Published by Dataweek Electronics Manufacturing & Production Handbook 2023
• AOI; X-ray • Component counters • Component storage • Conveyors • Device programming • Dot dispensing and conformal coating • ESD consumables • In-circuit testers • Jet printers • Low pressure injection moulding • PCB washing machines • Pick-and-place machines • Reflow ovens; vapour phase ovens • Rework and soldering stations • Selective wave soldering; wave soldering • Solder wire and solder paste • SPI • Stencil printers +27 11 869 0049 | [email protected] | www.mykaytronics.co.za The ultimate choice for a fast moving generation! MyKay Tronics We efficiently supply and support a total turnkey solution to the South African electronics market Supply Efficiency Support
EMP Handbook 2023 1 Opinions & insights The future of sustainable electronics manufacturing............................................................................................ 4 Critical questions manufacturers should ask for digital transformation success......................................... 6 Is it ‘back to normal’ or should we continue with digital resilience?................................................................. 6 4IR and the role of abrasives in robotics...................................................................................................................... 8 Technical articles What to look for when choosing a soldering station............................................................................................ 10 The advantages of using a micro nozzle................................................................................................................... 14 Complete engineering solution for PCB assembly and test...............................................................................15 Soldering robot: case study. .......................................................................................................................................... 16 High-performance inspection gets faster.................................................................................................................17 Equipment selection guide. ............................................................................................. 18 Consumables, tools & accessories selection guide............................................. 24 EMP 2023 Handbook Directory. .................................................................................... 27 contents Electronics Manufacturing & Production Handbook 2023
2 EMP Handbook 2023 From the editor’s desk Disclaimer While every effort has been made to ensure the accuracy of the information contained herein, the publisher and its agents cannot be held responsible for any errors contained, or any loss incurred as a result. Articles published do not necessarily reflect the views of the publishers. The editor reserves the right to alter or cut copy. Articles submitted are deemed to have been cleared for publication. Advertisements, inserts and company contact details are printed as provided by the advertiser. Technews Publishing (Pty) Ltd cannot be held responsible for the accuracy or veracity of supplied material. Gauteng Tracy Wolter, Tel: +27 11 543 5800, [email protected] KwaZulu-Natal Jane van der Spuy, Tel: +27 83 234 5412, [email protected] Western Cape Contact Durban or Jhb numbers for details Advertising: Print and Online Sales Manager: Malckey Tehini [email protected] Editor: Peter Howells, B.Tech (Electronic Engineering), [email protected] Subscription services For address changes, subscriptions, renewal status or missing issues call +27 11 543 5800 or [email protected] or WRITE TO: Technews Publishing (Pty) Ltd, Box 385, Pinegowrie 2123 Subscribe online: www.technews.co.za All rights reserved. No part of this publication may be reproduced, adapted, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Technews Publishing (PTY) Ltd. Reg No. 2005/034598/07 ISSN 0256-8934 Peter Published by: Technews Publishing (Pty) Ltd Wild Fig Business Park, Block B, Unit 21, 1494 Cranberry Street, Honeydew Tel: +27 11 543 5800 [email protected] A Dataweek Handbook Electronics Manufacturing & Production Handbook 2023 The future is hopefully looking brighter After having some time off over the Christmas period, without any deadlines to attend to, I managed get away to a bushveld hideaway. No cellular signal, no electricity, filtered water directly from the nearby river. It was bliss not to have to deal with the rat race. To be able to light a fire, grab a cold one and put my feet up is a wonderful feeling. That got me to pondering life in general and actually how good we have it here, despite the problems. And of course, problems we do have in abundance in SA. From the poor water quality in many rivers and seas, the lack of electricity generation, the non-existent infrastructure like a rail system or wellmaintained roads, and the list goes on. But we are not alone. Many countries worldwide have worse infrastructure than we do, and yet, they are fantastic to visit. This sentiment struck home for me when I spent time with a friend visiting SA after having left a few years ago. He absolutely loved coming ‘home’ for two major reasons: number one was the weather. Being able to spend time outdoors, swimming in rivers, and not having to get ‘dressed up’ even when raining was a bonus. And I think everyone in SA could agree – we do certainly have fantastic weather. The second reason was the freedom we have in SA. Freedom to enjoy an outdoor lifestyle wherever we are. Where he is (no names mentioned), for example, lighting a fire to have a braai is simply not an option. So, like everything in life, we suffer the bad here in SA for the greater good. Another positive we can take is that our education system is improving, if the results are anything to go by. Irrespective of what formula you applied to calculate the ‘real’ pass rates, no one can deny that across all provinces the Matric results were an improvement – and to think that this class of 2022 were the ones who had to suffer through either none or reduced teaching because of COVID and school closures, during grades 10 and 11 (two very important years, in my opinion). I take my hat off to all the educators who had a hand in making this happen. In terms of industrial manufacturing, we can also be proud of what our ‘smallish’ electronic engineering community can boast. Although engineering in general has experienced a decline in recent years, top-class engineers and technicians still drive a vibrant industry that is an important part of the South African economy. The worldwide chip shortage that occurred last year due to the drastic slowdown of industry caused by the coronavirus outbreak, has largely been resolved. This bodes well for our design and manufacturing sector. The revenue on the electronics segment on a global scale is projected to show a compound annual growth rate (CAGR) of 15,6% for the next five years from 2023 to 2027. Here’s hoping that government increases support of our local engineering industry. To start the year off on the right foot, here’s wishing everyone both a happy and a prosperous year. I, for one, am quite positive about the year ahead and believe that the start of all major changes takes a lot of very positive small steps.
