DTS-100 is an automated in-line tinning system for a wide range
of components such as DIPs, SIPs, most configurations of SOICs and
PLCCs and for power devices such as TO-220, TO-247, etc. Component
grippers are designed to handle devices in singulated form, but
it is also possible to specify conveyor set-ups that will handle
a wide variety of components in strips or lead frames.
It is also
especially suited for soldering Coils, Bobbins, small Transformers
and similar components which require simultaneous insulation stripping
and soldering and may be placed in-line with coil winding equipment
and output to test equipment, or set up to meet other interface
optional CF continuous feed conveyor is equipped with special
grippers, with multiple titanium blades, designed to handle components
fed continuously into the system, without the requirement for
singulation at the input. This system is suitable for high throughput
processing of a wide range of radial lead components, such as
SIP, TO and other power devices.
system is typically used to comply with the solderability and
cleaning requirements of MIL-STD 2000, MIL-PRF-19500, MIL-PRF-38534,
may be specified to run lead-free alloys with little or no equipment
modification. To convert existing machines to lead-free requires
only a change in solder module to avoid contamination.
is comprised of a central processing module and may be equipped
with several input and output handling options, depending on the
user's requirements. The system may be placed in-line with trim
& form, inspection, or other equipment to reduce or eliminate
In the standard
configuration the process is as follows:
The central processing module is a completely enclosed welded
tubular steel structure. Sliding glass panels are provided in
the front and rear of the system so the process may be easily
viewed and monitored. Vent stacks are located along the top of
the system. The standard system has a footprint of 67" long by
34" wide by 77" high (1702 x 864 x 1955mm). It includes a component
conveyor, a wave fluxing module, a preheating module and a wave
is equipped with explosion-proof interior lighting, giving good
visibility in the process area. Spill trays with drains under
each module facilitate clean-up and maintenance.
are located above the process modules on the upper panel. These
include Emergency Stop buttons at each end of the system and Alarm
Reset switches. Controls and indicators for Service Utilities,
Conveyor Control, Alarm Status and specific module control settings
are also located on these panels.
Door and Window
interlocks prevent operators from accessing the interior of the
system during processing. The standard door interlock package
provides interlocks on all doors covering electrical power cabinets.
The standard window interlock package provides interlocks on all
sliding windows covering the main processing module.
The variable speed component conveyor has a range of 0 to 30 feet
per minute (0 - 9.1 m/min). The standard conveyor comes with 6
component carrying grippers per foot of conveyor chain. This gives
a typical throughput of 7,200 components per hour (based on 6
grippers/ft and conveyor speed of 20 feet per minute). Depending
on the process requirements and the gripper design, the system
can be optionally equipped with 8 or 12 grippers per foot, increasing
the typical throughput to 9,600 - 14,400 components per hour.
It is also possible to process components in lead frame strips,
giving throughput rates as high as 75,000 parts per hour, depending
on component size.
design of the gripper assemblies with custom fingertips allows
them to hold the components by the body. This feature allows for
in-line processing of the components and ensures part-to-part
repeatability. The conveyor chain and cam-actuated gripper assemblies
are all constructed of stainless steel to prevent corrosion by
flux fumes from the process. The snap-fit fingertips, designed
so they can be changed quickly, are made from titanium which has
good corrosion resistance and is non-wetting.
safety guards with clear acrylic windows are provided to enclose
the conveyor and fingers at each end of the system.
Module: The fluxing module has a wave flux pot constructed
of PVC. The height of the flux wave is adjusted by a thumb wheel
potentiometer which controls a variable-speed D.C. motor pump.
Air knives are used to remove excess flux thereby eliminating
solder splash and solder balls during the soldering process. A
drain is provided, as is overflow protection. This allows for
speedy clean-up at the end of the work schedule, or rapid changeover
if more than one type of flux is being used. This module can accommodate
all standard flux types.
Module: The solder module has a stainless steel solder pot.
The solder pot rolls in and out by means of a lead screw to facilitate
position adjustment and access for maintenance. A positive stop
ensures repeatability when returning to the operating position.
