Hot Bar Soldering Machines - Alternative Technique!
When Hot Bar soldering, components are precisely and quickly soldered together:
- insert parts (tin depot + ﬂ ux on the connections)
- Parts are pressed together with cold thermode
- Thermode is heated up
- The tin melting creates a eutectic connection
- Thermode and solder joint are cooled down
- Cold thermode lifts off, solder joint is made
We manufacture a wide variety of contact parts, for which we can also offer the right soldering technology. This results in a rational production and a signiﬁcant cost saving for our customers who want to solder circuit boards, displays, cables and other parts.
We are happy to provide advice on your projects.
The initial idea:
When soldering in todays systems voltage currents of about 250 amps, correspond to the heating of the soldering iron. The power is generated in a special power supply and the soldering head is then connected to it with a thick feed line.
This cable has a diameter of about 10mm, is absolutely inﬂexible and the crossing points, such as e.g. clamping connections on the soldering iron, connections to the power supply unit and any transitional connections are all warm, ultimately leading to power losses and leading to cable breaks after a short time.
We wanted a soldering head, which has a ﬂexible supply line, is nevertheless controlled as we know it today, which has no line losses and thus can heat up faster accordingly: The basic idea for our hot bar soldering generator was born.
The main difference:
Unlike other standard systems, we do not need a foil protector for the thermode. These ﬁlms protect on other systems, the on-board electronics and on the other side the wear and tear of the Thermode.These measures are necessary because the ther-modes are operated with voltages of several volts.
Semiconductors switch on at voltages above 0.7 volts and, if necessary, allow currents to ﬂ ow during the soldering process that are not provided in this way and that lead to damage.
In our technology, the thermode voltage is much lower!
The higher thermode voltage in other systems also leads to an electrolysis process associated with the ﬂux. Here, too, due to the increased thermode voltage, this electrolysis is initiated, in which ultimately the thermode in the surface is slightly dissolved and undergoes noticeable wear after multiple soldering.
Hot Bar Soldering Generator BG-350
- Technical Specifications
- Limits BG-350
- Individual Components
- Important Info
Hot Bar Soldering Generator BG-350
< 1 volt
Secondary current (heating)
~ 300 amps
20-300°C in 0.5 seconds
Warm start temperature
Compressed air for cooling
max. 6.5 bar
Central control ZS-200
By means of a start signal, this controller can control and heat up the BG-350 hot bar soldering generator. Setpoint speciﬁ cation and display of the current temperature is carried out via the DB-200 module, which you also need for operation.
Operating voltage 24 V DC
Art.No. 77 2000 0010
Display and control module DB-200
This module has a 4-line plain text display for the status display of the soldering device. We consciously dispensed with a touch screen solution, and the inputs are therefore made via a rotary encoder, which can be operated safely even when wearing gloves.
Operating voltage 24 V DC
Art.No 77 2000 0020
Dialog key DT-200
We have developed this input system to give the machine operator all the necessary brief information. Instead of using a tiring mechanical button, the input is made via a reliable sensor button.
Operating voltage 24 volts
Art.No 77 2000 0030
As with all soldering processes, ﬂux is also required for soldering. When soldering a previously applied tin deposit is melted and ensures a eutectic solder joint. For this purpose, ﬂux should ﬁ rst be applied to one side.
Lot depots, which were made from reﬂowed solder pastes (in the SMD assembly after reﬂ ow soldering), still have enough ﬂux residues that a new soldering process (here soldering) sufﬁciently support - additional ﬂux need not be applied.
We can always solder without insulation foil!
In other system the initiated electrolysis causes problems. In the illustration you can see how an electrolysis in the area of the soldering head starts with other soldering processes and is thereby destroyed.
Other manufacturers therefore allow a ﬁlm to run between the thermode and the solder joint, which unfortunately also lengthens the soldering time due to simultaneous thermal insulation.
This electrolysis can not occur with our technology because our voltage at the thermode are much lower and we also work at a high frequency. In addition to this electrolysis problem results in cable break in the thick copper leads of other systems.
Self-cleaning of the thermodes
In combination with our ZS-200 controller, you can select a cleaning mode in which the soldering 5head switches into a pyrolysis process, heating the thermode to a temperature of up to 550 degrees Celsius. Deposits are charred and can then be removed with a cleaning brush; This happens automatically with some of our standard systems.
This means that plastics can now also be hot-stamped without any problems and thus joined together. In particular, this creates very strong deposits that are eliminated by this cleaning.
Of course, as described above, with our BG-350, you can also bond plastics together or just fuse pins to create a mechanical connection.
For this purpose, we manufacture a wide range of thermode heads, depending on your speciﬁ c requirements, which we of course accompany constructively with you.
Very important: the thermodes
The special feature of our soldering technique is the direct temperature measurement at the thermode. For this purpose, the temperature sensor used is welded directly into the thermode. As a result, the sensor experiences no thermal delay, as is the case, for example, with glued-in or attached temperature sensors.
Lightning fast thermode change
Especially in the industrial use of our soldering technique, there is the advantage that you do not have to remove the soldering head and change over when changing the thermode, because you will change the entire head. The change time is reduced to about 30 seconds and you can continue to produce immediately.