4 EMP Handbook 2023 www.dataweek.co.za OPINIONS & INSIGHTS A new wave of electronics manufacturing is on the horizon, aiming to satisfy the increasing demand for sustainability, and mitigate the impact of volatile energy prices. With the electronics industry accounting for 4% of global greenhouse gas emissions, it requires substantial innovation to reduce its environmental footprint. Fortunately, this area has a lot of movement, with several potentially revolutionary technologies entering the scene. IDTechEx’s report, ‘Sustainable Electronics Manufacturing 2023-2033’, explores the key opportunities for sustainable innovation and the most promising new manufacturing approaches. The report concentrates on the fundamental building blocks of electronics – printed circuit boards (PCBs) and integrated circuits (ICs). Figure 2. Adoption of PCB substrate materials in 2033. The future of sustainable electronics manufacturing By Dr. Isabel Al-Dahir, IDTechEx. Incentives for sustainable electronics manufacturing Sustainability within the semiconductor and electronics industries is being driven forward by government mandates and green investment initiatives worldwide. Increasingly relevant to the survival of traditional manufacturers is the conscious choice of the public to only purchase from, and even only work for, companies that prioritise sustainable practices. Environmentalism is often perceived as an obstacle laden with legislative red tape and burdensome disclosures. However, companies that embrace environmentalism reap long-term rewards with the negative perception being replaced by one of opportunity. The implementation of lowemission manufacturing processes or the adoption of material recycling and recovery schemes can be the financially astute choice, presenting an opportunity to reduce costs associated with energy consumption, waste treatment, and superfluous steps. Prioritising environmentalism keeps the industry ahead of the curve as legislation becomes stricter, while positioning individual companies well to benefit from designated ESG investment. As energy prices rise globally, low temperatures and rapid processing methods become more attractive. Some of these methods employ additive approaches that substantially cut waste by printing material only where needed. This spares manufacturers the costs and emissions associated with excess materials and etching required in traditional subtractive manufacturing. For example, switching to additive methods of PCB manufacturing can lower water consumption by up to 95% – an outcome Figure 1. Additive manufacturing is expected to gain traction within the development of flexible PCBs. that could save the sector hundreds of millions of litres of water annually. IDTechEx’s analysis expects additive manufacturing to be particularly significant to the scaling of flexible printed circuit boards. Flexible PCBs are an important part of the emerging electronics industry as they enable a wider variety of applications than conventional rigid electronics. Flexible PCBs inherently require an overhaul of traditional processing – for example, using plastic or paper rather than conventional FR substrates. Embracing a new technology enables scope for further changes, such as transitioning to new materials and additive methods. Low-temperature processing may also be imperative for PCBs made on plastics such as polyethylene terephthalate (PET), considering that these have relatively low heat tolerances. Digitalisation for smart manufacturing Sustainable electronics manufacturing presents many opportunities to be more efficient, reduce waste, and improve costeffectiveness. Sustainable manufacturing can be facilitated through artificial intelligence and the Internet of Things. Using smart digital manufacturing methods to automate processes as well as sensor technology to detect leaks and improper material usage can help companies to minimise waste and cut down on excess costs. Digital data analysis can help remove superfluous steps and illustrate where to focus efforts to eliminate excess material and energy consumption. Digitalisation is becoming increasingly popular, with many household name brands adopting similar measures. At the end of 2021, Apple announced it had joined Sustainable Semiconductor Technologies and Systems (SSTS) – a programme created by the Belgian research institute, imec, to reduce the environmental impact of semiconductor manufacturing. Imec’s SSTS programme aims to improve sustainability by employing digital solutions to identify improvements in three key areas: energy consumption, greenhouse gas emissions, and water consumption. Many other well-known companies, including Microsoft, Amazon, and ASML, are known to be employing imec’s digital analysis.