The pot has a thermally protected D.C. motor driven pump, which
provides precise wave height control in the solder nozzle, adjustable
via thumbwheel potentiometer. Standard or optional custom designed
wave nozzles are available.
is equipped with a digital temperature controller with high and
low temperature alarms (audible and visual). A low solder level
alarm is also standard. The system uses two non-contact heaters,
which uniformly heat the walls of the pot, thereby minimizing
the danger of an eruption during the warm-up phase. Corfin's dual
chamber pot is designed to draw solder from the base of the pot,
eliminating dross recirculation through the wave
System: The solder pot is equipped with an inert gas enclosure
around the solder wave, with stainless steel gas diffusers that
provide a non-turbulent protective gas cover over the wave. The
controlled atmosphere reduces dross formation on the solder wave,
promotes wetting and ensures uniform solder coverage of the component
leads. The process of solder coating component leads is greatly
enhanced by the inerting process, with the virtual elimination
of icicles and flags. A stainless steel shroud that covers the
rear of the solder pot, including the pump area, is injected with
inert gas to reduce the formation of dross and black powder from
the pump shaft. Consumption of solder and maintenance times are
greatly reduced by the inerting system.
of optional process modules is limited by available space in the
central frame. They may also replace standard modules, with appropriate
price adjustment. Consult Corfin for details and pricing of the
process configuration best suited to your specific requirements.
Feed / Level Control: A flux reservoir bottle is housed in
the base of the machine, with a pump that feeds the fresh flux
to the main fluxer tank. A level sensor in the tank provides the
signal to the pump, ensuring that the flux is maintained at the
correct operating level. The bottle is easily accessed through
the doors in the base for quick and clean changeover.
Control System: The flux density control system automatically
adds the necessary amount of flux or thinner to maintain the specific
gravity setpoint, as well as the correct liquid level in the flux
tank. The fresh flux and thinner containers are housed in the
base of the machine, with pumps that feed flux or thinner to the
main fluxer tank, as directed by the flux density controller.
The FDC unit also has a built-in temperature sensor, with a compensation
feature to ensure correct density at different operating temperatures.
The flux density
controller incorporates the features of the Auto Flux Feed / Level
Solder Module: For certain alloys and processes, higher than
normal operating temperatures are required. A specially treated
stainless steel solder pot, pump and nozzle assembly are available
for operating temperatures in excess of 650oF (343oC). This option
is also required if lead-free alloys are used in the process.
Module Auto Jacking System: The solder module is mounted on
a heavy-duty motorized jacking system, which raises and lowers
the module through a range of approximately 2.5 inches (65 mm).
In the event of a machine stoppage, which would normally result
in the main conveyor beam lifting clear of the process modules,
the solder module will instead jack down so that the solder wave
is below the component leads. Other process modules such as flux
wave, etc will switch off. The system can then resume operation,
without requiring manual intervention to clear components from
the input and output areas. The raise/lower function of the main
conveyor is still available, but is selected only when required
by the operator.
Exhaust Module: The supplementary solder exhaust module is
located directly at the solder wave area and extracts fumes as
soon as components touch the solder. This minimizes the spread
of fumes through the interior of the machine and is recommended
when solder coating large surface areas, which may generate excessive
Cam Over Solder Pot: A cam over the solder pot increases the
exit angle thereby guaranteeing uniformity of solder coverage
and no bridging on horizontal leads. Note: The exiting cam cannot
be used with the CF conveyor option.
Solder Wire Feeder: This unit draws solder wire from a 44
lb (20 kg) spool. When a signal is received from a fixed probe
at the surface of the solder, the DC motor/wire feeder drives
the required quantity of solder wire through a guide tube into
the solder pot. The probe is positioned to maintain a constant
pre-set solder level. The unit is self contained and functions
Feed Conveyor: The CF continuous feed conveyor is equipped
with special grippers, with multiple titanium blades, designed
to handle components continuously fed into the system, without
the requirement for singulation at the input. This system is suitable
for high throughput processing of a wide range of radial lead
components, such as SIP, TO and other power devices.
speed component conveyor has a range of 0 to 30 feet per minute
(0 - 9.1 m/min). The stainless steel and titanium gripper assemblies
link together through the process to form a continuous carrier
that ensures accurate and reliable pick-up of components. Depending
on the process requirements and the component size, throughputs
in excess of 45,000 parts per hour are possible.
solder module jacking option is recommended when the machine is
equipped with the CF conveyor.
Output Handling: A range of manual and automatic handling
equipment allows the user to choose the degree of automation that
best suits the application. The input / transfer module accumulates
and singulates the components for pick-up by the conveyor. This
may be fed manually or interfaced with the automatic or semi-automatic
handling options offered by Corfin, or with other third party
handling equipment. Similarly, at the output end, the transfer
discharge module can be interfaced with different handling options.
