldering iron and soldering iron and wire feeders
mounted on the assembly table and a control panel.
The platform (Base plate) is provided with a mounting of locator. The locator is being provided
with location for metal contact with base. The locator is provided with moving arrangement to
upward direction from the platform.
Locators for two bases are machined on a single plate. This locator plate is located through
dowel pins on another plate. This plate is mounted on center block. Two linear bearings are fitted
in center block. Two nos. pillars are passed through the linear bearings and mounted in given
holes in end blocks. Center block moves on pillars very smoothly with the help of handles
11
provided (Fig 4.1 A). A hand rest is mounted adjacent to base plate of the locator. The said hand
rest is provided with arrangement of adjustment in height as the requirement of the user. This
hand rest arrangement is adjustable and operator can set the height and distance from fixture as
per his convenience (as shown in Figure 4.1 A). When operator does the soldering, then this
hand rest will provide accuracy in placement of wires. This hand rest contains foam and cotton
cloth which provides comfort to operator and reduces the fatigue also.
The soldering station is provided with mounting soldering irons at predetermined location on the
assembly table. The said station is provided one or more mounting arrangements for mounting of
soldering iron. Preferably, the said station is provided to mount two soldering irons. The said
station is provided with mounting adjustment such that the soldering iron can move in six
directions i.e. horizontal, vertical, angular and radial. A support bracket for soldering station is
provided on the assembly table. A hood assembly, tray for controllers and control panels are
being mounted on this support bracket.
(Figure 3.2) This station holds both soldering irons and has the provision for adjustment of
soldering irons in various directions such as horizontal, vertical, angular and radial. This feature
facilitates the freedom to adjust the soldering iron in best suited desired position. This sub
assembly contains following partsa)
Base plate - (Figure-3.2) The base plate is made of any suitable materia! and
preferably is made of mild steel. The base plate is provided with four legs to maintain
a gap between the fixture and top surface of assembly table. Complete fixtures are
mounted on this plate.
b) Pillar assembly - (Figi4re-3.2) Needle bearings are press fitted in the base plate for
pillar assembly. Hardened pillars are passing through the needle bearings to give
smooth movement for soldering irons in upward/downward direction. One spring is
fitted over the each pillar to keep both fixtures for soldering irons at predetermined
position.
c) Iron holder -(Figure-3.2) This sub assembly will hold the iron and provide
appropriate pressure on metal contact of heated bit of soldering iron and ensure
contact of heated bit of soldering iron and metal contact. This is metal contact on
which wire is to be soldered. Iron holder is having one compression spring. When
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heated bits touches to metal contact, then by default some pressure applies on metal
contact, to nullify the extra pressure one spring is provided in this assembly which
compress slightly at this time. Due to the specially designed spring we are getting this
pressure and as a result we are getting maximum life of soldering bit. Two dowel pins
are provided on the upper ring to prevent the rotation of soldering iron during
soldering.
d) Vertical adjusting blocks - (Figure-3.2) These blocks are mounted on pillars to adjust
the position of soldering irons vertically. These blocks can slide on pillars and we can
lock the blocks on pillar with a bolt at desired location.
e) Angular adjusting blocks - (Figure-3.2) These blocks are fastened with the vertical
adjusting block and with the help of these blocks, the position of soldering irons can
be adjusted clockwise and anti-clockwise and radial directions also.
The support bracket for soldering station is mounted on assembly table which is fabricated from
pipes. The following items are mounted on it-(as shown in Figure-3.1)
a) Support bracket for soldering station - These are mounted on rear side of assembly table
(Figure-3.1). Two trays for controllers and one flange for exhaust fan are mounted on it.
Exhaust pipe is also clamped on it.
b) Trays for controllers- These parts are being used to keep various controllers of soldering
iron and wire feeders are kept in one tray and control panel is"kept in other tray. These
trays are mounted in between in two support brackets for soldering iron.
A fiime extraction system is mounted with soldering station. It contains hood, flange, flexible
pipe and two exhaust fans. Fume extraction system is to be fitted on table not the fixture. There
will be some gap between soldering fixture and hood of fume extraction system. End point of
this unit is at the same (height) level of table. There is an air filter inserted in a cassette which is
available at the end point of fiime extraction unit.
