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| Product brochure - Integra 503.4 | Download PDF → |
As the core of the soldering line, where the Integra offers plenty of room for automation and expansion in the era of Industry 4.0.
A processing area of 508 x 508 mm leaves many options open. With the various processing modes, throughput can be significantly increased.
The Integra Series meets all requirements. The required throughput determines the configuration of the system.
Designed for inline use in medium to high-volume production, our Integra Series offers flexibility and scalability. Fluxing, preheating, and soldering occur in separate zones within the system. The 508.4 model has an additional soldering zone. Depending on PCB size and required throughput, various modes can be selected (Single – Double – Parallel). In its fully expanded form (Model 508.4), the system can accommodate up to 4 solder pots. Thanks to its modular design, the system can be ideally tailored to meet the customer’s throughput needs. The Integra Series boasts numerous unique features and is available in two variants:
The configurability of the Integra Series makes it an extremely flexible and fast selective soldering solution. The large processing area, with a maximum PCB size of 508 x 508 mm, forms the basis for the adaptability of the system. This maximum product size can be processed either in Single Mode, with just one solder pot, or in Double Mode, with two mini-waves, which can also be configured with different nozzle sizes. The PD mode can be used for PCBs up to a maximum size of 350 x 508 mm, allowing two products to be soldered simultaneously on a 2-segment conveyor, doubling the system’s throughput. With its modular design (1 and 2 soldering zones) and selectable processing modes in conjunction with the 2nd segment conveyor, the Integra is the flexible solution ideal for medium to high-volume production. If you require even higher throughput or lack the space for the desired model, we recommend considering our Synchro system.
Numerous variables affect the selective soldering process. Therefore, monitoring and controlling quality-relevant parameters are crucial for reproducible soldering quality. Besides flux and tin levels, wave heights, PCB warpage, flux application, and preheat temperature are primarily decisive for soldering results. For some applications, marker recognition is also essential. Regulated top and bottom heating ensure a wider process window and are particularly important for thermal stability. Additionally, a camera provides real-time process monitoring. After extensive testing, the use of titanium solder pots with precision impellers has proven to be both process-safe and maintenance-friendly. This solution also accommodates the growing interest in low-melt solutions (low-melting alloys).
The company’s goal is to produce the required number of pieces in the optimal time with the best Total Cost of Ownership (TCO). Besides reproducible quality and throughput, direct and indirect costs must be considered. Adjustability of flux application and the predetermined tin consumption through layout design are factors, but the essential consumption of nitrogen (for nozzle wetting) and associated costs heavily depend on the required nitrogen purity level. Our systems require only a purity level of 4.0 (99.99% purity). Maintenance effort should never be overlooked in TCO considerations. From the tool-less maintenance of titanium solder pots with precision impellers to operator and maintenance friendliness, attention to detail has always been integral to the development and construction of our systems.
Can the Integra be linked in the line or integrated into a selective soldering line?Yes, that's what the system was designed and developed for. The Integra is an inline system. Together with our smart.e.connect transport and process modules and the smartControl software, you can set up a highly automated selective soldering line or integrate it into an existing line. |
We have to place some of our products in solder frames before we send them through the selective soldering system. However, we could solder most products without carriers. What could your planned soldering line look like?Of course, you first have to look at the quantities and the products. For many of our customers, a combined solution - and that's what you sound like - is the ideal option. This line has lift modules for the workpiece carriers as well as loaders and unloaders for the PCBs. |
What automation options do you have with your systems?All of them! Depending on the product and quantity, we can design the ideal soldering line for your selective soldering tasks. The degree of automation should always be based on an ROI analysis. This means that the investment in a production line and the degree of automation should be amortized within a reasonable period of time. |
Do our systems require nitrogen and what purity is needed?Yes, nitrogen is required for the selective soldering process. What sets us apart from our competitors - with all our selective soldering systems - is that we only need to achieve a purity of 99.99, which corresponds to purity grade 4.0. The savings compared to 99.999 (class 5) are striking. A separate nitrogen generator for the systems is therefore often the more cost-effective solution. |
Do you also sell the right nitrogen generators for your systems?Yes, we specify the optimum solution for you - as much as necessary, as little as possible. |
When is the Integra and when is the Synchro useful?The Intergra is the perfect inline soldering system for medium to high quantities. With two models and the option of synchronous or parallel soldering, the range of applications is very flexible. The selection of the ideal configuration depends on the product, quantity and cycle time. The Synchro comes into play when either very large PCBs are to be produced, the cycle time of the Integra 508.4 is not sufficient or there is a space problem in production. |
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