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Selective Wave Solder Machine in Power Electronics Applications

Selective Wave Solder Machine in Power Electronics Applications

Industry Overview of Selective Wave Solder Machine

  • High Efficiency

With increasing global awareness of energy consumption and environmental protection, improving the efficiency of switching power supplies has become a key research direction. High-efficiency switching power supplies can reduce energy waste and heat generation, thereby decreasing the size of heat sinks and reducing overall volume and weight. Industry Overview of Selective Wave Solder Machine reveals that adopting advanced soldering techniques contributes significantly to the high efficiency and reliability of electronic assemblies.

  • Intelligence

The intelligence of switching power supplies is achieved through digital control technology. This includes using microprocessors or digital signal processors (DSPs) to execute complex control algorithms, improving performance, and adding functions such as power management, fault diagnosis, and remote communication.

  • Miniaturization and Integration

With advancements in semiconductor manufacturing technology, the power devices and control components in switching power supplies are becoming more miniaturized and integrated. The application of power modules and integrated circuits reduces the number of components and interconnect complexity in switching power supplies, enhancing system reliability.

Development Prospects of Selective Wave Solder Machine

  • Green Energy

Switching power supplies are key in solar and wind energy systems for converting and storing energy. Selective Wave Solder Machines ensure reliable solder joints in these power electronics.

  • Electric Vehicles

Switching power supplies are vital in electric vehicle chargers and battery systems. Selective Wave Solder Machines ensure precise soldering, critical for vehicle performance and safety.

  • Portable and Wearable Devices

Small, efficient power supplies are needed for mobile and wearable devices. Selective Wave Solder Machines provide accurate soldering for these miniaturized components.

Application Field of Selective Wave Solder Machine

Selective wave solder technology is widely used in the manufacturing of various electronic equipment. It is crucial for ensuring the connection quality and reliability of electronic products.

Application Field of Selective Wave Solder Machine

Selective wave solder technology is widely used in the manufacturing of various electronic equipment. It is crucial for ensuring the connection quality and reliability of electronic products.

Solutions Configuration of Selective Wave Solder Machine

1. The overall size of the product PCB is 380MM x 290MM. It features a four-cylinder configuration to balance complexity and efficiency, customized to meet various product sizes and production requirements, offering flexibility and scalability.

DIP process flow: Plug-in → Soldering → Cleaning

Selective Wave Solder Machine process flow:

Selective Wave Solder Machine

2.Production line configuration:

3. Staffing

According to the production line setup and product adjustments, it is estimated that there will be 5-6 operators for plug-in operations, and 1 engineer.

4. DIP Production Line Configuration Data

DIP Line Configuration
Power Electronics: Using 4 welding stations, estimated productivity 240 PCS/H
Automotive Electronics: Using a single welding station, estimated productivity 50 PCS/H
Others: Calculated based on actual component quantity and personnel
Maximum Line Power: Approximately 52KW (using 4 stations)
Operating Power: Approximately 34KW (using 4 stations)
Others: Calculated based on actual equipment
Suitable Products:Suitable for mid-to-high-end products, maximum PCB width: 350MM
Line Dimensions: Requires L19m * W4m, total area 76 square meters

Process Challenges and Solutions

1. Solder Penetration and Fullness:

In electronics manufacturing, solder penetration and fullness are key indicators of welding quality. They ensure the mechanical strength and electrical performance of the solder joints. These factors mainly depend on:

1.1 Maintaining Flux Activity and Cleanliness

  • Use 99.999% pure nitrogen in the flux storage tank to keep the flux active.
  • Filter the flux with a high-precision filter before it reaches the nozzle.
Flux spray

Flux spray

Flux filters

Flux filters

1.2 Ensuring Precise and Even Flux Spraying

  • Use 130um high-precision imported nozzles for spraying flux with an accuracy of less than 0.1mm.
  • Control the movement of the nozzle with a Panasonic servo motor for precision.

1.3 Keeping Solder Materials Clean to Avoid Oxidation and Contamination

  • Use 99.999% pure nitrogen in the solder pot.
  • Cover the solder nozzle with nitrogen during welding to prevent oxidation and reduce dross.
  • Employ automated cleaning and calibration for nozzle cleanliness and solder wave stability.

1.4 Controlling the Appropriate Soldering Temperature and Time

  • Use PID+SSR for temperature control.
    Set soldering time and speed individually for each solder point.
  • Conduct welding inspection using 3D X-Ray to meet customer requirements, achieving results comparable to the European E-brand equipment used by the customer.

2. Different Solder Joint Sizes

2.1 DIP products have THT components with different pin sizes, requiring different nozzle sizes for soldering

  • Use a 4-cylinder mechanical configuration that can install four different nozzle sizes or four of the same size.
  • The equipment can work in three modes: individually, alternately, or simultaneously, solving the challenge perfectly.
  • Our equipment is more flexible compared to the European E-brand.

3. Production Capacity

3.1 The customer initially had no clear production capacity requirements. However, their use of a 4-in-1 jig design matches our 4-cylinder equipment configuration perfectly

  • Our current equipment can match the capacity of the European E-brand equipment used by the customer.
  • The modular design of our equipment allows for easy capacity expansion by purchasing additional modules.

Successful Delivery Cases

  • July 2023, Europe

Offline selective soldering delivery completed. Small module machine for small batch production, meeting high-quality soldering requirements.

I.C.T on-line selective wave solder machine
  • September 2023, Europe

Online selective wave solder machine delivery completed. Integrated online module machine for automotive electronics, including dashboards, actuators, and instruments. Online mode boosts production capacity.

  • November 2023, Asia

Online selective wave soldering delivery completed. Another dual-cylinder module machine for automotive electronics. High requirements for soldering speed and quality. Temperature control with PID+SSR keeps the solder pot and nozzle temperature stable. Preheating during soldering for consistent temperature.

2311 I.C.T online selective wave soldering machine in Asia
23.11 I.C.T on-line selective wave soldering machine in Europe
  • November 2023, Europe

Online selective wave solder machine delivery completed. Integrated online module machine for LED lighting products. Ensures both production capacity and quality. Provides the best service support.

  • April 2024, Europe

Online selective wave solder machine delivery completed. Multi-function online module machine with spraying, preheating, and soldering. Compact and flexible design.

online selective wave solder machine
selective wave soldering machine
  • April 2024, Europe

Online selective soldering machine delivery completed. Independent 4-cylinder design for electric vehicle power production. Matches top selective soldering manufacturers like the European E-brand, with comparable performance and platform usage. Our equipment offers better flexibility.

Conclusion

The selective wave solder machine is a major improvement in power electronics manufacturing. It handles complex soldering tasks efficiently and reliably. Key features like maintaining flux activity, controlling temperature, and managing different solder joint sizes ensure high-quality production.

As green energy, electric vehicles, and portable devices grow, so does the need for reliable power supplies. Selective wave solder machines will be crucial in meeting this demand.

Upgrade your manufacturing with our selective wave solder machine. Contact us today to learn more. Our experts will help you find the perfect machine for your needs. Improve your production and quality now by reaching out for a consultation.

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