OPINIONS & INSIGHTS Reshoring expected to reduce emissions The past three years have been full of upheaval, with pandemics, trade wars, and energy crises dominating front-page headlines across the world. The turmoil has brought to sharp relief how fragile the multi-billion-dollar electronics industry is. The global chip shortage is a salient example of the damaging consequences of supply chain disruption. While it may not be possible to fully immunise supply chains against all eventualities, there are acts that can be taken to minimise risk and reduce emissions. One method involves reducing dependency on geographic monopolies such as the Asia Pacific region, which currently dominates electronics manufacturing. Re-distribution of the electronics industry is gaining momentum of late, with hundreds of billions of dollars’ worth of funding going into revitalising localised electronics manufacturing in the West, as outlined in both the US CHIPS & Science Act and the European Chips Act. Increasingly, access to renewable energy is becoming a major factor as companies build new fabrication facilities. Samsung has already achieved 100% renewable energy for all its sites in the US and China, with other household name companies following suit, such as Apple, IBM, Intel, and Nokia. The availability of renewable energy sources varies substantially geographically, with the US and Europe leading the way with clean energy options compared to much of Asia Pacific. Greater access to renewable energy may give the US and Europe a new kind of leverage to encourage local manufacturing. Through substantial energy savings and energy independence, the production of various electronic components is likely to become increasingly cost-competitive with the Asia Pacific region. Additionally, since ‘reshoring’ will require the construction of new manufacturing facilities, there’s a substantial opportunity to design and equip with sustainability in mind from the outset. In contrast, in existing production lines, much of the equipment is already depreciated, increasing the relative cost of new investments into more sustainable manufacturing methodologies. Outlook Government mandates are cracking down on emissions, and public awareness and conscientiousness regarding global warming are growing, with many consumers making active choices to avoid certain companies. The electronics industry requires an overhaul of traditional manufacturing approaches contributing to global warming. Switching to low-toxicity, low-emission chemicals and processes is a key challenge to be addressed as more companies commit to attaining net-zero targets. Additionally, it is important to stay ahead of the curve as carbon prices may rise, making renewable energy the more reliable energy source to utilise. Reducing the carbon footprint of the electronics industry is a daunting task, particularly for well-established manufacturers that are reluctant to divert from traditional methods. Across the world, government and consumer pressure are forcing manufacturers to take on greater responsibility in reducing its emissions. IDTechEx’s analysis indicates that by embracing sustainable manufacturing methods, companies can benefit financially and demonstrate significant reductions in environmental impact. The rejuvenation of the European semiconductor industry presents the opportunity to build fabrication plants from scratch with sustainability as a priority. This means bypassing traditional legacy manufacturing processes and adopting new methods and equipment that minimise waste and lower emissions, for example, using additive approaches rather than subtractive. A comprehensive analysis and exploration of sustainable innovations within the field can be found in IDTechEx’s report, ‘Sustainable Electronics Manufacturing 2023-2033’. For more information visit www.idtechex.com
6 EMP Handbook 2023 OPINIONS & INSIGHTS Today’s leading manufacturing companies are adept at change. They must be in order to survive. Innovating, modernising and continual refinements of operational processes are driving factors in today’s complex market manufacturing landscape. It does not matter if an organisation makes automotive parts, industrial machinery or windows and doors, they need to stay on top of trends and challenges, and learn to adapt. New strategies and actions must sync, and also align with and exceed customer expectations. This is no easy task and many organisations struggle to find the digital transformation starting point. Are we organisationally ready for significant change? An organisations is only as good as its people, and manufacturers must look carefully at whether they have the right people and culture to support a different way of doing things. It is the people who will be responsible Critical questions manufacturers should ask for digital transformation success By Phil Lewis, senior vice president, Solution Consulting International, Infor. for implementing change, and they should be ready, committed, and on board with any type of transformation plan. An organisation’s culture can make or break a digital transformation project and“organisational change management” is one of the key components of such a project. Organisations should aim for an inclusive culture where people feel like they are key contributors to the company’s future success. What is hoped to be achieved and what is the outcome? Delivering successful digital transformation projects is difficult, and if an organisation does not understand the destination, the chances of success are minimal. Organisations should invest time and effort up front to understand exactly what they want to achieve from the digital transformation. No matter how many ideas an organisation has, they will fall into one of four categories: • Customer alignment. • Employee productivity. • Supply chain visibility. • Operational efficiency. In terms of customers, an organisation should ask whether it is transforming the way they connect and relate to customers, and whether it wants to offer a new product, increase the level of service, or use data to create a new revenue stream. When it comes to employees, an organisation should ask whether it is providing capabilities that help engage the workforce and how digital solutions will help improve workforce productivity, empower decision-making, and remove bottlenecks in processes. For supply chains, an organisation should examine if it is simplifying complex supply chains and increasing visibility to anticipate issues and take steps to resolve potential problems proactively. Finally, when looking at operational efficiency, a company will