Kontron eSystems expands its machine park with a 33 m line! Wave Soldering

However, this is not the first project for Kontron eSystems and Ersa. The two companies have been collaborating since 2018. As part of a joint manufacturing project, they installed an Ersa VERSAFLOW 4/55 selective soldering system featuring a notable concept for automated line peripherals.

It was clear even then that Ersa´s equipment solutions were an excellent fit for Kontron eSystems´ demanding requirements in quality, process performance, and system integration. As product diversity increased and expectations for stable processes and manufacturing complexity grew, the need arose to expand and further automate existing soldering operations. As part of that expansion, the Ersa VERSAGUIDE played a key role. This system provides operator guidance and process support which ensures process efficiency, repeatability, and quality assurance at the highest level.

Matthias Baurath, Plant Manager at Kontron eSystems, summarizes the project in a nutshell: “By expanding our production capacities, we pursued our vision of further automating and digitizing electronics production and making it future-proof in the long term. The goal was to supplement existing processes with a powerful, flexible, and data-integrated soldering line that entirely meets our high quality and traceability standards.”

Project success through coordinated IT deployment

Ersa impressed as a strong partner with a holistic approach. In addition to their technological expertise in wave soldering (POWERFLOW) and inline selective fluxing (POWERFLUX), Kontron´s IT department provided significant support that contributed to the project´s success. Close coordination between the IT teams of both companies ensured optimal system integration and interface connectivity, an essential step toward a highly automated, networked smart factory. During the planning phase, intensive discussions took place to tailor the line configuration precisely to Kontron´s specific process requirements. Specifically, this involved an application in the field of e-mobility. The analysis clearly recommended using a wave system. In this context, the peripherals were worked out in an extensive joint process, which was extremely challenging.

“As has since become apparent, our other products also run on the new production line. We are therefore taking this opportunity to significantly reduce the load on the existing line,” says Olaf Arnold, Team Lead of SMT/THT Technology at Kontron eSystems. “With its soldering module, the POWERFLOW ULTRA is ideally suited to the requirements – it combines unique process control with maximum flexibility. Thanks to its innovative drive, which can travel at speeds of up to 5 mm/s, and precise software control, the nozzle distance and solder wave height can be adjusted precisely to the assemblies to achieve lead-free soldering processes of the highest quality. Our wave is even more powerful thanks to the 3-meter preheater installed here, which transfers a large part of the required soldering heat,” adds Ersa Area Sales Manager Mark Birl.

The Ersa VERSAGUIDE 2.0 digital worker assistance system played a special role in the project by intuitively guiding the operator through all process steps, ensuring reproducibility and providing maximum process stability. Compared to earlier versions, the 2.0 version has improved performance. The camera resolution is now 10 megapixels, which makes it an even stronger quality factor than before. “Of course, we also have to get the workers on board and communicate the advantages of the new system to them. We are all on the same page, so communication involving all parties is very important. Clearly, a system like this impresses customers and potential new customers alike and helps acquire new projects,” says Olaf Arnold. He adds: “It wasn´t an easy project. But in the end, it was the constructive yet professional friction in the coordination that led to the best solution. This system will take our production to a new level!”

Thanks to the Ersa service team´s expertise and the close coordination of the project, the installation and commissioning of the soldering line went smoothly. The new line was delivered in January, installed in February, and up and running by March. Multi-shift operation will be possible at any time in the future, and 24/7 production is also an option. The strength of the partnership is evident in the ongoing operation as well. Through its continuous service and support approach with fast response times and proactive support, whether on-site or remote, Ersa contributes significantly to high system availability and process reliability. “One thing is clear: we want to produce units – and not just in any way, but in top quality,” summarizes Olaf Arnold. Rainer Krauss, Ersa´s General Sales Director, also draws a positive conclusion: “In a project of this magnitude, both sides must benefit. This can only be achieved through trust, competence, and communication, all of which were present from the beginning of this project. This applies to the ambitious project we just successfully completed as well as to the selective project seven years ago.”

Clear Focus on Smart Quality

Open communication and a clear focus on quality define the partnership between Kontron eSystems and Ersa. Both companies share a vision for networked, intelligent electronics manufacturing that meets the highest standards of process reliability, traceability, and energy efficiency. Thus, Kontron eSystems remains focused on its strategic goal of continuously developing its electronics manufacturing to adapt to future requirements regarding automation, digitization, and process reliability, while optimizing existing production processes and enabling the implementation of new technologies.