The goal of quality management in any electronics production is an error-free production process, because manual rework is not only time-consuming and expensive, it is also often not permitted. All process steps must be reproducible and, above all, fully traceable.

Automatic control functions can effectively support electronics manufacturers in making their manufacturing processes sustainably stable and cost-efficient. This is based on continuous recording of machine and process data, bidirectional data exchange between systems, the possibility of control by higher-level systems and, of course, clever ideas from the system manufacturers.

You can read about the clever ideas in SEHO’s wave and selective soldering systems in a technical article published in SMT Germany, issue 6-7 2021.

Der Beitrag How innovative ideas make the soldering process more reliable erschien zuerst auf SEHO - Complete Solutions.

At RAFI’s headquarters in Berg/Ravensburg, traditional German pragmatism and reliability meet international innovation. The company has set itself a high bar: RAFI products make things happen at the push of a button.

RAFI has been committed to progress right from the start. The company’s pioneering spirit and innovative strength and the exceptional know-how of its workforce have enabled it time and again to introduce trail-blazing new products to the market and to win first place in innovation competitions.

Quality and reliability are the main criteria for the product portfolio, which includes components, HMI systems and EMS. All of RAFI’s employees share in the philosophy that every good thing can still be made a little bit better. With its focus on exceptional and tangible product quality, the company will only consider ultra-modern plant engineering solutions that support highly flexible manufacturing workflows.

“Our procurement of new manufacturing equipment is defined by a range of factors,” explains Romano Reising, process technology expert at RAFI’s Electronics division. “In addition to a solid partnership with our suppliers, we primarily look for innovation and new ideas that help us further optimize our manufacturing processes so that ultimately, we can offer better quality and more flexibility to our customers.”

It is precisely these innovative ideas that are embodied in SEHO’s MWS 2340 wave soldering system that was recently installed at RAFI’s factory in Berg. “This, too, demonstrates RAFI’s pioneering spirit,” says Romano Reising with a smile, “the latest features of this system were used in our production process even before the product was officially launched on the market.”

The modular concept of the MWS 2340 provides maximum flexibility. The system stands out in particular for its extremely high degree of automation and many innovative features for monitoring and controlling soldering processes.

The fluxing area is equipped with a spray fluxer with HVLP technology (high volume – low pressure) that ensures a homogeneous spray pattern when the flux is applied. The assembly dimensions are customizable, which means that there is less environmental impact and at the same time, a sustainable cost reduction can be achieved by lowering the consumption of flux. In order to meet RAFI’s high quality requirements, an additional flux volume monitoring feature was integrated that detects the relevant flow rate while flux is being applied. If an error is detected, the monitor outputs a corresponding message and records all values in the operating data log. “The proper application of flux is crucial for the quality of a solder joint,” explains Romano Reising. “This volume monitor provides detailed evidential data for the parameters of a manufactured assembly even years later.”

RAFI will use the new production line in 3-shift operation for the manufacturing of a broad range of products with highly diverse assemblies for medical engineering, the automotive industry and telecommunications. Individual products may weigh up to 10 kg including their soldering frames, which accordingly creates high heat requirements. This demands high flexibility of the system technology.

Despite its compact size, the new MWS 2340 at the RAFI factory includes a pre-heating section of 3300 mm. The customizable pre-heating area consists of a convection pre-heating zone that provides for an even warm-up of the assemblies. The required flexibility is provided by the eight pulsar pre-heating zones that follow. The new pulsar emitters combine the benefits of conventional quartz and infrared radiators and stand out for their high energy density. A particular benefit is their especially high efficiency which is achieved through the extremely fast reaction speed of the pulsar emitters in combination with an exact monitoring system and the individual actuation of the heating elements. This pre-heating concept is based on the activation of individual emitters rather than entire pre-heating segments. This makes it possible to apply the specific, exact amount of thermal energy to each product that is needed for the process without losing out on cycle time. As a result, high-mix manufacturing – even of assemblies with different thermal requirements – and high-volume production are no longer impossible to combine. This is the kind of flexibility that RAFI really appreciates. “Our older systems used a transport speed of 120 cm/min. during production and still, for some assemblies it was a challenge to introduce enough heat into the product,” says Romano Reising. “With the new pre-heating concept, we use a speed of 140 cm/min., and we have not yet reached the limit. There is still more room to manoeuvre, for example for high-performance electronics.”

