Utilizing a robotized soldering process gives following possibilities and benefits:
1. Excellent repeatability and quality of solders – thanks to controlling soldering parameters (listed below) by a microprocessor, every soldered connection has the same shape, volume of solder etc. Robot never makes faulty connections i.e. cold solder or connects two soldering areas placed close to each other. Even such difficult applications as soldering flexible PCBs are executed almost flawlessly. Robot executing soldering program won’t miss any pad. Of course well trained operator with a lot of experience is able to provide high quality of soldered connections, but training of personnel in the field of soldering take a lot of time and money. Additionally, precise soldering is really tiring for a human so quality of his work drops with number of hours works within a shift.
2. Increase of production effectiveness – motion of a robot is faster and more optimal than of a human. Machine is capable to solder continuously 24 hours a day, 7 days per week, doesn’t need a break, doesn’t take a sick leave, doesn’t have to rest. All that ensures much higher efficiency than in case of operators’ work.
3. Possibility of miniaturization of soldered components – with use of the right soldering tip, a robot is able to solder miniature components. Thanks to high precision, soldering areas can be located close to each other. These features allow miniaturization of whole product.
4. Possibility of controlling soldering parameters – controller Zeus adjusts all parameters of soldering (listed below), thanks to that the process is perfectly adapted to given application. If a need arises , there is a possibility to modify online the parameters on the level of HMI of the robotized station. Thanks to dedicated technological packet Zeus for KUKA robots all soldering parameters can be changed and set directly through robot’s controller – in programming phase as well as in production phase. Precise adaptation of the parameters is especially important during lead – free soldering and in applications, in which soldered elements are close to each other and/or of small size.
5. Possibility of soldering in protective atmosphere i.e. nitrogen – in the process of lead – free soldering, it’s advised to use protective atmosphere of a neutral gas. Zeus controller has a built – in valve for steering the flow of nitrogen. Benefits of utilizing a protective atmosphere are: lower solder oxidation, and extended lifespan of soldering tip.
6. Constant efficiency – soldering robot executes operations with constant “takt time” so it’s easy to calculate efficiency and more importantly keep it at on a constant level.
7. Considerable decrease of the number of defective products – excellent quality described in point 1. brings along reduction of production waste. Elimination of manual transport and handling of delicate components ( i.e. PCB ) in robotized soldering process additionally reduces risk of creation of defects.