Method and apparatus for bonding terminals to electrical devices

A method of bonding terminals to electrical components, which comprises:

• moving the terminals into engagement with bonding sites on an electrical component;
• applying a train of a predetermined number of electrical bonding pulses to each of the terminals to resistance heat and bond the terminals to the bonding sites on the components;
• sensing the magnitude of the current of each of the bonding pulses;
• counting the number of bonding pulses above said predetermined magnitude;
• and
• automatically and selectively reapplying the train of predetermined number of bonding pulses to those of the terminals to which there is a counting of less than the predetermined number of bonding pulses of the predetermined magnitude.

A method of bonding pairs of terminals projecting from a carrier strip to a succession of electrical components, which comprises:

• advancing said strip and components to move each pair of terminals into proximity to each component;
• bending each pair of advanced terminals into engagement with each advanced component;
• moving a pair of bonding electrodes into engagement with the terminals;
• applying a predetermined number of electrical bonding pulses to each of said bonding electrodes to resistance heat and bond each pair of terminals to a component;
• sensing the magnitude of the current of each bonding pulse;
• counting each bonding pulse above a predetermined magnitude;
• and
• automatically reapplying another predetermined number of bonding pulses to one or both of said bonding electrodes in response to the failure to count a predetermined number of bonding pulses above the predetermined magnitude applied respectively to said one or both terminals.

A method of bonding pairs of terminals to electrical components, which comprises:

• incrementally advancing a strip having pairs of terminals projecting laterally therefrom;
• positioning an electrical component adjacent to each pair of incrementally advanced pairs of terminals;
• bending each pair of advanced terminals into engagement with each positioned electrical component;
• applying a predetermined number of electrical bonding pulses to each bent terminal to bond each terminal to the positioned electrical component;
• sensing the magnitude of the current of each applied bonding pulse;
• counting the number of bonding pulses above a predetermined magnitude;
• and
• automatically reapplying another predetermined number of bonding pulses to a bent terminal in response to counting less than said predetermined number of bonding pulses above said predetermined magnitude.

A method of bonding a terminal to a heat fusible and deformable electrode on an electrical component, which comprises:

• moving the terminal and electrical component to position the terminal on the heat fusible and deformable electrode;
• pressing the terminal while applying bonding energy to the terminal to heat and fuse bond the terminal to the electrode while deforming the electrode;
• and
• upsetting and reshaping any flash created by the deforming of the electrode during the bonding step.

An apparatus for bonding a terminal to an electrical component, which comprises:

• means for positioning the terminal against the component;
• a pair of spaced bonding electrodes;
• means for moving the electrodes to engage spaced sections of the terminals;
• means for applying a predetermined number of electrical bonding pulses to said electrodes to establish a current flow between said electrodes and the engaged sections of the terminal to bond the terminal to the component;
• means for sensing the magnitude of the current of each of the applied bonding pulses;
• means for counting each applied pulse that is above a predetermined magnitude;
• means responsive to said counting means failing to count the predetermined number of pulses above the predetermined magnitude for applying a second predetermined number of bonding pulses to said bonding electrodes.

A bonding device, which comprises:

• means for advancing a pair of parts into juxtaposition;
• a bonding electrode means;
• means rendered effective following the juxtapositioning of the parts for advancing the electrode means into engagement with one of the juxtaposed parts;
• means for applying a predetermined number of current pulses to said electrode means to resistance heat the engaged part to bond the parts together;
• means for sensing the magnitude of the current of each pulse;
• a counter operated by said sensing means for registering a count for each pulse above a predetermined magnitude;
• and
• means responsive to the failure of said counting means to register a total count equal to said predetermined number of pulses for reoperating said pulse applying means to apply another series of pulses.

An apparatus for bonding a pair of terminals to a pair of end electrodes formed on an electrical device, which comprises:

• means for positioning a pair of terminals adjacent to said end electrodes;
• a pair of bonding electrode means mounted for movement toward and away from the positioned terminals to press the terminal against the end electrodes;
• means for advancing the bonding electrode means into and then out of engagement with the terminals;
• means rendered effective by advance of the electrode means for applying bonding energy to the electrode means;
• means for sensing the bonding energy and reoperating the advancing means when the sensed energy is below a predetermined value;
• means for counting the number of advances of the bonding electrode means;
• and
• means operated by the counting means counting a predetermined number of advances of said electrode means for interrupting further advances of said electrode means.

An apparatus for bonding a pair of terminals to an electrical device, which comprises:

• means for abutting the pair of terminals to the electrical device;
• a pair of electrode devices for bonding the terminals to the electrical device;
• means for moving said electrode devices into and out of engagement with the terminals;
• first and second means operated upon movement of the electrode devices into engagement with the terminals for respectively applying a predetermined number of current pulses to each of said electrode devices;
• first and second means for respectively sensing current pulses above a predetermined magnitude applied to said electrode devices;
• first and second means for respectively counting the pulses above the predetermined magnitude;
• first and second means respectively operated by either of said counting means failing to count the predetermined number of pulses above the predetermined magnitude for conditioning the associated first or second pulse applying means for reoperation;
• and
• means rendered effective upon either of said counting means failing to count the predetermined number of pulses above said predetermined magnitude for reoperating said electrode device moving means to again move both electrode devices into engagement with the terminals to reoperate the conditioned pulse applying means to apply another predetermined number of pulses to the engaged terminal.