As shown in figure-3.1. The fiime extraction system is provided to suck the smoke (with flux and
elements of solder wire) and exhaust to further filtration. This system is required because smoke
from filler metal has some hazardous elements which are not advisable to expose in the air
without treatment. The sub assembly, mounted on bracket has following parts13
a) Hood - (Figure 3.1) This part is made of mild steel and smoke which is generated during
soldering process, enters from this part only. This is fastened with the brackets.
b) Exhaust fan - (Figure 3.1) Two exhaust fans are fitted for better suction of smoke. One
exhaust fan is fitted at the start of the hood. This fan sucks the smoke and through the
smoke to flexible pipe. Another exhaust fan is fitted at the end of flexible pipe and before
carbon activated filter. All the smoke will pass through the carbon activated filter, this
filter will arrest all hazardous element from the smoke.
Referring Figure 3.3, 3.4, The foot paddle assembly comprises a movable foot paddle, fixture for
paddle, Bracket for paddle, cable assembly and a wooden box. The wooden box encompasses the
foot paddle and the cable assembly. The said cable assembly is connected with the foot paddle
via a cable wire in such a way that when the foot paddle moves up-down, the cable wire also
moves. The movement in cable results in movement in soldering iron. For example, when the
foot paddle moves downward, the cable attached to the foot paddle is being pulled. This pulls in
cable wire which results in motion in soldering iron.
Referring Figure 3.3, A specially developed cable is used to pull the soldering irons downwards
by pressing the foot paddle. One end of cable is fastened with foot paddle and other end with a
plate of fixture for soldering iron. When operator presses the foot paddle, then specially
developed cable pulls down both soldering irons and metal contact touches with bit of soldering
iron and perform the soldering proce'ss. The foot paddle assembly comprises a foot paddle -
(Figure 3.4). This part is made of mild steel and has such mechanism when operator presses the
paddle, then specially developed cable pulls both soldering irons. This foot paddle is mounted on
a fixture and enclosed in a wooden box. The foot paddle is mounted in a wooden box to provide
comfort to operator. This is open type box and having two hinges which facilitate easy cleaning
of box from inside.
A control panel is provided on the support bracket. The said control panel comprises a
microprocessor based panel and it controls the function of wire feeder, gives a signal after
completion of process, digital display settable counters and timers. This microprocessor based
control panel is being specially developed only for present invention. The feature of this control
panel are as follows:-
14
a) Control the logic of sequence;
b) Gives input to wire feeder if all conditions are met; and
c) LCD display forvarious data.
The device of present invention is being provided with a.provision to clean the heated bit after
some soldering, a provision is given in control panel (Figure- 2.5). After achieving
predetermined number of soldering joints, a signal is being indicated by the control panel. For
example a continuous beep will come from the control panel and one red LED will glow
continuously. Simultaneously, the wire feeder stops working. Along with glowing of red LED, a
massage can be shown on an LCD screen provided with the control panel according to an
embodiment of the present invention. This signal indicates that operator has to clean the bit of
soldering.iron. This counter is preset. After cleaning the bit of the soldering iron, when the
operator will press a reset switch, then beep sound will stop and system will be ready for next
cycle after cleaning the bit. This cleaning is required to enhance the life of bit.
The operation of the device of the present invention can be understood with following steps:-
1. Checking the type of filler metal (Solder wire) suitable for insulated wire, metal
contact and quality requirement of solder joint.
2. Switching on Controllers of soldering iron, wire feeders and control panel.
3. Checking the set temperature of soldering irons and setting of wire feeders and type
of solder wire (Filler metal) to be used.
4. Putting base with metal contact in locator. The wires are to be soldered on the said
metal contact.
5. Pressing the foot paddle than cable pulls both soldering irons downwards toward the
metal contact.
6. The heated bits of both soldering irons touches with metal contact & at the same time
following action takes place -
a) One limit switch presses and gives an input to control panel.
b) Delay time for feeding the filler metal by Wire feeder starts.
c) One LED on control panel starts glowing to ensure locator has reached at desired
location.
d) A beep sound comes from panel.
15
e) Pre heating of metal contact starts.
The limit switch presses and gives signal to control panel and ensure that locator has reached on
its desired position and one LED glows. Metal contact touches with both heated bits and same
time operator places insulated wires at its required location. He touches the ends of insulated
wires with heated bits. As soon as the limit switch gives the signal to control panel, delay to start
wire feeder starts. Then Preheating of metal contact starts- Firstly, the heated bit will touch to
metal contact to preheat the metal contact and this is compulsory for good quality of soldering.