benefit from asking whether it can streamline the way it operates as a business, and if it is using technology to bring efficiency to its processes, to predict issues, and prescribe the next best action. Is the systems landscape digitally compliant and ready? Before starting a digital transformation project, an organisation’s systems should be digitally compliant and highly flexible. Ideally, the organisation has a systems ecosystem where people can access work, data, and processes without barriers, at any time and from any location. Often having solutions available in the cloud is the best way forward. Ideally, the organisation’s end-to-end systems and applications should be running on a common digital platform that provides integrated modern capabilities such as Internet of Things (IoT), artificial intelligence (AI), machine learning (ML), big data, mobility, and predictive analytics. An organisation’s IT landscape must support the concept of hyper-connectivity – not just connecting applications and digital capability, but connecting everything: its people, applications, devices, data, customers, and suppliers. For more information visit https://www.infor.com/mea As companies in South Africa revert to a semblance of the ‘normality’, many businesses are moving their employees and operations back to the original workplace. However, digital transformation and the mobilisation of a remote workforce should not have been in vain, and organisations should continue to leverage these established systems and investment. Conversely, the same applies to business operations and resilience – both digitisation and digitalisation must continue to establish a transformed foundation for the future. Is it ‘back to normal’ or should we continue with digital resilience? By George Senzere, solutions architect, secure power at Schneider Electric. This sentiment is also echoed by analyst group, IDC, which estimates that by 2025 there will be 41,6 billion connected IoT devices, including machines, sensors, and cameras. “In hospitals, datacentres, critical manufacturing plants, and industrial sites, continuous uptime is non-negotiable, especially during catastrophic events,” says IDC. To contextualise and re-emphasise the above, it’s important we take one step back. The pandemic caught a lot of organisations off-guard, particularly when it came to allowing remote access. In a matter of weeks or even days, organisations had to transform their infrastructure to allow for remote working. Unfortunately, as with most things in life that require a quick turnaround, the above came at a hefty price tag. In some instances, organisations had in days changed their IT corporate networks to allow for remote connectivity. This included making sure VPNs were up and running quickly, and organisations that were fortunate enough to have up-to-date architectures, implemented other alternatives such as SD-WANs and secure access service edge (SASE). Continued opposite
EMP Handbook 2023 7 www.dataweek.co.za OPINIONS & INSIGHTS This was undoubtedly a costly exercise. Which introduces the next important point: no one can predict what the future holds, which is why the adage ‘rather safe than sorry’ couldn’t be truer. Building on what we have Currently, most organisations have systems in place to allow for hybrid working. And whilst many employees have returned to company offices, they have the option and flexibility to work from home, depending on organisational policy. If anything, we should encourage and foster agility amongst workers, which is why digital resilience is key; it allows organisations to adapt to business disruptions by making use of digital technologies to continue with the daily operations. Digital resilience was one of the key attributes that saw some organisations adapt to the pandemic quicker than others. Thus, to prepare for the future, organisations must take a strategic approach to deploying digital technologies. For example, in the datacentre industry, those companies which already had advanced Datacentre Infrastructure Management (DCIM) systems in place, had no problem running and securing their infrastructure even with datacentre staff working offsite. DCIM allowed organisations to conduct remote health checks of the power infrastructure, which included overall performance and cooling. Also, datacentre owners were not the only ones to benefit from the DCIM tools. Organisations moved quickly to install DCIM and reaped the benefits. Establishing an agile workforce Not all organisations have the luxury of running a remote workforce. However, those industries and resultant organisations that are in the position to do so, should take the following steps to establish a secure, productive, and agile workforce: • Conduct a thorough evaluation of the type of business and its workforce. • Deploy the applicable digital tools and connectivity solutions that include remote software and devices. • Cybersecurity must be prioritised. • Provide continuous power to mitigate potential disruptions. • Ensure that the remote and on-site working environments of the employees are ergonomic and professional. • Adjust management styles to allow for a more ‘flexible’ working model with an emphasis on results and realistic performance matrices. • The workforce must be trained and prepared to work in remote environments. • Regular review via meetings to ensure teams are still productive. • Consistent and continuous technical support. • New employees must be given enough time to adjust to a hybrid and/or working model. Lastly, cybersecurity remains a crucial element of organisations’ infrastructure and working models. The attack surface is much bigger, and organisations must ensure they are fully protected, and their employees trained to identify any potential threats. For mor information contact Schneider Electric SA, +27 11 254 6400, [email protected], www.se.com/za/en
