Product category:
Electronics manufacturing: quality control equipment, software
News Release from: DMI International | Subject: Adjustable Spring Loaded Plungers
Edited by the Manufacturingtalk Editorial
Team on 12 September 2003
Top hats stop PCB components riding the
wave
Adjustable spring-loaded plungers incorporated into a top hat design, that snaps on and off in an instant, avoids components floating when wave soldering PCBs.
Today's PCB (Printed Circuit Board) assembly engineers are often overworked, underpaid, underestimated, and unappreciated for their accomplishments and contributions Faced daily with a multitude of problems which may or may not include time schedules, cost overruns, machinery problems, employee problems, customer demands, company demands, spousal demands, and yes, personal demands, it's a wonder that anything gets done at all
This article was originally published on Manufacturingtalk on 13 Jun 2003 at 8.00am (UK)
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Well, I don't know if that statement is true or not, but for (at least) one circuit board assembly problem, there is a new and innovative solution.
Component(s) floating during the wave solder process is a fairly common problem, generally caused by the wave height being too high and the components being too light.
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Usually, high wave height is the result of forcing solder into tiny apertures, trying to get the solder to stick; light components being the result of engineers trying to out do each other when it comes to size, weight and ability of components.
Today's ever evolving search for smaller, lighter, and faster components demands these upgrades, a problematic situation that adds to the already long list of problems that PCB assembly engineers must deal with on a regular (if not daily) basis.
Being that DMI International is in the business of producing wave solder fixtures, many process engineers tend to share their 'frustrations' directly and openly with us in the hope of finding a relatively painless (and inexpensive) solution.
One engineer did just exactly that when he stated that he not only wanted to hold the components down during the wave solder process, he also wanted to be able to adjust the spring tension (or pre-load) as well for each of the varying components on the PCB.
His desire in accomplishing both objectives simultaneously culminated in the expressed aim of applying just enough spring tension to hold the component in place while avoiding any excessive tension that may cause bowing or seepage around the apertures of the wave solder pallet.
Also of paramount importance and concern was the quick and easy installation of such a device in relation to the wave pallet PCB loading and unloading process.
As a direct result of this particular engineer's unique problem, DMI International has developed a way to incorporate Adjustable Spring-Loaded Plungers into a top hat design that snaps on and off in an instant.
The unique tooling solution our team at DMI International created begins with spring plungers being loaded into a hollow bolt.
Each completed bolt module is then screwed into the threaded material of the top hat assembly.
The entire top hat is then snapped onto the fixture over the PCB by using yokes attached to the fixture.
As the top hat assembly is lowered, spring-loaded clips attached to the yokes separate and allow the top hat to be secured.
Once the top hat is installed, the precisely aligned plungers can then be independently adjusted to the desired pre-load condition.
Releasing the top hat assembly from the pallet merely requires the processing technician to push the spring-loaded clips back and raise the top hat away from the yokes.
Once all of the plungers are adjusted to satisfaction, the top plate need only be snapped on or off when loading the fixture with a new circuit board.
The versatility of this combination allows precise positioning over the components, adjustable pre-load of the spring plunger, adaptability to any fixture using yokes with clips around the perimeter of the image(s), and, almost instantaneous installation and removal.
This innovative design can be used over a single component or over any multiple of components.
With this design, other adaptations such as custom made feet, longer or shorter plunger length, heavier or lighter spring tension, or, extra long or short adjustment bolts can be easily accomplished.
Driven by expressed frustrations and desired performance, DMI International's creative thinking and innovativeness outside the "box" originated and refined a solution.
The Adjustable Spring-Loaded Plunger stands alone as a truly versatile tool with infinite possibilities for solving some of the seemingly limitless problems faced by process engineers in today's dynamic PCB assembly and manufacturing Electronics Market arena.
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