What are the core advantages of Rio Tinto's fully automatic dip soldering machine?
Date: 2019/7/18 21:33
In the development of modern electronic soldering technology, it has experienced two historic changes: the first is the transition from through-hole soldering to surface mount soldering; the second is the lead soldering we are experiencing Technology shift to lead-free soldering technology. （ 焊接成本问题） ；二是通孔元器件（尤其是大热容量或细间距元器件）的焊接难度越来越大，特别是对无铅和高可靠性要求的产品 ， 三是中小批量多品种焊接需要预成型的短脚工艺及双面混装的高避焊焊接需要（成型人工及高避只能波峰机焊接一面，另一面需要手工焊接） 。 The evolution of soldering technology has directly brought two results: one is that fewer and fewer through-hole components need to be soldered on the circuit board ( welding cost issues) ; the other is through-hole components (especially large thermal capacity or fine pitch elements). Devices) are becoming more and more difficult to weld, especially for products that require lead-free and high reliability . Third, small and medium batches of multiple varieties require pre-formed short-foot processes and double-sided mixed high-avoidance welding needs Manual and high avoidance can only be welded on one side of the wave machine, and the other side needs to be welded by hand) .
图一： 高透锡焊接案例 - 汽车控制产品） ( Figure 1: High-penetration soldering case -automotive control products)
Let's take a look at the new challenges currently facing the global electronic assembly industry: global competition forces manufacturers to bring products to the market in a shorter period of time to meet the changing requirements of customers; seasonal changes in product demand require flexible production Manufacturing philosophy; global competition forces manufacturers to reduce operating costs on the premise of improving quality; lead-free production is the general trend. 传统波峰焊针对大批量单品种单双面板的生产模式，已经难以满足上述生产要求，那么我们在工艺上面临什么样的挑战！ The above challenges are naturally reflected in the choice of production methods and equipment. The traditional wave soldering production mode for high-volume single-variety single-dual panels has been difficult to meet the above production requirements, so what kind of challenges do we face in the process!
图二：大热容量双面混装产品 - 大功率电源类产品） ( Figure 2: Large-capacity double-sided mixed products - high-power power supply products)
Automatic dip soldering is an automatic soldering technology developed based on the optimization of traditional dip soldering. Compared to wave soldering, the advantages of automatic dip soldering are that it can meet large heat capacity and double-sided mixed high-density avoidance welding, and its extremely low operation. Cost (low oxidation and low power consumption, minimal solder investment), the best welding equipment to meet the welding needs of fewer and fewer through-hole devices at this stage, and small and medium-sized batches with many varieties.
The main application areas of automatic dip soldering machine:
仪器仪表， 新能源控制，电源产品，工业控制，仪器仪表，家电控制板，安防产品等大中小批量多品种高要求焊接。 For products that are mainly direct plug-in and mixed assembly welding, such as: aerospace electronics, marine electronics, automotive electronics, instrumentation, new energy control, power products, industrial control, instrumentation, appliance control panels, security products, etc. Many varieties require high welding. It can also be used for the tin plating test and dip soldering temperature test of the high temperature lead of the motor coil and the lead of the through-hole device.
大热量及高避焊焊接案例 - 安防控制类产品） (Figure 3: High heat and high welding avoidance welding case -security control products)
高度及密度避焊焊接案例 - 汽车控制类产品） (Figure 4: Height and density welding avoidance welding case -automotive control products)
Welding principle of automatic dip soldering machine:
PCB进行助焊剂喷涂，对喷涂后的产品进行可停留式预热（激发助焊剂活性预热降低PCB接触高锡温变形及溶剂挥发掉，这样可以减少焊接时产生气体），通过对预热的停留时间及温度的精准控制，满足不同产品及焊剂需要预热要求，预热完成后进入浸焊区，通过对各项浸焊参数的设定（如：浸焊角度，浸焊时间， 浸焊温度， 脱锡速度， 脱锡角度等精密控制）完成不同产品需要的焊接参数，完成焊接后再进入冷却出板区，完成整个焊接过程。 First , spray flux on the PCB that has been plugged in , and perform pre-heating on the sprayed product (excitation of preheating of the flux to reduce PCB contact with high tin temperature deformation and solvent evaporation, which can reduce gas generation during soldering). Pre-heating dwell time and temperature are precisely controlled to meet the pre-heating requirements of different products and fluxes. After the pre-heating is completed, it enters the dip-soldering zone. By setting various dip-soldering parameters (such as dip-soldering angle, dip-soldering time (Precise control of dip soldering temperature, de-tinning speed, de-tinning angle, etc.) Complete the welding parameters required for different products, and then enter the cooling out area after completing the welding to complete the entire welding process.
