​Hot Bar Soldering Machines - Alternative Technique!

​​Our theme


​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.

​​Our answer

​Hot Bar Soldering Generator BG-350

  • ​Techni​cal ​Specifications
  • ​Limits BG-350
  • ​​Individual Components
  • ​​​Important Info

​Soldering temperature

max. 400°C

​​Warm start temperature

max. 120°C

​​​Pyrolysis temperature

max. 550°C

​Compressed air for cooling

max. 6.5 bar

​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.

​​Wear of the thermodes by the electrolysis
process of other manufacturers at thermodes voltages above 1.5
volts

​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.

​​​Heat sealing

​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!)

​​Some thermodes of special customer projects. Thermode change is relatively easy.

​​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
cycle time.


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

  • ​​Thermode exchange: 30 to 60 seconds
  • ​Heating time: from 20 ° C to 300 ° C in 0.5 seconds

​​The soldering head and the soldered parts are cooled quickly and reliably with compressed air. For this purpose, the system has two adjustable
cooling tubes.


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.

 

​Features

  • ​​Table system
  • ​​Compact work system
  • ​​Two-hand operation
  • ​​System open on both sides
  • ​​Short cycle time: insertion time + approx. 6 seconds, soldering time + cooling time
  • ​Warm start
  • ​​Dimensions B: 40cm D: 30cm H: 50cm

​​Built-in BG-350:

​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

  • ​​Robust construction
  • ​Adjustable illuminance
  • ​Open to the front - protected to the rear
  • ​Large rear work area
  • ​Very clear operation
  • ​​Top design

​​Rear view with closed protective cover during operation

​​Rear guard open for service and setup work

​Features

  • ​​table system (​underframe optional)
  • ​Double drawer system
  • ​Fast insertion time possible
  • ​cycle time: approx. 6 seconds, insert time <= 6 seconds

​​

  • ​warm start
  • ​Cycle and production time monitoring
  • ​Suction system
  • ​Dialogue via 4-line display
  • ​Dimensions B: 100cm D: 90cm H: 90cm
  • ​Connection: 240V/16A compressed air: 6 bar

​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

  • ​Fastest product change during ironing
  • ​Multiple tool holders can remain permanently mounted
  • ​Convenient and fast operation
  • ​Clear controls
  • ​System with underframe

​​Features

  • ​Worktable system
  • ​Two-button operation
  • ​Each position of the table lockable
  • ​cycle time: approx. 6 seconds + working time
  • ​Multiple material can remain spanned at the same time
  • ​Also suitable for sample construction
  • ​Dimensions B: 100cm D: 60cm H: 90cm
  • ​Connection: 240V/16A compressed air: 6 bar

​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

  • ​​Full freedom of movement through the combination of an industrial robot with our patented brazing technique!

​BLR-100: Basic unit with industrial robot

​operation ready complete module

​​Features

  • ​Closed work cell
  • ​Automatic start
  • ​Each position of the table is reachable
  • ​cycle time: approx. 6 seconds + insertion time


  • ​Flux application optionally possible
  • ​Conveyor belt, rotary table, drawer possible
  • ​Dimensions B: 160cm D: 170cm H: 195cm
  • ​Connection: 400V/16A Compressed air: 6 bar

​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.


​Production lines

​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.


​Example of an automatic soldering machine with material supply, cleaning, camera inspection, soldering, electrical testing, bonding and UV curing

​​​Custom-built systems

  • ​Own design department
  • ​​Modern metal production
  • ​​​Implemented at short notice
  • ​Process know-how and design experience of 40 years