8 EMP Handbook 2023 www.dataweek.co.za OPINIONS & INSIGHTS It is well known that the most sustainable and productive manufacturers in Africa will be those embracing the fourth industrial revolution (4IR). To not embrace these technologies would mean lagging behind global peers. In an age when all that 4IR has to offer, like accelerated digitalisation, artificial intelligence, cloud computing, 3D printing and robotics, no manufacturing entity utilising automation can hope to compete without being abreast of advances in these spheres. It is important for a business to invest in equipment and processes that improve efficiencies to boost both its growth and bottom line. To endorse this, Dennis Phillips, national sales manager at PFERD South Africa, said, “The most significant benefits of 4IR are around automation, including automating routine and repetitive tasks to allow for better productivity and efficiencies. The manufacturing sector is ideally placed to benefit from these advances.” Abrasives in robotics Robotic applications such as grinding, milling, and surface preparation and structuring, require a range of high-performance abrasives to have the desired impact on efficiency. PFERD can assist with the optimisation of automated processes by assessing the applications and advising on the correct tools. Professional tools for automated processes South Africa does, however, struggle with the infrastructure required to ensure that what 4IR has to offer, can be implemented to its fullest capabilities. These include: 4IR and the role of abrasives in robotics • Being able to educate people to have the technical skills to employ the benefits of 4IR. • Faster more streamlined internet connectivity and 5G mobile technology (which is being improved on). However, having a reliable energy supply is vital and this is proving to be somewhat of a challenge. SA manufacturers who implement robotics (probably the most meaningful addition to manufacturing operations) need to choose the most suitable consumables to maximise the efficiency, which in turn optimises the operations’ overall productivity: • Milling, drilling and countersinking tools: Applications for these tools include chamfering, deburring, rounding edges, machining cast parts, together with trimming fibre-reinforced plastics. The milling tools’ precision design and dimensional stability allow for the easy programming of robots, while their performance and long tool life make them highly suitable for robotic applications because the frequency of tool changes is greatly reduced. • Fine grinding and polishing tools: PFERD offers a wide range of high-performing coated and non-woven abrasives, suitable for numerous fine grinding and polishing jobs. Tasks such as automated stock removal, surface preparation and structuring can be done efficiently with consistent results. • Diamond and CBN tools: Due to diamond and CBN tools’ constant tool geometry, they are highly suitable for robotic applications within the foundry industry. Their hardness and very long tool life reduces unproductive idle time attributed to tool changes, making them ideally suited for demanding applications within this industry. • Composite filament brushes: High-quality technical brushes specifically developed for industrial, automated use. These brushes are particularly suitable for deburring complicated components such as cylinder heads and gear toothing. Boosting the bottom line and gaining global recognition The distinct advantage of robotic applications is that a workpiece can be produced and finished in fewer processing steps, resulting in less manual work, and with more consistent results. Maximising the efficiency of business processes boosts local manufacturers’ bottom line and generates a better breed of SA manufacturers capable of competing on a global level. For more information contact PFERD-South Africa, https://za.pferd.com
10 EMP Handbook 2023 TECHNICAL ARTICLES If one is testing the waters and just feeling one’s way, it’s worth trying a few different soldering stations until one is found that suits all needs. And even if you think you’ve already discovered the only model you’ll ever really want, we’d like to challenge you to test your limits by exploring the other options that are out there. To help you explore the different models available, a guide on how to choose a soldering iron has been written. Some of the specific options available will be considered, while we also take a serious look at which criteria one should be considering when it comes to the type of soldering iron to purchase. How to choose a soldering kit Like many different tools, a soldering kit is a personal choice. Everyone is going to be using the soldering iron for a slightly different purpose and will therefore have different criteria that they want the soldering iron to meet. Because of this, it’s not as simple as merely pointing out the ‘best’ soldering iron. Instead, the requirements and the intended application, need to be looked over and the question“what is right for you?”needs to be asked. Beloware a fewdifferent criteria to keep inmind. Price Cost will always be a factor. No matter what the budget is, the simple fact is that everyone has What to look for when choosing a soldering station Information fromWeller. a budget they are working from and everyone has a price limit they cannot exceed. In some ways, this makes the choice easy, as any irons that fall far above the price limit can be ruled out, just as irons that fall far below one’s budget may also be disregarded. Rather than simply setting an arbitrary price limit, however, it’s a good idea to first look around at some of the different types of soldering irons for sale. See what’s out there, and begin to get a feel for some of the typical prices. Then, decide where one’s budget falls, and certain models can quickly be ruled out on either end of the budget. Usage Different soldering irons have different strengths, weaknesses and capabilities. If one is looking for the best soldering iron for circuit boards, for example, one would not want to choose an iron that’s better suited to automotive work. One of the best methods for choosing a soldering iron, then, is to first ask what the soldering iron is going to be used for. Is it going to be in a professional setting, or an educational one? Are you going to be working with circuit boards? Stained glass? Automotive parts? All three, on different occasions? The way this question is answered will play a significant role in determining which soldering iron is best for those needs. Each potential soldering iron can then be examined regarding its intended use. Ideally, an iron will be found that is perfect for the industry and the intended work. Another option, however, is to choose a more generic model that can easily handle a variety of different applications. This is an excellent choice particularly if you frequently solder many kinds of items. Specifications Depending on what kind of work is going to be tackled, a soldering iron with different capabilities and specifications will be required. Many different specs might be important. Maybe a soldering iron or soldering station that reaches a specific temperature is needed. Maybe it needs to be compatible with a tool that is already owned. Maybe there is a specific application that needs to be soldered, or certain regulations or requirements need to be met. Maybe it needs to be small enough to fit into a tight workspace. Making a list of all the features that are needed in a soldering iron will be a great starting point. A secondary list of things that that are not strictly needed, but that would be nice to have, could also be compiled. Then, refer to this list as different soldering stations and irons are viewed while shopping. In this way, any irons that don’t have all the features that are required can be quickly discarded. Examples of Weller soldering solutions With a better idea of things to look for, let’s take a closer look at a trio of example soldering irons and kits, as well as what makes them unique. 