VERSAFLOW ONE X
VERSAFLOW ONE X
High throughput at low cost
Cost pressure and competitiveness pose major challenges for electronics production, where decreasing quantities often come up against an increasing number of variants. Production is increasingly switching from traditional wave soldering to selective soldering processes, as these are more flexible and adaptable.
This advantage is making “selectives” increasingly popular. However, there was a gap – high throughput at low cost for SMEs. The VERSAFLOW ONE was developed to make these advantages accessible to a wider range of customers. As an addition to the Ersa portfolio, it enables entry into the world of inline selective soldering systems at the price of a batch machine. All ONE systems are based on the same functional modules as the large VERSAFLOWs. This makes processes comparable for Ersa customers – whether batch system or high-end system.
Ersa has further developed the successful VERSAFLOW ONE in the direction of high throughputs. With the F series, only one solder pot per soldering module is possible, which can limit throughput in certain applications. The focus of the VERSAFLOW ONE X is therefore high assembly throughput at low cost. Previously, this required a VERSAFLOW 3 or 4 with double-track transport and several soldering modules. The ONE X solution: Two assemblies can be processed simultaneously in one transport system in the available working area of the fluxer, preheater and soldering unit. The working area of the ONE X enables a maximum assembly dimension of 610 x 508 mm (L x W). As such assemblies are rather rare, the working areas of the ONE X can optionally be divided into two separate processing areas. For this purpose, a second assembly stopper is also installed on the transport system in each module. Although this reduces the processable assembly length to 350 mm, the overall throughput is doubled compared to the soldering system without this option. The VERSAFLOW ONE X with one flux and one preheating module as well as two soldering modules can thus process eight assemblies simultaneously – inline with just one transport system.
Throughput doubling with “second stopper”
An additional stopper doubles the throughput of the system in the fluxer, preheating and soldering modules. The distance between the two stoppers on the transport system is fixed at 400 mm. The assemblies are transported into the modules one after the other with a slight time delay. When assembly group one reaches the first stopper, the additional second stopper in the respective module closes and the following assembly group stops. When this position is reached, simultaneous processing of the two assemblies begins in the corresponding module. Once processing is complete, the stoppers open and both assemblies move into the free subsequent module and the next processing cycle begins.
THE FLUX MODULE: The VERSAFLOW ONE X generally has a flux module and is equipped with a multidrop spray head as standard. A second spray head with its own storage tank is available as an option. If the “second stopper” option is selected to increase the throughput, the second spray head is also included as standard.
THE PREHEATING: The ONE X is equipped with a preheating module for preheating the assemblies. The module is located below the transport system and is equipped with quartz radiant heaters. The output can be set in the range from 0 to 100% in several time windows. A convection top heater can be installed in the preheating module as an option.
THE SOLDERING MODULE: The soldering modules of the ONE X are generally equipped with two soldering pots, with a second soldering module available as an option. This means that the ONE X offers a maximum of four solder pots for the simultaneous processing of assemblies. The solder pots comply with the VERSAFLOW standard with maintenance-free induction solder pump, solder level control, shielding gas cover for the solder waves and optional solder wire feed.
With the VERSAFLOW ONE X, Ersa shows that there is still potential in selective soldering technology. The cost-effectiveness of the new product line with high throughputs combined with solutions in terms of networking and digitization is a clear statement to increase competitiveness – especially for SMEs.
Considerations on economic efficiency
The possible throughput of a simulated assembly (300 x 300 mm) with 25 s processing time for fluxing, 30 s preheating and 90 s soldering is considered below. A batch selective soldering system ECOSELECT and the systems of the VERSAFLOW ONE series are considered in the analysis of the assembly throughput.