Thereafter, the thermode can be exchanged stress-free on the removed head, if necessary.
(Depending on the application, the service life of the thermodes may amount to a few 100,000 solderings!)
The direct thermode connection
With only one turn, the high output from the soldering generator is fed directly to the thermode.
This results in almost no power losses on the supply line.
Standard system BLS-50
The soldering station BLS-50 is a compact desktop device with which you can realize a series production. The system works with one station and two-hand operation. This allows the system to be open for faster parts replacement. Even long cables can be laid back easily.
The base plate has a pegboard on which different workpiece holders can be mounted. We also offer an optional manual drawer or turntable for the BLS-50. When using the turntable, parts can already be inserted, for example, in the front position, while parts are soldered at the same time in the rear position. This saves cycle time and helps reduce the overall
As with all our systems, you can also change the soldering head very quickly. You only need about 30 to 60 seconds! This means that two different types of thermodes can be used with two soldering heads
to quickly change different products without a large changeover time. (Only one soldering head is included with the machine)
The BLS-50 is operated via a rotary encoder on the front panel. Even with gloves, easy and safe inputs can be made. All information is displayed via a readable LED display.
The pressure of the Thermode can be inﬁ nitely adjusted and the working height is absolutely variable by the use of a compressed air cylinder in the Z-axis.
Robust and fast
The soldering head and the soldered parts are cooled quickly and reliably with compressed air. For this purpose, the system has two adjustable
The system can be run in the „warm start“ mode via the corresponding menu selection, whereby the soldering head is preheated to about 120 degrees C (adjustable), which saves heating time and shortens the cycle time. If no renewed soldering takes place after a set time, the warm start will be switched off automatically to avoid damaging the system. All our systems have a pyrolysis function, while the thermode heats up for a short time up to 550 degrees (adjustable) and burns any existing deposits.
Production system BLS-200
This machine has been specially developed for series production, therefore it also has two drawers: While the parts of the ﬁ rst drawer are soldered in the machine rear, the second drawer can be rearranged at the front. This achieves the shortest possible times for a manual part assembly.
The drawers have a universal drill pattern on which various tool holders can be mounted. The soldering position can be set exactly for each table in the X and Y directions to approach the same soldering positions on both drawers.
The system is open in the work area, thus shortening the workpiece change times. A light panel provides security, our dialog button indicates clearances or hazards. The system is operated via a rotary encoder, which can also be operated with gloves. All information is displayed via a 4-line LED display.
The soldering head automatically changes from the ﬁrst to the second drawer. As a result, the soldering always takes place with the same soldering head.
The pyrolysis function ensures the cleaning of the thermode, whereby burnt deposits are automatically removed by a cleaning brush. A cleaning is done after each soldering cycle through a brass brush. Resulting solder vapors are sucked directly from the solder joint (external exhaust fan required).
Double table system for series production
Small series production UBS-100
This system concept was developed by us in order to make the soldering attractive also in the workshop development and small series range:
A swivel arm allows the positioning of an attached BG-350 bracket soldering tool on each table position. The arm is then locked via three brake discs. So you can now permanently assemble different devices on the work table and approach them manually at any time and ﬁ x the position. At this position now also series can be soldered. This eliminates the time required to manufacture a workpiece carrier precisely and adapt it to the soldering system.
It is also possible to solder individual pieces on this system, whereby longer solder joints can be realized even if the thermodes are too short due to repeated touchdowns.
The soldering head change is very fast as with all our systems. Warm start and pyrolysis are also integrated in this system.
For adjustment, there is a control panel with rotary encoder and an LED display on the work table. The soldering head is operated with two hands and two-key operation directly on the locked head. There is also a button that solves a detected position to set up a new one.
For changing series and quantities
Three brake discs spontaneously stop each set table position:
Ironing robot BLR-100
For networked systems or systems for large throughputs, we also supply solutions with industrial robots. This technique is only possible with our sporty soldering head, because we supply the soldering head with a standard power cable, which makes all movements.
Through this combination not only all positions, but of course all angular positions can be areached. Furthermore, the materials can also be supplied with ﬂux in advance. For this purpose, a ﬂux stamp is mounted next to the soldering head. A greater ﬂ exibility and mobility can not be imagined.
Changing the product is no problem and replacing our soldering head takes less than a minute. Allowing other thermodes can be used.
The system has a modular structure and modules with infeed belts, rotary tables or exchangeable drawers can be used for the material supply.
Normally, the attachment to the basic machine BLR-100 always produces an individual production arrangement, which is not only used for soldering, but also for hot stamping.
More ﬂexiblity is not possible
Integrated soldering systems
In addition to the standard machines listed in this brochure, we also offer any special solution for your requirements. Our focus is always on the implementation of the shortest possible cycle times, so in such systems always a higher-level control coordinates the coordination of all processes. We always plan such systems with large industrial touchscreens.
Thanks to our own design department and modern metal production, we can always implement customer-speciﬁc systems at very short notice. Take advantage of our design experience as well as our process know-how of 40 years.