Soldering wires on a three position electrical socket

Objective

Soldering wires onto three connector tabs on a three position wall socket plug

End Product

wall socket

Equipment

Ambrell 4.2 kW induction heating system, equipped with a remote workhead containing one 1.0µF capacitor.

An induction heating coil designed and developed specifically for this application.

Materials

Plastic plug receptacle with 3 connector tabs, 0.187” (4.7mm) wide, 0.05” (1.27mm) thick, copper wire 0.08” (2.03mm) diameter

Temperature

400 ºF (204 ºC)

Frequency

400 ºF (204 ºC)

Testing

A two turn folded “U” shaped coil is used to individually heat each connector tab. Tab and wire are placed in the coil for 2 seconds to complete the soldering process. Total soldering time is approximately 6-9 seconds for the soldering of the 3 tabs.

Narrative • Customer is currently using a soldering iron & individually touching each soldering point which is producing inconsistent results and quality issues. By using induction heating the customer produces consistent, repeatable clean joints. 

Benefits

Induction heating provides:

• Rapid localized heat only where needed

• Repeatable, consistent results

• Neat, clean joints

• Hands-free heating that involves no operator skill for

• manufacturing

• Even distribution of heating

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