Relay Solenoid Coil Dip Soldering Machine Manufacturer India
In Relay or solenoid coil manufacturing process, the soldering on bobbin pin terminals is most mandatory process after finishing the copper wire winding on bobbin.
Without soldering, the copper wire remains loose or breaks contact from terminal pins, which can damage or failure of relay or solenoid coil.
We are here to announce some of the best techniques to describe how to proper solder a relay or solenoid coil bobbin terminal pins precisely and accurately.
Dip Soldering process
In case of manufacturing, to increase production quantity and to ease the soldering process, dip soldering method is very best.
In this method, a titanium solder pot is used with high temperature melt tin and the relay or solenoid coil is directly dip inside it after applying the proper flux on bobbin terminal pins.
With dip soldering method, manufacturer can achieve better quality of soldering with high production.
Types of Machines used in Relay or Solenoid coil Dip Soldering process
- Semi Auto Coil Dip Soldering Machine
- Fully Automatic Coil Dip Soldering Machine
Semi Auto Coil Dip Soldering Machine
In this semi automatic machine, some of the manual work is involved like fluxing, loading & unloading.
Solder pot is made of titanium material which can hold very high temperature of tin with great life of min. 5 years.
Soldering arm is rotary type which helps to solder with different angles, dip position is accurate, and soldering dip time is also programmable.
Working Video of the Machine:
Features
(1) Multi-purpose & functional soldering machine.
(2) With 99 set of parameter memory, each set can store up to 10 steps.
(3) One program can set 3 types of functions, each step can set:
A): random angle B): dipping height C): pre-heat time
(4) Horizontal component, first angle one side soldering, second angle other side soldering, then return back to parallel level for a dragging soldering.
(5) Can be set soldering time.
(6) Heater pipe is a single unit and can be easily exchange for maintenance.
(7) Using of solder cup in solder bath.
(8) Titanium solders pot; sustain high temperature up to 6000C.
(9) 360 degree with free random rotary setting,
(10) Optional device: Nozzle, solder Cup or dragging mechanism.
Technical Specifications
| Model | WCE-02R |
| Cycle Time | 10~20 pcs/12 sec. |
| Traverse | Max. 76 mm |
| Air Pressure | 5 kg / cm2 |
| Electric Source | AC220V 50/60Hz 2000W |
| Inner Tank | 300x100x60 (LxWxH) |
| Unit Dimensions | 550x600x530 (LxWxH) |
| Optional Device | Nozzle, Solder cup or Dragging mechanism |
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Operation guide for CNC-200S controller
- Power: To switch ON/OFF the unit of power with light indication
- Keys: 0~9 : Total 10 Keys, to key numerical values
EDIT：To enter or leave setting mode.
QTY SET：To set target production quantity.
START STEP：To set the start step from memory.
END STEP：To set the end step from memory.
DATA SEL：When in edit mode, it is for choosing data; When in operation mode, it is to switch display soldering shaft and rotary pole position.
SWEEP：When in edit mode, it is to set the step if it is to perform “dross clean” function.
CUP：When in edit mode, it is to set the step if it is to perform “solder cup” function.
TURN DIR：When in edit mode, it is to set the step for rotary direction.
MOVE：When in edit mode, it is to set the step if it is to perform drag function.
AUTO START：When in edit mode, it is to set the step if it is to activate “Automatic” function.
—-：When in edit mode, it is to jump to previous edit step; idle mode, press done for 2 seconds for reduce one for production.
CLR：When in edit mode, it is to clear numerical value to zero.
COPY：When in edit mode, it is to copy last data to present step.
ENT：When in edit mode, it is to save data to memory.
TIME：Time and production display (switch).
ZERO：Set production quantity to zero.
AUTO：Auto cycle key, when light ON, it is activating.
MANUAL：To entry or exit “manual” type interface.
NEXT：To force to jump to the next step of soldering shaft position; when in edit mode, it is to give soldering and rotary position forward.
PREVIOUS：Force to jump back to last step of soldering shaft position; when in edit mode, it is to give soldering or rotary position backwards.
RESET：On any mode, to stop operation, and return home and idle mode condition.
STOP：To pause
START：To start or re-start operation.