After some time solder wire (Filler metal) will touch the metal contact & heated bits
simultaneously and melts. At the same time, operator touches the insulated wires to heated bit.
After mehing the solder wire operator releases the paddle, soldering irons goes back to its initial
position. Melted solder covers end of wires and metal contact and make a joint.
7. After preset delay time, control panel gives output to wire feeder.
8. Motor of wire feeder starts running and wire comes forward and touches to heated bit,
metal contact and end of insulated wires.
9. Solder wire melts in required quantity and spread on metal contacts and wires.
10. Operator waits till solder solidify. After few seconds indication (beep)/signal comes
from panel and one LED glows (to confirm job has been completed. One count of
good joint increases. This Control panel is microprocessor based. Coming beeps is a
part of program. It can be programmed as our requirements; off course" start of
sequence is by pressing of limit switch only. Limit switch presses when operator
presses the foot paddle. This is a signal that- now soldering has been completed and
operator can release foot paddle.
11. Operator releases the foot paddle, then soldering irons moves back in upward
direction.
12. Operator picks the sub assembly from the locator and system is ready for soldering of
next parts.
In an alternate embodiment; Soldering assembly is used for the soldering of double base
Operator will slide aside the locator then another base will come pnder the soldering bit. He will Q
do repeat all steps for soldering of another base and wires (Fig.4.1 A)
16
After perfonning soldering for so many days, the surface of bit starts deteriorates. A provision is
given in the control panel that- if number of soldering reaches to preset quantity, then an
intermittent indicatroTi will be provided by the control panel and at the same" time LED glows
intermittently. Also, the wire feeder stops working. This is a signal that shows operator has to
change the bit of soldering iron. This counter is preset.
Another feature of this control panel that if operator releases the paddle before completion of
process, then an indication is given by the control panel- such as one LED glows. The operator
presses a reset switch to stop the indication and thereafter the device of present invention is ready
to use for next cycle. If this happens, then one defected piece will be produced and a not good
(NG) counter increases in the control panel. This control panel also displays the total number of
complete operations and total 'Not good' operations.
The present invention provides good quality soldering by less skill person and also high in
productivity as compared to conventional soldering according to an embodiment of the present
invention. Also, no energy consumption is required to move the locator of fixture. This feature
results in not adding the running cost of fixture. A complete set up of device for soldering of
present invention is shown in Figure 3.1. The fixture for soldering locator (Figure 3.5) locates the
part which is to be soldered. This locator is mounted on four small pillars which are fastened
with the base plate.
Some of the advantages of the switch modules of the present invention are as follows:
An advantage of the present invention is mechanism of pulling both soldering irons as this
requires no cost or energy because no actuator is actuating. This comprises foot paddle,
especially design and developed cable, a fixture and a wooden enclosure.
Another advantage of the present invention is combination pulling down soldering irons and
logic control panel ensuring pre-heating of each joint which further ensures good quality of every
joint.
Still another advantage of the present invention is logic of control panel which is based on
microprocessor and controls the entire sequence. This panel ensures that this will give input to
wire feeder only after confirming input by limit switch. Also this have two settable timers. One
timer is a delay timer which provides a delay to start the wire feeder and another timer ensures
17
solidification of melted filler metal (solder) and gives three times beep sound. In this panel there
are two settable counters-one counter is used to count no. of soldering points and gives input to
microprocessor after set counting, than continuous beep sound comes and one LED glows which
will reset by a reset push button. Other counter is used to enhance the life of bits. Its counts total
no. of soldering and gives an input to microprocessor after reaching preset counting then one
LED glows and intermittent beep sound comes from panel. The complete logic ensures
preheating of metal contacts and ends of insulated wires on which solder is to be melted.
Yet another advantage of the present invention is specially designed and developed cables which
connects foot paddle and lever. This was developed to save energy cost to run this fixture.
Another advantage of the present invention is visualization of status at various stages. Three
LEDs are provided on panels. The objectives of LEDs are as under-
1. One LED glows as confirmation of reaching soldering irons at its required position.
2. Second LED glows as confirmation of complete the soldering or solidification of filler
metal
3. Third LED glows-when NG counter increases, preset counter for bit cleaning and bit
change reached at its preset counts & One LCD panel shows various data/steps of process
Still another advantage of the present invenfion is the design of mounting mechanism of
soldering irons. This mechanism applies appropriate pressure of metal contact which always
ensures soft touching of heated bit of soldering iron and metal contact. This mechanism ensures
same pre-heating of all the joints which is a prerequisite for good soldering joint. Also enhances
the life of bit.