An apparatus for bonding pairs of terminals to electrical devices, which comprises:

• means to advancing successively the electrical devices to a bonding station;
• means operative upon each advance of an electrical device to the bonding station for advancing and positioning a pair of terminals in engagement with the advanced electrical device;
• a pair of bonding devices;
• first and second means for moving said bonding devices into and then out of engagement with the positioned terminals;
• first and second means for respectively applying a predetermined number of current pulses to each of said bonding devices;
• first and second means for sensing the magnitude of the current of each of the applied pulses;
• first and second means for respectively counting the applied pulses above a predetermined magnitude;
• first and second means individually operative in response to either or both of said counting means failing to count said predetermined number of pulses above said predetermined magnitude for conditioning either or both of the associated pulse applying means to reoperate;
• and
• means also responsive to either or both of said counting means failing to count said predetermined number of pulses above said predetermined magnitude for reoperating said first and second bonding device moving means to again move said electrode devices into engagement with the positioned terminals to operate either or both said conditioned pulse applying means.

An apparatus for bonding pairs of terminals to a succession of electrical devices, which comprises:

• means for incrementally advancing pairs of terminals into an assembly station;
• means rendered effective with each advance of a pair of terminals into the assembly station for advancing an electrical device into said assembly position in close proximity to said pair of terminals;
• reciprocating means for bending each pair of advanced terminals into engagement with an electrical device positioned in the assembly station;
• a pair of electrode devices mounted for movement into engagement with each pair of bent terminals;
• means for moving said electrode devices into engagement with said terminals to press the terminals against the electrical device;
• means for applying a predetermined number of electrical pulses to said electrode devices to bond the terminals to the electrical device;
• means for sensing the magnitude of the current of each pulse applied to each electrode device;
• means activated by the sensing means detecting pulses of a predetermined magnitude for counting said pulses;
• and
• means rendered effective upon said counter means failing to count said predetermined number of pulses reoperating said electrode device moving means and said electrical pulse applying means.

An apparatus for upsetting welding flash protruding from opposite sides of a part, which comprises:

• a first anvil member;
• a second hammer member spaced from said anvil member;
• means for advancing a part with welding flash to a location in alignment with the space between the anvil member and the hammer member;
• means for moving said anvil member and said hammer member to position the anvil member in close proximity to one side of the welding flash on the part and the hammer member in spaced relation to the opposite side of the welding flash so that the hammer member is spaced a greater distance from the welding flash than the anvil member;
• and
• means rendered effective upon positioning of said anvil member and hammer member on opposite sides of the flash for moving the hammer member to strike and move the protruding flash against the anvil member.

An apparatus for solder bonding pairs of terminals to a succession of capacitors having a pair of solder end electrodes, which comprises:

• a pair of spaced apart bonding elements;
• means for incrementally advancing a succession of capacitors to position the solder end electrodes between the bonding electrodes;
• means for incrementally advancing a strip of a pair of terminals to position each pair of terminals between the bonding elements and the capacitor end electrodes;
• means rendered effective upon each advance of a capacitor and a pair of terminals between said bonding elements for moving and energizing said bonding elements to solder bond each pair of terminals to the end electrodes of each capacitor;
• an anvil member and a hammer member positioned to be aligned with each capacitor advanced by the incremental advance of the strip emanating from between the bonding elements;
• means rendered effective following each operation of the strip advancing means for moving the anvil member into close proximity to a first side of the end electrodes of each capacitor;
• means rendered effective following each operation of the strip advancing means for moving the hammer member into a spaced position with respect to a second side of the end electrodes of each capacitor;
• and
• means rendered effective following movement of said anvil member and hammer member for moving said hammer member toward said anvil member to crush therebetween any flash protruding from the solder bonded terminal and capacitor.

An apparatus for attaching terminals to heat fusible end electrodes formed on opposite ends of an electrical device, which comprises:

• an anvil;
• means for incrementally advancing a strip of spaced oppositely extending pairs of terminals over the anvil;
• means rendered effective following each operation of said strip advancing means for positioning an electrical device beneath the anvil;
• means rendered effective following each operation of said positioning means for bending a pair of the terminals over the anvil to position end sections of the bent terminals in alignment with the end electrodes of the positioned electrical device;
• a pair of oppositely disposed bonding electrodes mounted for movement into and out of engagement with the pair of bent electrodes to press the end sections of the terminals against the end electrode of the positioned electrical device;
• means for moving the bonding electrodes into and out of pressing engagement with the bent terminals;
• means rendered effective upon movement of the bonding electrodes into engagement with the bent terminals for applying bonding energy to said electrodes to fuse the bent terminals to the end electrodes of the positioned electrical device;
• and
• means for sensing the bonding energy and for controlling the electrode moving means to move out of and back into engagement with the bent terminals upon sensing an applied energy condition below a predetermined level.

An apparatus for bonding terminals to an electrical device, which comprises:

• a slide bar having a slot formed in one side for receiving an electrical device;
• a pusher bar mounted for movement transverse of said slide bar and having a slot formed in one side of a forward end thereof aligned with said slide bar;
• means for reciprocating said slide bar to move through said end slot of said pusher bar and advance an electrical device into said end slot;
• means rendered effective upon advance of said slide bar for moving said pusher bar to move the electrical device into an assembly position;
• means for moving a pair of terminals to the assembly position and into engagement with opposite sides of the electrical device;
• a pair of bonding devices mounted for movement toward and away from said terminals in the assembly position;
• means for moving said bonding devices into engagement with the terminals;
• and
• means rendered effective upon movement of the bonding devices into engagement with said terminals for energizing said bonding devices to bond the terminals to the electrical device.