Stator tinning is a crucial step in the stator assembly process. Previously, it was done manually or with semi-automated equipment. With technological advancements, fully automated production lines are now commonly used. So, what are the process requirements for automated stator tinning production lines? How can we achieve good tinning results? Vacuz will briefly introduce this below!
I. Process Requirements
1. Accurate Temperature and Time Control
Temperature Range: The tinning temperature needs to be adjusted according to the type of solder. For example, lead-free solder typically requires about 20°C higher than leaded solder. In some scenarios (such as cooling fan stators), the tinning temperature needs to be 380°C~430°C. This requires real-time monitoring using a high-precision temperature sensor and feedback to the control system to ensure temperature fluctuations are ≤±5°C.
Time Control: The tinning time must be strictly set. For example, cooling fan stators require a soldering time ≤2 seconds to avoid copper blistering or component burnout due to excessive time. The time control accuracy needs to reach ±0.1 seconds, which can be achieved through PLC programming or servo motor drive.
2. Automated Material Handling and Positioning
Conveying Mechanism: Utilizing synchronous belts, tooling, or robotic gripping systems to achieve automated stator loading, positioning, and conveying. For example, the stator can be conveyed to the divider turntable tooling via a synchronous belt, or a robot can grip the stator and rotate it 180° for tinning.
Positioning Accuracy: Positioning error must be controlled within ±0.05mm to ensure accurate contact between the pins and molten solder during tinning. This can be achieved through a vision guidance system or high-precision fixtures.
3. Tinning Mechanism Design
Tin Pot Structure: Employing a temperature-adjustable tin pot equipped with an oxygen scraping mechanism and a solder lifting mechanism to reduce solder dross and solder holes. The tin pot needs to be cleaned regularly to remove the oxide layer and avoid affecting soldering quality.
Tinning Method: Selecting an appropriate tinning method based on the stator structure, such as vertical or inclined tinning. For example, a cooling fan stator requires tinning from the pin tip to at least 2/3 of its length to avoid solder dross contamination.
4. Auxiliary Equipment and Environmental Protection Measures
Fumigation Purification: Equipped with fumigation purifiers to reduce environmental pollution from flux evaporation.
Fluorescence Management: Flux usage is controlled through an automated dispensing system to avoid waste and residue. For example, a pneumatic dispensing machine and metering valves are used to control the amount of flux dispensed.
5. Inspection and Quality Control
Automatic Inspection System: Integrates sensors and inspection mechanisms to perform visual inspections (e.g., whether the tinned surface is bright and smooth) and performance tests (e.g., high-voltage testing, insulation resistance testing) on the stator after tinning.
Defective Product Removal: The automatic inspection system must have the function of identifying and removing defective products to ensure that qualified products flow to the next process.
6. Intelligent Control System
PLC Control: A PLC control system is used to achieve intelligent control and monitoring of the entire automated process, including real-time adjustment of parameters such as temperature, time, and conveyor speed.
Data Traceability: Key parameters in the production process (e.g., temperature, time, test results) are recorded to facilitate quality traceability and problem analysis.
II. Methods to Improve Soldering Results
1. Optimize Process Parameters
Temperature and Time Matching: Adjust the soldering temperature and time according to the solder and stator materials. For example, a cooling fan stator requires a soldering temperature of 380℃~430℃ and a time ≤2 seconds; the parameter combination needs to be determined experimentally.
Fluent Selection: Select a flux with moderate activity and low volatility to avoid poor soldering due to flux residue.
2. Improve Soldering Mechanism Design
Solder Pot Design: Use a deep-tank solderer to increase the depth of the molten solder and reduce surface fluctuations during soldering. Simultaneously, equip it with a heating and stirring system to ensure uniform solder temperature.
Solder Pot Optimization: Select a suitable soldering method based on the stator structure. For example, for stators with long leads, an inclined soldering method can be used to avoid lead bending or deformation.
3. Strengthen Equipment Maintenance and Care
Regular Solder Pot Cleaning: Regularly clean the oxide layer and solder dross inside the solder pot to avoid affecting soldering quality. For example, stir the molten solder every 2 hours to ensure the tin-lead alloy is fully fused.
Check equipment precision: Regularly check the precision of the conveyor mechanism, positioning system, and detection mechanism to ensure stable equipment operation. For example, check the wear of the timing belt and the positioning accuracy of the fixtures.
4. Introduce advanced technologies
Visual inspection technology: Through high-speed cameras and image processing algorithms, monitor defects (such as incomplete soldering, cold solder joints, solder dross, etc.) in real time during the tin-dipping process and adjust process parameters promptly.
Laser welding technology: For stators with high precision requirements, laser welding technology can be used to replace the traditional tin-dipping process, improving welding quality and efficiency.
5. Operator training
Skills training: Provide regular training for operators to familiarize them with equipment operation, process parameter adjustment, and troubleshooting methods. For example, train operators on how to adjust the tin-dipping temperature and time according to the stator model.
Safety training: Strengthen safety training to ensure operators comply with safety regulations and avoid accidents caused by improper operation. For example, require operators to wear protective gloves and goggles to avoid burns.
What are the process requirements for an automated stator tin-dipping production line? How to achieve good tinning results? Vacuz has provided a simple explanation above, and we hope this information will be helpful!
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