Yet another advantage of the present invention is the provision of freedom of adjustment of
soldering irons. This mechanism provides freedom to adjust the soldering irons in horizontal,
vertical and radial adjustment in two axes which is the ultimate mechanism. With this
mechanism we can fix the soldering irons at any desired position.
The present invention is described with reference to the figures and specific embodiments; this
description is not meant to be construed in a limiting sense. Various alternate embodiments of
the invention will become apparent to persons skilled in the art upon reference to the description
18
of the invention. It is therefore contemplated that such alternative embodiments form part of the
present invention.

We claim ^ ^ Qm ^'\f.
1.) A Soldering assembly for soldering of metal contacts and insulated wires, comprises of:
a) Assembly table;
b) Foot paddle assembly containing Foot paddle, Fixture for paddle. Cable assy, and
a wooden box;
c) A platform for mounting soldering locator;
d) Fixture for mounting soldering iron;
e) Soldering iron with controller;
f) Wire feeder;
g) Control panel;
h) Fume extraction system containing hood, flange, flexible pipe and an exhaust fan;
i) Support Bracket for soldering station;
j) Trays for controllers and
k) Cables.
2.) A platform for mounting soldering locator as claimed in claim 1, wherein Locator for base
parts and Hand rest are mounted on a base plate with arrangement of adjustment in height
and distance to fixture and a arrangement of accommodating two bases.
3.) A fixture for mounting soldering iron as claimed in claim 1, wherein two mounting
arrangement for 'Soldering Iron' are provided with adjustment in six directions, The said
arrangement provides provision of freedom of adjustment of soldering irons in horizontal,
vertical and radial adjustment in two axes.
4.) A control panel as claimed in claim 1, wherein control panel consists of a microprocessor
based panel and controlling fiinction of wire feeder are also there, which further gives a
signal in form of glowing LEDs after completion of process as following:
a) First LED glows as confirmation of reaching soldering irons at its required position;
b) Second LED glows as confirmation of complete the soldering or solidification of filler
metal;
c) Third LED glows on increasing NG counter or on preset counter for bit cleaning or bit
change reached at its preset counts & One LCD panel showing various data/steps of
process;
,Gi«^^ 2238°^''i4^' »^**
5.) A foot paddle as claimed in claim 1, wherein specially designed cables are connected to
foot paddle, lever and pulls lever down to uplift the locator.
6.) A Soldering assembly as claimed in claim 1, wherein Wire feeder will start only after
reaching the locator at its desired location and also after preset delay time in panel.
7.) A Soldering assembly as claimed in claim 1, wherein pulling and uplifting soldering iron
requires no extra cost or energy because no actuator is actuating and a good quality
soldering with high productivity is achieved.
8.) A Soldering assembly as claimed in claim 1, wherein Preheating of metal contact and wires
& fix quantity of .filler metal are also confirmed. A appropriate pressure of metal contact is
confirmed with soft touching of heated bit of soldering iron and metal contact.
9.) A process of soldering of metal contacts & insulated wires comprises of following steps:
a) Checking type of filler metal (Solder wire) suitable for insulated wire, metal contact and
quality requirement of solder;
b) Switching on Controllers of soldering iron, wire feeders and control panel;
c) Checking the set temperature of soldering irons and setting of wire feeders and type of
solder wire (Filler metal) to be used;
d) Putting base with metal contact in locator;
e) Pressing foot paddle & Cable pulls both soldering irons downwards;
f) One limit switch presses and gives signal to control panel and confirming that locator has
reached on its desired position and one LED glows. Metal contact touches with both
heated bits and same time operator places insulated wires at its required location. Ends of
insulated wires are touched with heated bits. As soon as the limit switch gives the signal
to control panel, delay to start wire feeder starts;
g) After preset delay time control panel gives signal to wire feeder;
h) Motor of wire feeder starts running and wire comes forward and touches to heated bit,
metal contact and end of insulated wires and required quantity melts and makes the
required joint;
i) After few seconds three beeps sound comes from panel and one LED glows to confirm
for job has been completed. One count of good joint increases;
j) Operator releases the foot paddle and takes out the soldered sub assembly.
*'*"*''2238*"-i'*^' ''"'*
10) A Soldering assembly for sdBWRn^^i metal contact and insulated wire substantially as
herein described with reference to the accompanying drawings.