Machine for Soldering and Electrical Testing

Challenge

The challenge was to design and develop an automated machine capable of assembling and testing electrical terminals efficiently, ensuring high precision and reliability. The solution needed to integrate multiple processes, including soldering, mechanical pull test, and electrical continuity verification, all within a compact cycle time.

Implemented Solution

We implemented a turntable machine with four operational stations, each dedicated to a specific step in the process:

ST1 – Loading/Unloading/Dispensing: Manual loading and unloading of the models followed by automatic dispensing of tin paste.
ST2 – Soldering: Automatic manipulation of Terminals and Heat soldering process.
ST3 – Pull Test & Plastic Riveting: Mechanical testing of the soldering quality followed by plastic riveting to secure the components.
ST4 – Electrical Continuity Testing & Soldering Protection: Electrical continuity tests are carried out, and a UV-sensitive liquid is applied to protect the solder, solidifying under ultraviolet light.

With a cycle time of 30 seconds, the machine ensured smooth transitions across all stations, improving both the efficiency and reliability of the process.

Results

The final solution delivered a fully automated assembly process, drastically reducing manual intervention and error rates. The machine achieved the required 30-second cycle time, ensuring efficient production while meeting stringent quality standards. The incorporation of UV-sensitive liquid solder protection further enhanced durability and ensured long-term reliability of the electrical connections.