The electronics manufacturing at RAFI requires the use of solder masks depending on the specific product. The mask cut-outs vary in size from 5 mm to 10 mm. “Sometimes it was a bit tricky to achieve really good solder joints,” says Romano Reising.

The new system’s soldering area is fitted with two solder nozzles that create turbulent waves, which make them suitable for a wide variety of different products.

The automatic nozzle height adjustment is a particular highlight. This new MWS 2340 feature allows for the software-controlled height adjustment of the individual solder nozzles over a distance of 20 mm; this allows setting the optimal distance between the circuit board and the solder nozzle for each product. This means independence from the workpiece carrier design without any impact on the cycle time.

“The automatic nozzle height adjustment provides additional process stability and higher product quality because all solder joints are reliably wetted and a defined solder peel-off can be achieved,” explains Alexander Riedel, Key Account Manager at SEHO and point of contact for the RAFI Group. Romano Reising adds: “Currently, our solder programs for the different products are designed in such a way that the pulsar emitters are programmed individually depending on the thermal requirement of the respective assemblies. The nozzle height is adjusted between 3 mm and 4 mm and is absolutely reproducible, even after servicing. Like the pre-heating power, there are still plenty of reserves for the nozzle height adjustment, so we are optimally prepared for new applications. On the whole, we can say that the combination of pulsar emitters and the new nozzle height adjustment is simply the best system there is.” 

With a view to product quality as the top priority, the new MWS system at RAFI was expanded with other features that mainly pursue one goal: increase process stability even further.

This also includes the stability of the nitrogen atmosphere inside the system. Nitrogen provides multiple benefits to the wave soldering process, primarily the higher wetting activity which ultimately decides the quality of the solder joints.

The active extraction controller at the intake and exit of the system ensures the stability of the nitrogen atmosphere. Unsymmetric airflows in the tunnel are compensated, and the system responds automatically to changing external factors.

“Solder balls continue to be a frequent phenomenon in the manufacturing of electronic assemblies,” says Alexander Riedel. Solder balls can detach later when the assembly is in use, and can cause short-circuits. For this issue in particular, defect prevention must come before defect elimination. Depending on the application, if the nitrogen atmosphere during the soldering process is too good, this can promote the formation of solder balls. “Our experience has shown that a value of 350 – 400 ppm of residual oxygen yields the best results,” explains Romano Reising. In order to guarantee this target value consistently, a controlled aeration management function was added to the system. The residual oxygen is measured constantly and if needed, raised to the desired level. 

“Another function is now available for the MWS 2340 that also aims at increasing process stability for wave soldering,” says Alexander Riedel. A crucial factor for process stability is of course the stability of the solder wave height. But up until now, it was not possible to measure the wave height without disrupting the production process and applying external test instruments, and there was no automatic adjustment. 

In view of these issues, SEHO developed an automatic wave height measuring feature that guarantees stable processes across the entire soldering width both for laminar and turbulent waves. Inside a configurable tolerance range, the system automatically regulates the wave height to the correct value based on the measured values and a mathematical model. “By the way, the automatic wave height measurement feature can be retrofitted in newer systems,” says Alexander Riedel with a smile and a sideways glance at Romano Reising.

“For some of the new features, such as the automatic nozzle height adjustment, we were able to play an active role during the development stage and were constantly sharing information with the product management at SEHO,” says Romano Reising. Regarding the collaboration with SEHO, RAFI did not just value the high quality standards of the machines and the advanced technology but also the competence and reliability of their contacts. “Sometimes there are technical challenges that need to be solved – that is unavoidable,” says Romano Reising. “How a company handles such situations, that really tells you how good they are.” 

This shows how collaboration among partners can turn initial ideas into technology solutions.

Der Beitrag Committed to progress for decades erschien zuerst auf SEHO - Complete Solutions.