- Numerical value display :
Step display: To display the number of current work or edit step.
Data display: To display the editing data, soldering shaft or rotary shaft position.
Production Q’ty display: To display production quantity and times(S).
- Status light indication :
- READY ：Light ON means “standby”, OFF means in operation or edit mode, FLASH means in Pause.
- RUN ：Light ON means in operation, OFF means in “not operation”.
- MOVE ：Light ON means it is on “dragging” performance.
- UD ：Light ON means it is performing “solder cup” function.
- UD ：Light ON means sweeping shaft is performing “up & down” movement.
- FB ：Light ON means sweeping shaft is performing “forward & backward” movement.
- P：Light ON means soldering shaft it toward preheat point movement.
- P ：Light ON means soldering shaft is towards soldering point movement.
- A ：Light ON means soldering shaft is moving away from soldering point.
- A：Light ON means soldering shaft is moving away from preheat point.
- FINISH ：When the number of production has reached production targets, it is Light ON.
- TIME ：When Light ON, the present displays is “times”.
- QTY ：When Light ON, the present displays is “production quantity”.
- Soldering data indicator :
When editing soldering data, if any light is ON, it means you are performing that particular soldering data.
- P：Soldering shaft of first position (from home), setting range [0～999.99]mm.
- P ：Soldering point’s second position (from original point), setting range [0～999.99]mm.
- A ：Soldering shaft’s third position (from original point), setting range [0～999.99]mm.
- A：Soldering shaft’s fourth position (from original point), setting range [0.0～999.99]mm.
- T：It is a waiting times that after reach to soldering shaft’s first point position, setting range [0～9.9]S.
- T ：It is a waiting times that after reach to soldering shaft’s second point position, setting range [0～9.9]S.
- S：Speed to preheat and away from preheat point, setting range [0～99%].
- S ：Speed to dip soldering and away from soldering point, setting range [0～99%].
- DEGREE ：To set rotary angle, setting range[0～99] degree.
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Fully Auto Dip Soldering Machine
Relay or Solenoid Coil Dip Soldering Machine with Vibrator Bowl Feeder
In this fully automatic soldering machine, no manual work is involved, loading-unloading, fluxing & soldering all operations are automatic.
Solder pot is made of titanium material which can hold very high temperature of tin with great life of min. 5 years.
Soldering arm is rotary type which helps to solder with different angles, dip position is accurate, and soldering dip time is also programmable.
One machine can operate with two types of different vibrator bowls, which works independently and unload in different bins.
Features
(1) This automatic soldering machine is dedicated for various types of small transformers and inductors soldering application.
(2) Fully automatic feeding materials, flux dipping, dip soldering and unloading.
(3) This unit is equipped with vibration bowl feeder and operated mainly by air cylinders to drive the system and perform functions of automatic grasp material, fluxing and soldering movements.
(4) Programmable angle rotation for dip soldering.
(5) It adopted with a user friendly control touch panel, functional PLC control, precise servo motor and high quality Pneumatic components.
(6) Allowed custom design according to customer’s special soldering request and specification.
(7) Functional, stable, high efficiency, labor cost saving and simply operation.
Working Video of the Machine
Specifications
| Model | WCE-03VB |
| Operation | Control Touch Panel Interface |
| Control | Servo Motor & PLC |
| Air Pressure | 4-5 kg/cm2 |
| Power | AC220V 50/60Hz ; 3500W |
| Weight | 350kg. |
| Unit Dimensions | 920(L) x 700(W) x 1300(H) |
Main devices/Parts on Machine Description
Amplifier and Fiber-optic:
Supporting the use with fiber-optic.
Function：
When feeding channel is full of product, it will output a signal to the programmable controller (PLC), to execute a material grasp. It can be adjusted to sense the distance of material (close or far distance).
The indicator of orange light is lit if it senses material and will output a signal.
L and D switch uses:
When the switch is on D status, it will output a force status. (If there are no material being close, it will output a signal, when material approaching to the signal output, it will stop output signal), D output is contrary to L output, therefore in normal use, L status shall be selected in status.