The input and output can be set up to automatically load/unload
using tubes, trays, bulk, etc, or any combination required. Request
further information from the Corfin. Some of the options offered
by Corfin are as follows:
/ Transfer: Accumulator and Singulator: The input module is
designed to accumulate components received from the loading module.
It then singulates these components as they move onto the transfer
conveyor. This transfer conveyor is synchronized with the finger
assemblies on the component conveyor. This method of device transfer
allows us to handle a number of different length components with
no changeover required. Input modules are designed and available
for most standard device types and widths. Transfers will vary
according to component types and widths.
the optional CF continuous feed conveyor, singulation of the devices
is not required.
/ Transfer: Transfer and Discharge Assembly: The Output Module
receives the devices from the component conveyor and transfers
them to the unload module. It also counts the devices to ensure
an accurate number is loaded into each tube or tray. Output modules
are available for most standard device types and widths.
Tube Handler: 2 Position Star Index: This option provides
semi-automatic feeding into the input/transfer of the DTS system.
The operator places two full tubes into the star-index loader.
The loader is then moved in line with the feeding slide to the
tinning system and the tube empties. When the first tube is empty
the operator manually moves the star indexer to position 2, and
while this tube empties replaces the first tube with a full one.
This operation is repeated as each tube empties.
Tube Handler: 2 Position Shuttle: The shuttle is interfaced
with the output/transfer to provide semi-automatic loading of
the processed parts back into tubes. When one tube is filled,
the operator switches the shuttle to an empty tube. While the
second tube is filling, the first is removed and replaced with
an empty tube, and the process repeated.
Insert Sets: The star index loader and unload shuttle come
equipped with a set of inserts (4), dedicated to a tube/component
type. To change over to a different tube/component type requires
only changing the inserts, supplied as a set of four.
Tube Handler: The handler takes tubes from the magazine and
automatically advances them into the loading position. Tubes are
then indexed to the emptying position, and the components slide
out of the tube into the input/transfer of the machine. When the
sensors indicate that the tube is empty, it is ejected and a new
tube is brought into position. At the output end, a similar operation
takes place with empty tubes being retrieved from the magazine,
and filled with processed parts delivered from the output/transfer.
The handler is customized to accomodate the user's tube and component
type(s), and is controlled via the machine's PLC. This system
provides for continuous operation at high throughput rates.
Tray Loader / Unloader: The 15 tray automatic loader consists
of two magazines, each with a 15 tray capacity. Full trays are
loaded into the one magazine; after the components have been offloaded
for processing, the empty trays are transferred into the second
magazine. A tilting table, located between the two magazines,
aligns the tray with the input/transfer. As the tray is indexed,
each row empties its components into the transfer slide. At the
output end, the system can be equipped to feed the processed parts
automatically back into trays, or may be equipped with tube, or
other handling equipment depending on customer requirements.
Covers and Locks: Transparent acrylic panels can be installed
with locks to restrict access to any of the process controls on
the overhead panels. Strategic cut-outs in the panel can permit
operator access to customer specified controls.
Set of Instruction Manuals: The hard-copy operating manual
for the system is normally supplied in two 3-ring binders; one
with the operating and maintenance instructions; one with a full
set of bills, assembly drawings, and electricals. This option
provides a full duplicate set of binders.
Electronic Manual: The operating manual, with full system
bills of materials, assembly drawings, and electrical schematics
are supplied on CD-ROM allowing loading to standard PC. The electronic
manual has internal "links" for ease of access. Any part of the
manual, including drawings, can then be printed out if a duplicate
copy is required.
Kit: The spares kit is recommended to ensure that first line
spare parts are available at customer location. The 5% of system
cost guideline is normally sufficient to ensure a comprehensive
range of essential spares.
are built into the DTS systems and are clearly outlined in the
system's complete operating manual.
visual alarms are standard on the system to monitor the levels
and temperature in each module and report any fault conditions.
The operator may stop the audible alarm using the alarm reset
button, however the visual alarm will continue until the fault
condition is corrected.
If the conveyor
is stopped for any reason while processing components, the entire
conveyor assembly automatically lifts clear of the process modules,
eliminating the potential for thermal or chemical damage to any
components that are in process.
system with interlock ensures that all process fumes are evacuated
from the machine. Where appropriate, local venting at the process
modules supplements the overall evacuation of the process chamber.
· Door and
window interlocks protect the operator from electrical hazards
and from moving parts in the process chamber.