Wave Solder Optimizer
The process wave soldering took its name from the fact
that the process uses a tank containing molten solder. In this process the
electronic components are inserted in the PCB into their right place and them
the PCB is made pass through a wave of soldering metal. The molten solder passes
through the uncovered metallic area and creates a consistent electrical
connection between the components. The areas where the connections are not to be
made are protected with the solder mask. The process of wave soldering is much
faster then the process of manual soldering; it creates a quality product in
less time as compared to that in manual soldering.
Wave soldering process
can be used for both holed PCB or for mounted PCB. But in case of the mounted
circuit board the electronic components are placed on the PCB with the help of
glue Rigid flex PCB Board, before
they are made to pass through the wave of solder. Now boards with hole
components had been mostly replaced by exterior mounted components, wave
soldering has been replaced by reflow soldering method in a lot of large-scale
electronics application.
Though there are many types of wave soldering
machines available now a days but the basic operating principle of all the
machines are same. A typical wave solder machine consists of three main zones;
first being the Fluxing zone China PCB
Prototype, second Preheating zone and the Soldering zone. Though some of the
machines do have an additional fourth zone of Cleaning but this thoroughly
depends on the kind of flux used.
Wave Solder Optimizer:-
Wave solder
optimizer is one of the extremely urbanized, precise, and simple to employ wave
solder process tool in modern era. It is the only device which can measure the
critical parameters in the wave solder course, during the interface of the PCB
with the wave. The optimizer goes through the wave machine like the printed
circuit boards do. Original board-wave sensors on the base of the optimizer
experience the wave just similar to Lead on an assembly. A temperature sensor on
the board allows daily thermal profiles. A particular Flux sharing Window gives
you the information on whether the flux is being applied carefully and evenly.
The wave solder optimizer makes the process of wave soldering easier and more
efficient, with improved results.
In present time optimizer is the worlds
best for the measurement of control and optimization of the interaction of board
and wave of solder.
Cost of the wave soldering
defects:-
As it is clear that the use of the wave soldering has made things
more simple and well-organized, but again this process too has some drawbacks.
The process of wave soldering has severe hazards too, the production cost
increases automatically with the involvement of this process in manufacturing.
Apart from the increases in the manufacturing cost if the wave soldering fails
then too it costs a lot to the firm.
The site SWPC ha covered all the points
describing the cost factor involved in the usage of wave solder.
Dwell
time:-
Dwell time for any dynamic process can be defined the time for which a
dynamic process remains halted so as to make the other process
happen.
Lead Free Wave Soldering:-
The whole world of PCB assembly is
working towards implementation of lead-free soldering in order to get lead free
electronic components. So the process of wave soldering must be transformed into
a lead free process. In order to achieve this lead free process vital changes
are to be made in the process of wave soldering and this involves more then just
changing on solder alloy with other.
Thermal Profiling: -
The process
of profiling includes the measurement of time against temperature relationship
during the travel of the product throughout the soldering process. The data
collected through this process generally involves the statistics likes of
temperature peak point, time above liquid and many more.
KIC's thermal
profiler instrument is used to make the measurement for the relevant data's of
the process. On the basis of these statistics it is measured that how well the
products profile matches the established window for the process.
Daily
Thermal Profiling:-
In today's time all the PCB assembler's wants to have
profiling equipment which delivers the cost effective technology on a daily
basis use of the industry. The basic demand of modern day assemblers can be
understood with the following, five points;
1.) Simple in
operation
2.) The data obtained with the process of profiling should be
immediate accssecible.
3.) The software should be user friendly.
4.) It
should withstand the harsh conditions during the operation.
5.) It should
come at an affordable cost.
Now the idea of doing thermal profiling for
reflow soldering is extensively established all through the printed circuit
board (PCB) assembling industry. The process of Thermal profiles is used
board-by-board during prototyping. The preferred thermal profile then should be
protected and its parameter should be maintained when organization
boards.
Training for Wave solders process:-
The site has a
complete section for the training session of wave solder process and for the
troubleshooting of the process. In this section all the minorities involved in
the process of wave soldering is involved. Users can definitely take a benefit
of this section and could help themselves in knowing all the terms and process
required to do the wave soldering safely and efficiently. This will help them in
using the proper tools and materials for effective welding at a relatively low
cost.
Apart from the mechanical aspects of the welding the chemical parts
are also being described there in a very meaningful manner. It helps the user in
choosing and using the suitable chemical which will make their welding process
quite productive.
Training section in the site also describes and listens to
the personal experiences of the users at machines. The also provides a reliable
solution for the problems an individual has faced in the past while using the
wave solder. The training section of the site tries to solve the board problems
the users faces during the process.
Various leading electronic firms, likes
of Samsung, Panasonic and others had been benefited by this online training
program of SWPC. The training program here is different then the others in some
manners as it not only help by providing instructions but it helps by solving
the personal problem.
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