1. Weller WE 1010 For an easy, convenient and highly versatile tool for many situations, consider theWellerWE 1010 soldering station. This station comes equipped with theWEP70 soldering iron, an excellent tool for a variety of different purposes and one suitable for professional, prosumer and educational settings alike. Because this iron is so versatile and If you’re in the market for a soldering iron, there are many options available. Whether you are an old hand at these tools and already have a favourite brand a nd design that is purchased every time a replacement is needed, or you are newer to the scene, there is value in knowing the full range of options available. Figure 1. Weller WE 1010 soldering station. Continued on page 12
www.dataweek.co.za TECHNICAL ARTICLES can accommodate somany situations, it is the only tool available for this station. Just a few of the features that make the WE 1010 worth one’s time and consideration include: • Fast heat-up and recovery time. Time is precious. That’s why it is important to use a soldering iron that heats up quickly. Then, once finished, the recovery time is quick and convenient as well. • Intuitive navigation. Nobody likes a machine that feels like a chore to navigate. With the WE 1010, that won’t be a problem. A handy menu button and easy selection keys make the navigation both intuitive and easy. • Digital LCD screen. With this bright and clear screen, it’s easier than ever to view the level readouts and monitor the progress. • Power switch location. The power switch on this model is exactly where it is needed – on the front and in easy reaching distance, making it a breeze to switch on and off. • Greater power. A powerful tool that can get the job done when it counts is needed. This machine packs 70 W of power, completing any task quickly and efficiently. • Easy tip change. This model is designed for toolless tip changes, meaning one can easily disassemble the iron, change the tip and reassemble it with minimal hassle. • Reinforced safety rest. The handy design of this safety rest allows for extra stability when the soldering iron needs to be set down for a moment, meaning that one can rest easy knowing that it won’t fall to the ground or cause any damage to your tabletop. 2. Weller WT 1010 TheWT line isWeller’s mid-range soldering station, which comes with 12 compatible tools to choose from. TheWT 1010 and the entireWT line of products all pack some serious power, meaning these are great tools to help get the job done. They’re extremely flexible, making them suitable for a wide array of different applications. One of this soldering iron’s greatest strengths comes from the small and compact nature that allows it to fit neatly onto any workbench or tabletop. Best of all, this model is compatible with all tools across the entire WD andWSD families, making it versatile and usable in multiple applications. A few of the features include: • WTP 90 hybrid soldering iron. This highperformance 90W hybrid soldering iron is a combination between a micropencil (meaning it offers the highest performance with the best heat transfer) and a passive tip pencil with very good heat transfer, while also controlling costs. It comes equipped with a motion sensor in the iron, allowing it to automatically enter standby mode when not in use. • Changeable heating element. On the soldering iron itself, the heating element is easily changed and replaced, instead of requiring a long and laborious process to access. • Replaceable soldering tip. Changing the soldering iron tip is a critical part of maintaining an iron. With this model, changing the tip is an easy and convenient process that can be done independently of dismantling the rest of the iron. • Adjustable background illumination. No matter the lighting or working conditions, the information on the screen will always be clearly seen so that the work can be monitored. This LCD displays all necessary functions in a simple and easy-to-read display. • Front-mounted tool connection. This soldering station places the tool mount conveniently in the front, allowing for easiest access and simplest means of use. This means one can spend more time working and less time untangling cords and reaching for inaccessible connections. • Simple menu access. No one likes a machine that is complicated and difficult to navigate. The simple menu button allows for quick access to the machine’s different functions. • Front-mounted main switch. Like the front-mounted tool connection, this main switch is prominently located on the front of the machine, providing convenient access to it. • Reversible safety rest. With so much versatility and flexibility throughout the rest of the soldering station, it’s important to extend this to all applicable accessories. That’s why this safety rest is entirely reversible, and features both wet and dry cleaning for convenience. 3. Weller WX 1010 TheWX line isWeller’s high-performance offering, and theWX 1010 boasts 15 compatible tools, a motion sensor, micro tools with ultra-precise performance, and extremely accurate tip temperature. Retraceable process reliability, otherwise known as traceability, is extremely important in particular sectors of industry such as automotive and electronics. If this is an important criterion, theWX 1010 may be best suited to your needs. Some of the handy features you’ll find embedded in this model include: • Traceable capacities. In many areas of industry, the ability to perform in a traceable capacity is becoming increasingly important. The WX 1010 delivers this ability. • High levels of compatibility. When the Continued from page 10