Servo Motor:
Distribution box with supporting the use of servo drive, its function primarily handles the material after the grasp on a forward & backward sliding movements, it is fast and accurate in position!
It is driven by a synchronous belt wheel. If there is synchronization between the loose wheel and servo motor shaft position appears inaccurate traverse phenomenon.
Stepping Motor:
It is to drive an up & down movements of a mechanical clamper.
Similarly, there is a screw loose synchronization between wheel and the motor will cause the phenomena of improper soldering (dipping height not even) and grasping the material in leaning position.
Robot cylinder：
Functions of grasping the product, clipping mouth with strip pad to avoid any damage on transformers & copper wire!
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Flux cylinder：
It drives the fluxing cup in vertical movement (up/down). There are two corresponding sensors on all cylinders (except robot cylinder), sensor located at end of cylinder is called “lower limited”, sensor located front of cylinder called “upper limited”.
If cylinder is on movement status, but senor not lit, the machine will stop operation and display an error message.
Solder cup cylinder：
By lifting up solder cup (up/down) to achieve soldering process, it delivers a highly consistent tin solder level on each cycle.
When the solder cup cylinder rises up and the limited sensor lit, the stepping motor reaches to the dipping level of soldering; it then will start counting as a soldering time.
Sweep cylinder (clean dross forward/backward)
It is a round cylinder that drives a sweeping plate to move forward and backward to clean dross before soldering.
When the cylinder extends and reaches to the corresponding sensor (upper limited), it will lit and movement forward stops; then cylinder moves backward until reaching to lower limited on sensor, the movement is completed.
Sweep cylinder (up/down movement)
Same as above
Sensor:
All cylinders of status corresponding to sensors should be lit, otherwise action cannot continue and the failure red text prompts up! Make sure all sensors are on position and light is lit!
Motor home sensor only works when it is back to home position. Return back to home position is to complete a cycle; it ends as “0”. Each positional parameter corresponding to a position, it is an absolute position.
Temperature controller:
Functions with the temperature probe, solid state relays, heat pipe used.
Featuring at AT auto tuning function indication, OUT heating output indications, AL temperature reaches & output signal, PV current tin solder pot temperature display, SV set temperature display.
Wiring/distribution box：
The description of parts from left to right and from top to bottom in the box as shown on picture, they are the programmable controller (PLC), relays, terminal blocks, solid state relays, fuse holder, power switch leakage protection, servo motor drives, stepping motor drives, switching power supply (stepping motor power, solenoid valve sensor touch screen power).
Filter:
It contents air supply connector and air pressure indicator.
The left side is the air filter chamber, right side for the oil chamber, by adding quality of lubricants can improve the life of the cylinder solenoid valve.
Software Parameters Adjustment
Time Parameters:
Grasp material time: It is a setting time counts only when the mechanical clamper reaches and grabs material from feeding channel (counts time), then return to origin position.
Flux time: It is a time setting counts only when the ceiling sensor on flux cylinder lit, up down motor reaches to the exact height of fluxing level (counts time), when time’s up, motor returns to origin position and flux cylinder goes down.
Release material time: It is a time setting counts for releasing soldered material which waiting for cooled down to release on conveyor belt.
Unloading time: in terms of Conveyor rotation time. It is a time setting only after released material on conveyor belt, and stepping motor returns back to origin position, the conveyor will start rotate.
If the parameter is 0, the conveyor belt does not rotate.
Feed sensor time: When the product is fully packed in feeding channel, optical sensor will output a signal (amp orange lights), start delay until stepping motor comes down to pick up material.
No angle solder time: The rotary motor does not perform an angle rotation; it directly goes down to the soldering position, and then pauses. Time counting starts.
Clockwise soldering time:: It is a time setting counts when the rotary motor goes clockwise direction then down to soldering position, pause and time counts.
Reversal of soldering time:: It is a time setting counts when the rotary motor goes reversal/ anti-clockwise direction then down to soldering position, pause and time counts.
Speed Parameters:
Grasp material up/down speed: Control the moving speed of stepping motor going down to pick up material & returns back to original position.
Release material up/down speed: It is to control the moving speed of upward & downward to release material on conveyor belt.
Flux up/down speed: Control the moving speed of stepping motor going up and down to dip flux.