Baudisch Electronic is one of the leading EMS full-service providers with its own EMC laboratory, and manufactures prototypes as well as small and large series. Due to the continuous growth, the company reached its capacity limits in the THT production area in 2020. “In order to continue to offer our customers a high level of flexibility and short throughput times, it was clear that we had to expand our production facilities,” explains Matthias Lenz, Managing Director of Baudisch Electronic, and he adds: “On the one hand, production should become even more efficient through a higher degree of automation. In addition, a new THT production line should give us the opportunity to produce higher quantities, but at the same time we wanted to be able to react quickly to different order volumes and assembly layouts.”

As a full-service provider, Baudisch Electronic knows the advantages of having everything from a single source. “With SEHO we have found the right partner for our project”, says Matthias Lenz. A high-end wave soldering system, assembly workplaces and fully automated workpiece carrier handling – plus competent advice and a good price-performance ratio.

Click here to read the full article.

Der Beitrag Successful Modernization of the THT Production. erschien zuerst auf SEHO - Complete Solutions.

The next generation of electronics manufacturing must be flexible and cost-efficient, even in manufacturing areas that have traditionally been dominated by manual processes. The only way to make this possible is via smart, scalable automation.

Siemens AG is among the pioneers of new manufacturing processes. In the modernization of the Siemens equipment manufacturing plant in Amberg, the project team had set itself ambitious goals – for the selective soldering process, these goals were achieved using a SEHO SelectLine system with some very special features.

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Der Beitrag Soldering cycle times almost halfed erschien zuerst auf SEHO - Complete Solutions.

Most wave soldering systems installed in electronic productions are equipped with one or two solder nozzles that generate a turbulent wave. This configuration is ideal for most products, however, this concept reaches its limitations if, for example, PCBs in masks are to be processed. The reliable wetting of all solder joints is not guaranteed, depending on the thickness of the mask and the size of the cutouts. Additionally, it might be challenging to achieve a reproducible process if the distances between covered SMD components and the THT pins to be soldered are too small. Sophisticated assemblies that are processed in soldering masks often show soldering defects such as incomplete solder joints or solder bridges.

Automatic nozzle height adjustment that does not influence the wave soldering system’s cycle time provides an innovative approach for these applications. The height of each solder nozzle can be adjusted via the software within a total distance of 20 mm, creating the optimal product-specific distance between circuit board and solder nozzle. The automatic nozzle height adjustment provides additional process reliability and better product quality because all solder joints will be reliably wetted and a component-specific defined solder peel-off will be enabled.

The system is linked to the sector soldering feature. This function allows program parameters for pump revolution speed (wave height) and conveyor speed individually for up to 16 circuit board sectors. By adding the individual nozzle height, i.e. the optimum distance between PCB and solder nozzle, at up to 16 different circuit board sectors, this system provides a large process window and maximum flexibility. It also ensures sustainability of the wave soldering machine with regard to future applications.

Der Beitrag MWS 2300 with automatic nozzle height adjustment erschien zuerst auf SEHO - Complete Solutions.

Pioneering new methods, setting new standards for efficiency, taking on new challenges: This is the foundation of the success of the Digital Industry Division at Siemens Motion Control in Erlangen. Drawing on innovative ideas and manufacturing concepts that were implemented together with SEHO, the company enters the home stretch on its way to the lean digital factory.

One of the hightlights at the Siemens Erlangen production plant is the new THT line made by SEHO. It is designed for the matrix manufacturing concept that is Siemens’ goal. The line is expandable and its degree of automation is successively scalable. “We worked very closely with SEHO on the realization of this line. This allowed us to implement a concept that alligns perfectly with our corporate strategy: flexible automation for a lean, digital factory”, says Werner Eckert, manufacturing technology expert at Siemens Erlangen.

The new manufacturing concept allows to assemble the different product types in variable quantities with great efficiency, thus allowing flexible reaction to customer requirements.

Der Beitrag Automated and efficient processing of thts erschien zuerst auf SEHO - Complete Solutions.