EMP Handbook 2023 13 www.dataweek.co.za TECHNICAL ARTICLES WX 1010 is purchased, a machine that is compatible with every soldering tool in the WX line is obtained, providing a higher degree of flexibility and allowing the use of more than simply the pencil that comes with this set. • Use as a benchtop controller. IntegratedUSBports allowWX stations to connect to and control ‑preheat plates, fume extractors, andprogrammable logic controllers. Any connected toolswill feed its parameters and status back to thedisplay. • Intelligent tools and integrated parameter memory. Different parameters can easily be stored in the soldering iron, including standby temperatures and automatic switch-off time. These programparameters need to be entered only once. The soldering iron stores them and can use themwith anyWX station. The stations automatically detect individual tools and shows the tool names on the display. • Large LCD. All the necessary data and readings can be easily viewed on the screen. • Intuitive controls. The WX 1010 features an intuitive set of controls that react in just the way expected. From the turn-and-click wheel to the Enter key and finger guide, these controls are extremely easy to operate. Comparing the options These are far from the only options out there, and we encourage more research on the other models available. Between these three models presented here, however, one can get a good idea of some of the different types of models that will be found. So, let’s look at how these three models stack up against one another. Price The WE 1010 is by far the most inexpensive option of the three, representing a highly affordable option that can fit almost any budget. The WT 1010 is slightly more expensive, coming in at more of a middle-ofthe-road price. Finally, the WX 1010, being the premium model, is priced accordingly as the most expensive item on this list. Usage Wondering what type of soldering iron should be used for electronics? Not sure how to choose a soldering iron for stained glass, cords, or automotive parts? Let’s look at the intended uses of each of these three models. The WE 1010 is a very versatile model that can perform good-quality work without having one specific area that it specialises in, whether one is a professional, prosumer or educator. The WT 1010 has a handy ability to perform micro-soldering tasks, making it convenient in areas that larger tools might not be able to accommodate. Finally, the traceable abilities of the WX 1010 make it ideal for both the electronics and automotive industries. Specifications While all three of these soldering iron stations have the same basic capabilities, one will find that each brings a unique set of features to the table. For example, the WE 1010 allows the soldering tip to be changed without the use of additional tools. The WT 1010 offers a 90 W hybrid pencil. The WX 1010 boasts compatibility across the WX line. Decide which features mean the most to the intended application and move forward from there. For more information contact Allan McKinnon & Associates, +27 11 704 3020, [email protected], www.ama-sa.co.za Figure 2. Weller WT 1010 soldering station. 012803 8218 www.omnigo.co.za [email protected] ELECTRONICMANUFACTURING SERVICE Automated SMT and THP Assembly Automated Selective Soldering and Conformal Coating Automated and Manual Functional Testing Technical Sourcing and Procurement X-ray, 3D and 2D Automated Optical Inspection Product Design, Industrialisation, Test Jigs and Design for Manufacturing (DFM) Services
14 EMP Handbook 2023 TECHNICAL ARTICLES The first challenge to overcome when designing the micro nozzle was the fact that the smaller the nozzle, the less thermal energy it has. Before the micro nozzle was designed, the standard method of overcoming small nozzle requirements was to use a smaller standard nozzle design and then superheat the solder with an extremely high tip flow rate. One of the issues with this approach is that the temperature has a much smaller effect on the resulting heat transfer than flow rate. It also creates a situation where the process is susceptible to copper dissolution because of elevated solder temperature and dwell times. Additionally, an exaggerated flow rate at the tip was required to keep the solder from solidifying, so the advertised nozzle size is misrepresented, and the true contact area is much larger than the nozzle diameter would predict. Pillarhouse’s solution is to provide a multi-section nozzle that enacts a solder flow rate internally equal to a nozzle 2,6 times as large, with a resulting tip flow equal to a standard design nozzle. This means the heat of the solder is refreshing the energy in the tip at a high rate, but the PCB is not exposed to the unsteady and vigorous flow. The next patent involves the wettability of the nozzle itself and the ability to solder without bridging. Typically, the smaller the nozzle, the more quickly it will de-wet. This is a function of exposure time of the solder to O2 but mainly due to the small nozzle having less wetted area than the PCB wetted area (pads and leads). The rule of thumb is the greatest wetted area wins when trying to avoid bridging. The patent provides a design including external features on the tip itself that multiplies the surface area, much like corrugated cardboard has a greater surface area than flat paper. The result is a particularly small nozzle that has a strong ability to de-bridge fine and ultra-fine pitch components with enough thermal energy to solder multi-layer PCBs without extended dwell times, exaggerated contact flow or extremely high solder temperatures. Heat/thermal energy What are the advantages and disadvantages of heated nitrogen? Heated nitrogen raises the environment temperature around the solder nozzle, The advantages of using a micro nozzle requiring less energy to maintain temperature. As selective soldering nozzles do not have infinite thermal mass, this is important in reducing solder dwell times. Additionally, the heated nitrogen has an added benefit of locally heating a circuit board during the process which reduces the dwell times. What are the advantages of heating nitrogen with a separate heat source? Heating the nitrogen has diminishing returns once it exceeds the nozzle tip temperature. If the nitrogen provides energy to change the nozzle tip temperature, it is competing with the control on the heat source for the solder. The solder heat source has no ability to reduce temperature. Heated nitrogen can become another process variable that needs process control. Additionally, if you ‘superheat’ the nitrogen, you must be concerned about extended dwell times because it could potentially reflow SMT devices surrounding the target soldering area. What are the main causes of copper dissolution solder temperature/dip time solder choice? Alloy choice is particularly important in the copper dissolution scenario because lead-free