高度及密度避焊焊接案例 - 仪表类产品） (Figure 5: Height and density welding avoidance welding case -instrument products)
Eight core advantages of automatic dip soldering machine:
35MM，是目前市场上焊接最大高度的设备之一。 One: It can weld the secondary jig avoidance welding of the double-sided mixed products that are mainstream in the current process. The maximum welding avoidance capacity of the standard machine is 35MM, which is one of the equipment with the highest welding height on the market.
Second: Long-foot welding operation, short-foot technology can not meet the high-density plug-in, small and medium batches of multiple varieties of welding can reduce the product components need to pre-form the welding troubles, cut the feet after welding!
3: The solder penetration rate of large heat capacity products can be controlled higher. Different preheating parameters and tin dipping parameters can be set for different products. The solder penetration rate is flexible and controllable.
Four: For the soldering of temperature sensitive devices, the purpose of stable soldering can be achieved by optimizing the preheating and tin temperature and immersion time.
: 目前客户最关心的运行成本，目前整机功耗低于2.5KWH，8小时运行氧化物低于0.5KG（不同锡材与焊剂可能会有区别）且波峰焊机的1/10左右，另无需氮气介入，无额外的焊接成本。 Five : At present, customers are most concerned about the operating cost. At present, the power consumption of the whole machine is less than 2.5KWH, the operating oxide of 8 hours is less than 0.5KG (different tin materials and fluxes may be different) and about 1/10 of the wave soldering machine. There is no need for nitrogen intervention and no additional welding costs.
Six: The welding parameters are digitized, there is no need for professional soldering technicians, reducing the reliance on personnel experience, and ensuring the consistency of the quality of each product at different times and by different personnel.
，电子企业在最短时间需要交付不同款产品的订单数量，可以通不同产品通过相同宽度的治具，通过条码及电子标签类的扫描系统，将每一个产品的焊接配方化，每一次都调用对用的焊接参数焊接，实现同一线生产多款产品应对交付。 7: Different batches of different welding parameters mixed production mode, product diversification orders today , electronic companies need to deliver the number of orders for different products in the shortest time, can pass different products through the same width of the fixture, through the bar code and electronic labels This type of scanning system formulates the welding formula of each product, and each time the welding parameters for the welding are called to achieve the delivery of multiple products on the same line. (Function optional)
Eight: Equipment maintenance costs are low, ordinary wave soldering, selective wave soldering, and robotic soldering machines all require professional technicians and production consumables, such as transmission claw loss of wave soldering, nozzle and nitrogen loss of selective wave soldering, The wear of the ferrochrome head of the manipulator, while the fully automatic dip soldering machine has almost no wear parts in this regard.
大热量及高透锡度焊接案例 - 动车控制板） (Figure 5: Cases of high heat and high tin penetration welding -motor vehicle control board)
DS300FS全自动浸焊机分体版配线案例） (Figure 6: DS300FS full-automatic dip welding machine split wiring case)
+自动插线（3工位） 自动喷雾系统+DS300FS全自动浸焊机组成的自动生产线 Figure 7: An automatic production line consisting of two elevators + automatic wire insertion (3 stations), automatic spray system + DS300FS automatic dip welding machine
DS300TS全自动浸焊机全新四代整体版） (Figure 8: The new four-generation overall version of DS300TS fully automatic dip soldering machine)
+自动插线（3工位） DS300TS全自动浸焊机组成的自动生产线 Figure IX: Automatic production line consisting of two hoists + automatic wire insertion (3 stations) DS300TS full automatic dip welding machine