Electronics manufacturers are facing daily challenges to be competitive in a global environment. The quality of the manufactured products, price pressure, and manufacturing process sustainability are just some of the tasks to place the future of electronics manufacturing on sound footing. Equipment suppliers can efficiently support this.

SEHO is in close contact with customers worldwide. Energy-efficient machines, flexibility, a higher degree of automation in terms of process control, and reduced wear susceptibility are major approaches for the beneficial support of electronics manufacturers. SEHO scrutinized the soldering processes and refined them in this direction. Innovative technologies help to establish more efficient processes and often are the small details that make the difference.

This article discusses latest innovations for wave soldering and selective soldering processes that effectively help to reduce production costs and increase product quality at the same time. Unique features such as automatic wave height control in wave soldering processes or miniwave solder nozzles that are virtually maintenance-free will be introduced.

Der Beitrag Soldering processes rethought erschien zuerst auf SEHO - Complete Solutions.

Maximum process and system flexibility while using the smallest possible footprint – this was one of HELLA’s main requirements for a large-scale benchmark test for selective soldering systems. HELLA specializes in vehicle lights and electronics and is among the top 40 automotive suppliers in the world. For this reason, the company also places stringent demands on its system providers in order to safeguard its ability to deliver top-quality technologies at all times.

“The high quality standard of our products is our top priority, regardless of which factory manufactures any given assembly,” says Vinson G. Foo of Operations Industrial Engineering at HELLA in Lippstadt. “The production equipment as well as the manufacturing processes follow international standards, and the process technology specialists from the different factories meet on a regular basis in order to share their experience and establish the worldwide manufacturing strategy,” adds Foo.
For this reason, the large-scale benchmark test in the selective soldering field looked beyond Germany and included aspects of global importance in the decision-making process. The benchmark test spanned one year and involved an intensive cooperation with all well-known soldering system manufacturers.

Vinson G. Foo: “In SEHO, we have a partner at our side who is equally committed to our idea of quality. Our technology partnership is working out very well, and we have the set-up and the flexibility to meet the demands of today and of the future.”

Der Beitrag Focus on flexibility and throughput erschien zuerst auf SEHO - Complete Solutions.

The potential for innovation in electronics makes it one of the most dynamic industries today. Selective soldering has seen a dramatic increase for years, more so than any other soldering process in electronics manufacturing.

A high degree of automation in production typically means large investments in machinery. Especially for the investment in an automated selective soldering process appears unprofitable. However, this perspective changes if automation is not excessive, but adequate. The result is a perfect interplay of man and machine. The priority is on keeping it simple. The operator must be able to understand the processes and know how to operate the system at a glance, what the machine is doing and why.

With these factors in mind, SEHO developed its StartSelective selective soldering system. StartSelective is a ‘plug-and-produce’ selective soldering system for those just entering the automated soldering field, and for anyone looking for a short-term capacity expansion.

Der Beitrag Plug and produce – selective soldering made easy erschien zuerst auf SEHO - Complete Solutions.

Its modern manufacturing concept helps the Siemens AG in Karlsruhe to produce groundbreaking solutions and to set new standards on a regular basis. The production concept behind the fulfillment of individual customer requirements is based on modern manufacturing islands. In addition to the ability to cost-effectively produce smallest lot sizes, the standalone “island” production approach largely eliminates process-related waiting times and supports the manufacturer of highest quality products.

The basic prerequisite for flexible manufacturing islands is of course the flexibility of the individual production plants within an island. “We ensure this flexibility by using selective soldering systems and automation technology from SEHO” says Josef Kühn, a planner and designer in the Technology department at Siemens Karlsruhe.
The newest IPC manufacturing island at Siemens in Karlsruhe is used in a 2-3 shift operation scenario, production stoppage to allow the soldering nozzles to be cleaned manually was not an option. Instead, the SelectLine was fitted with SEHO-patented ultrasonic cleaning technology. “Our experience has shown that cyclical ultrasonic cleaning significantly improves the service life. With SelectLine soldering nozzles, we have an average service life of approximately 2 months – typically we would just get a few days with other comparable systems,” says Josef Kühn.

Der Beitrag Programmed for success erschien zuerst auf SEHO - Complete Solutions.