alloys have a propensity to aggressively leach copper from the PCB. The downside of using an alloy that causes less copper dissolution is that it usually wets slower, making the process more difficult. For instance, SAC305 causes higher rates of copper dissolution than SN100C, but it is inverse in the dwell times required to solder, meaning extended dwell times and higher pot temperatures for the SN100C. The flow rate of the nozzle itself and the solder temperature/dwell time at contact also have a significant impact on copper dissolution. Pump control There are different pump styles currently on the market, including: • Mixed-flow flat blade impeller mechanical. • Mixed-flow impeller mechanical. • Magnetic. Pillarhouse uses both mixed-flow flat blade impeller mechanical, and magnetic pumps. Mechanical pumps provide higher resolution and better pump deceleration control for de-bridging fine pitch and PCBs with poor lead length. Mechanical pumps are rebuildable A micro nozzle is Pillarhouse’s patented 1,5 mm nozzle which helps to solve the challenges of particularly small nozzle requirements in selective soldering. Figure 1. Pillarhouse’s patented micro nozzle. Figure 2. The micro nozzle is available in 1,5 and 2,5 mm sizes. and have only nominally more dross per shift than magnetic pumps. Magnetic pumps have good solder acceleration and recovery, which is better for cycle time. There are no moving parts, the design is simple and has nominally less dross production than mechanical pumps. Thermal calibration and its advantage over the mechanical method? Thermal calibration is the single best process control in the Pillarhouse arsenal. The test confirms that not only are the XYZ axes working properly (contact out of place or wrong size otherwise), but it also shows that the nozzle is evenly wetted and the pump, solder level, and wave height are in control. By using thermal calibration, a customer can take a programme from another Pillarhouse system, recalibrate, and know the system will work the same as the previous machine, without wasting product. It is Pillarhouse’s belief that anyone can make a product work in a lab – the true test is when they have established a process and try the same product after six months with different nozzles and a new solder; can the system reproduce the same results? For more information contact MyKay Tronics, +27 11 869 0049, [email protected], www.mykaytronics.co.za
TECHNICAL ARTICLES Dedicated professional customer service Quick turnaround • Country-wide delivery • Solder paste stencils • Laser cutting services • Pneumatic stencil frames • Prototype stencil printer • Stepped stencils • SAWA ultrasonic stencil cleaners • Precision metal parts • Stencil storage systems • Polyimide high temperature labels • Personal protective equipment (PPE) +27 11 793 1318 • [email protected] • www.lstec.co.za i ate rofe i l u to r ervi e i k turn ro • try-wi li ry • Solder paste stencils • Laser cut ing services • Pneumatic stencil frames • Prototype stencil printer • Step ed stencils • SAW ultrasonic stencil cleaners • Precision metal parts • Stencil storage systems • Polyimide high temperature labels • Personal protective equipment (PPE) 27 1 793 1318 • [email protected] • ww .lstec.co.za Dedicated pr fe sional c st mer service Quick t r ar und • Country- ide delivery • Solder paste stencils • Laser cutting services • Pneumatic stencil frames • Pro otype stencil printer • Ste ped stencils • SAWA ultrasonic stencil cleaners • Prec sion metal parts • Stencil storage ystems • Polyimide high temperature labels • Personal protectiv equipment ( PE) +27 1 793 1318 • stencils lstec.co.za • w.lstec.co.za Siemen’s Valor Process Preparation solution provides manufacturers with everything they need to run the manufacturing process accurately and efficiently, while saving costs. Valor Process Preparation offers a unique approach that creates a single, central database of all manufacturing process definitions (MPD) and engineering data, leveraging ODB++ Design and bill of materials (BOM) files. Valor Process Preparation provides a single environment for all stages of the manufacturing process, including assembly, test, and inspection. Changes that are made during these stages are updated in a centralised location to make sure that data is always up to date. The change and revision management eliminates the need for manual, error-prone updates, which can cause inconsistency and reliability issues throughout the manufacturing process. Manufacturing mistakes are reduced with a single data model that covers multiple processes and multi-vendor programming support. Built-in error checking, learning library, and profiles for each design centre make it easy to achieve intelligent hand-off of PCB design with a complete and accurate data model of the PCB assembly that is fully optimised for manufacturing. A single, centralised programming resource, along with a centralised part library for all SMT machines, helps avoid a machinespecific library, which limits the manufacturer’s work flexibility and efficiency. Part libraries can be created for each machine directly from the Complete engineering solution for PCB assembly and test master parts library, and custom parameters can be created or modified to enhance part and shape data. The Valor Parts Library (VPL) is ISO 9001-certified, covering over 1 billion part numbers. It is a centralised location of all accurate shape data, pin contact area, and component classification based on the JEDEC standard. Valor Process Preparation helps you improve yield by promoting an error-free manufacturing process. It gives you the flexibility to move between machine vendors and different manufacturing sites and to optimise your SMT programmes, which is essential for optimised productivity and manufacturing. The application reduces work in process (WIP), increases overall equipment effectiveness (OEE) and enables you to achieve a streamlined flow in your production process. Surface mount technology (SMT), through-hole technology (THT), stencil design, hand work, box build, electrical test, and both optical and X-ray inspections, are all supported. It is easily configured for your specific workflows, including data preparation, design-for-assembly (DFA) analysis, documentation, SMT programming, test and inspection engineering, and stencil design – all in one seamless, cohesive solution. Valor Process Preparation is the only complete process engineering solution available for PCB manufacturing. For more information contact ASIC Design Services, +27 11 315 8316, [email protected], www.asic.co.za
RkJQdWJsaXNoZXIy MjEzMjU=