Highly-flexible & modular THT soldering in PCBs with MODUL4R
As global manufacturers face increasing pressure to produce more customized, available on-demand products while maintaining efficiency, flexibility has become one of the most valuable assets on the factory floor. Yet in highly specialized processes such as automated Through-Hole Technology (THT) soldering, adapting production to constant changes is where things get complicated.
The MODUL4R project is helping to change this. At Swiss Smart Factory, in Biel, Switzerland, one of our four use-cases, we validated the project’s solutions on an automated Through-Hole Technology (THT) soldering machine for Printed Circuit Boards. Our solutions permit the rapid reconfiguration of the machine’s capabilities and make production changes simple with minimal human involvement.
The THT soldering machine, which consists of four modular systems, can now switch between different production scenarios. Individual machine components can be repurposed to meet new production requirements, while specific components can be used independently when only part of the machine's functionality is needed.
The machine's process management is coordinated through the CPS-izer, which gathers and manages data from multiple machine assets. The CPS-izer transmits data to a MQTT broker for data treatment and use, and then adopts the process based on specific production requirements. This intelligent orchestration allows the system to automatically adapt machine behavior according to product characteristics and process needs, creating a more responsive and modular manufacturing environment.
On the left: Real time machine data on CPS-izer. On the right: process handling on the CPS-izer.
Beyond operational flexibility, MODUL4R also provided simulation tools for hands-on applicable scenarios on how to optimize processes without time consuming trial and error. While the data use and analysis solutions, helped the team to analyze interactions between machine components and better understand if factors such as vibrations and robotic movements affect them because of the lack in accuracy in XPlanar movements.
Simulation of the THT soldering machine.
Automated THT soldering processes have traditionally limited flexibility due to their complex nature. MODUL4R’s solutions show the potential to create flexible processes in this field. The machine's modular design also makes it possible for individual modules to be exchanged as needed, extending its applicability beyond PCB soldering and opening opportunities for deployment across a wide range of manufacturing environments.
THT soldering machine at SSF.
