Cobot-Enabled Work Cell and Integrated Tools for Automated Soldering/Desoldering of Electronic Assemblies

The aim of this project is to complete a feasibility study, design and build a proof-of-concept, low-cost prototype collaborative robot soldering solution to use as a base for further development in Phase II, through which a Phase III production and Army maintenance-worthy system would eventually be reached.  There is a continuing need to have a novel robotic soldering solution with the flexibility of a human to solve the requirements for reducing direct labor costs associated with tedious and repetitive soldering, desoldering, and/or rework tasks involved with PCBAs, and connectorization/wire terminations that are found on both PCBAs and standalone assemblies such as high-density connectors on cables and especially branched wire harnesses.  Another key goal is to enhance repeatability and stable quality of the soldering outputs.  Current Army artisan rework, soldering/desoldering of electronic assemblies is primarily a manual process for through-hole and surface mount components. Similarly, for electronic/electrical manufacturers, performing connectorization/wire terminations of high-density connectors with many solder cup positions is also a very manual process.  Many desktop or cellular robot soldering stations available on market today are 4-axis, and these are okay for printed circuit board assemblies (PCBAs). However, these types of robots are deficient in integral capabilities for automating the repetitive and tedious, but precise soldering required for terminations of wire to solder cups on mil-spec and rugged industrial connectors.  Today, with the advent of 6-axis collaborative robots, 2D/3D machine vision and quality inspection, and other complementary technologies that can be seamlessly integrated (e.g., latest in solder head/feeder technology as an effector; precise kinematic positioning and compensation module on cobot wrist for superb control during pick and place and fitment moves; and handheld portable/handheld rework station tools that can also be cobot-enabled), it is now possible under this SBIR to complete a value added integration of these and related elements to prove out feasibility and demonstrate a novel capability for cobot soldering.  This technology will meet an unmet need and is one that is very applicable to the shop tools solution sought for this topic and Army sustainment.