“A” soldering speed: For feeder of “A” product, the moving speed from origin position to soldering position. And it also to control the moving speed away from soldering point.
This is the same as applying to “B” product setting as above.
“A” separate speed: It is a leaving upward speed movement control after dip soldering position.
This is the same as applying to “B” product setting as above.
Turn rate of grasp material: It is a returning backwards speed movement control to the station of grasp material.
Rotation speed: Control the moving speed of rotary motor turning and returning to origin position
Traverse speed: Control the moving speed of the distance from the grabbing material station to the flux station, soldering station and material release position respectively.
Traverse soldering speed: Control the moving speed of the distance from the flux station to the soldering station.
Traverse material release speed: It is to control the moving speed from soldering position to material release position.
Vibrator Bowl Installation & Adjustment
Place the stand on a flat and stable floor. (if stand included)
Place the vibrator on the stand, set and level the height corresponding and fit to the bobbin feeding chute by adjusting the screw legs.
Connect the power to the vibrator and fill bobbins into it.
Turn ON power and see it is working and delivering bobbin to the chute.
Adjust carefully the connection at feeding outlet to chute. (If it is not well adjustment, bobbins cannot be delivered smoothly to the chute)
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Other Models of Automatic Dip Soldering Machines
-
Fully Auto Dip Soldering Machine (Conveyor Belt Type)
- Applicable for Vertical or Horizontal or Relay component soldering work
- Fully automatic conveyor feeding material, auto flux dipping, auto dip soldering and auto unloading
- Different type of product may only need to manually adjust bezel of conveyor for compatible feeding, no extra fixture or mold required
- Programmable angle rotation for dip soldering
- Custom design according to customer’s special soldering request and specification
- Functional, stable, high efficiency, labor cost saving and simply operation.
2. Six Stations Auto Dip Soldering Machine
- Applicable for Vertical or Horizontal or Relay component soldering work
- Auto dross clean, adjustable for soldering height
- Programmable setting for daily or week production schedule
- Heater pipe is a single unit and can be easy exchange & maintenance
- Two times solder per cycle, timer setting for dipping (solder cup raise up)
- Adopted with titanium solder pot, sustains high temperature, max 600 degree
- Addable testing or pressing function for DC fan coil or FBT low V coil
- For relay, pin bending and 90 degree bend back can be added
3. Four Stations Auto Dip Soldering Machine
- Applicable for Vertical or Horizontal or Relay component soldering work
- Auto dross clean, adjustable for soldering height
- Programmable setting for daily or week production schedule
- Heater pipe is a single unit and can be easy exchange & maintenance
- Two times solder per cycle, timer setting for dipping (solder cup raise up)
- Adopted with titanium solder pot, sustains high temperature, max 600 degree
4. PLC Auto Dip Soldering Machine
- Selectable for an angle soldering process
- Adopted with PLC controller system, it can store up to 99 sets of memory, each memory can be set up to 10 parameters memory harmony with stepping motor
- One program can position 3 steps function, each step can have a setting for:
1). Angle setting
2). Dropping height setting
3). Pre-heat time setting
- For horizontal coil, angle one side position for solder, and then angle other side for solder, then parallel, finally dragging soldering.
- Equipped with titanium solder pot, temperature control, reduce tin oxidation, and heater pipe is a single unit and can be easily exchange for maintenance.
5. Auto Dip Soldering Machine (Fixture Down Soldering)
- Applicable for Vertical or Horizontal or Relay component soldering work
- Auto dross clean, adjustable for soldering height
- Programmable setting for daily or week production schedule
- Heater pipe is a single unit and can be easy exchange & maintenance
6. Lead-Free Titanium Dip Solder Pot (Porcelain-zed crucible coating)
Working Video of Manual Solder Pot
Specialization in Dip Soldering
We have specialization in dip soldering for all transformer coils, relay type component, solenoid coils, high frequency transformers, SMPS coils etc.
With 10 years of experience in this field, we have installed many machines semi auto and fully auto in reputed companies in all over India with great customer satisfaction on quality and production.
Relay Solenoid Coil Dip Soldering Machine Manufacturer India
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