VERSAFLOW ONE X: High Throughput at Low Cost

As already described, the machine´s throughput can be doubled by adding an additional stopper in the flux, preheat and solder module. The distance between the two stoppers in the conveyor system is a set 400 millimeters. The assemblies are conveyed into the modules one at a time with a slight time delay: When assembly one reaches stopper 1, stopper 2 in that module closes, and the following assembly stops. Once the second assembly has reached its position, simultaneous processing of the two assemblies begins. The stoppers open when processing is complete, and both assemblies are transferred to the free downstream module, where the next processing cycle starts.

The Flux Module: VERSAFLOW ONE X generally has one flux module and comes standard with one multi-drop spray head. A second spray head with its own storage tank is available as an option. If the machine configuration with an additional stopper is selected to increase throughput, the second spray head is also included in the standard configuration. The distance between the two spray heads is mechanically adjustable in the direction of transport. With the “additional stopper” option, the distance is generally set to 400 mm. If the option is not used because an assembly is longer than 350 mm, it can be disabled in the corresponding soldering program. In this case, the machine operator can manually set the spray heads´ distance from 100 to 400 mm, and standard assemblies or PCB panels can be processed. Simultaneous processing is always performed in the X direction, i.e. in the direction of transport.

The Preheat Module: VERSAFLOW ONE X is equipped with one preheat module to warm up assemblies. The heater is installed underneath the conveyor system and consists of IR emitters. Its power can be adjusted from 0 to 100% within several time windows. A top-side convection heater can be added to the preheat module as an option. The additional stopper is also available for the preheat module and works as described above. A further optional feature is the pyrometer measurement of the assembly temperature at both stoppers after the preheating process has been completed. If the assembly´s temperature is outside the set process window, an error message is issued.

The Solder Module: The solder modules of the VERSAFLOW ONE X come standard with two solder pots. A second solder module is available as an option. Thus, VERSAFLOW ONE X provides a maximum of four solder pots to simultaneously process assemblies. The solder pots themselves comply with the VERSAFLOW quality standard incorporating the maintenance-free induction solder pump, solder level monitoring, N2 cover of the solder waves and optional solder wire feeding. The solder pots can be used for a wide range of applications. The variability of the two pots in relation to each other in height (Z direction) and in the horizontal distance in transport direction (X direction) is included as standard. The X distance is generally mechanically set. The distance in transport direction X is used for processing assemblies with the additional stopper option. In this case, the distance between the two solder nozzles is 400 mm. For processing individual assemblies or panels, the distance between the pots can be variably adjusted mechanically in the range from 100 to 400 mm, and the second stopper is deactivated in the soldering program.

The solder pot´s Z variability opens further applications. Due to this feature, the solder module of the VERSAFLOW ONE X can be equipped with two different solder alloys, for example, or with two different nozzle sizes. In both cases, different temperatures can be set in parallel so that temperature-sensitive components such as film capacitors can be soldered at lower temperatures than neighboring inductors with a high heat capacity.