PCB (Printed Circuit Board) Assembly - Wave Solder Capability

C

Chris May

#1
Dear all,

This is my first post on this forum. (All the way from England)

I have been searching a while for a "meaningful" forum that deals with process issues.......and here you are.

Anyway,
I am looking at a way to monitor the wavesoldering or flowsoldering element of our PCB assembly.

I have been gathering data (simple tick charts) to ascertain failure modes for certain assemblies and the flowsolder machine/process is the biggest culprit.

I have now conducted soldering theory training and practical training to the two operators. This has helped.

I have been here (Horstmann Controls, OEM for heating/metering controls) for about 3 months and had a few quick wins, but I need now to monitor the processes...first wavesolder...then SMD dept (aagghhh).

There are no controls/measures at present for process.

Anyone out there in a similar environment ?
I have done a search on the site to find any useful threads...nope.

I assume that I need to perform a process capability study on the wavesolder machine (!?). (first step)
How would I achieve this? Do I need to take the fluxer, preheat and solder bath individually?

I have visited various sites and downloaded a tree load of info, but nothing that directly relates to electronic assembly/manufacturing.

Thanks in advance for your time,

Best Regards,
Chris May:frust: :frust:
 
Elsmar Forum Sponsor
S
#2
Chris, The wave soldering process is ideal for "design of experimants." The best source I have (had), if I haven;t lost it , came from mcDonnel- Douglas. I' ll check this weekend and if I find it I will fax it to you.
 

Atul Khandekar

Quite Involved in Discussions
#3
Chris,
Welcome to the Cove Forums.

May be a little more info would help.

What type of inspection is carried out? Is there any inspection / rejection / rework after fluxer, preheat and solder bath stage individually? How many opportunities for defects?

-Atul.
 
Last edited:
M

Michel Saad

#4
Previous life !

Hi Chris,

In my previous job, we did wave and SMT soldering. We started by "calibrating" the temperature profile from entry to exit of the wave/furnace and verifying every 6 months to that profile. We monitored daily the temperature setting of the different zones of the wave/furnace. We had flowmeter with alarms for the nitrogen input. PM's did the rest. No control chart since you can't measure anyting without ripping it off the board.

The control was simply a visual inspection at the exit of the wave/furnace according to IPC-610 standards.

Regards,
 
D

Dave W 2005

#5
Chris,

I'm also based in Bristol (maybe same company?) One of the guys I did my blackbelt training with, carried out a project to improve the capability of his wave soldering process (for CCTV camera circuits) - I'll try and get a copy of his report.

Dave
 
C

Chris May

#6
Atul,

In the flowsolder process, the flowsolder machine is totally self contained, so the PCB goes into the load end onto a conveyor. It is then transported over a fluxer (actuated via optic sensors), over a preheat to thermally condition the board and raise it to about 100C prior to the wave and then over the wave itself.

So...after you load the board (PCB) the next time you see it is at the exit end when it is soldered. The "inspection" is then to see if there are any solder shorts/bridges. The defect opps will vary depending upon product, but this is easily counted (say 100 on a smallish board).

Some ideas I have had since my original post are as follows.

FLUXING- This is critical so I am thinking about weighin a bare laminate. Then passing the bare laminate over the fluxer and then weighing this again. On the datasheet for the flux it specifies optimum coverage in micrograms per square so I could get data that way.

PREHEAT- This could be set (and should not be changed) and measured say 20 times a day using a temp probe for a week to get "sample" temps.

SOLDER POT- This could be measured with adip type temp probe as above for preheat.

I think this could give me enough data to start with.

Any more thoughts ??........anyone?
 
W

wing_a

#7
Chris,
We're performing a SS project on wave soldering touch-up reduction. The objective of the project is to reduce solder-related defects (missing solder, insufficient solder, solder bridging, excessive solder, etc) to a stabilized rate of 100 dppm or less. This according to the Handbook of Machine Soldering, by Ralph Woodgate (pp 206-207), is considered zero defect soldering. After conducing the process map, C&E matrix, and FMEA we drew a conclussion that the parameters of the wave solder machine such as preheat temp., conveyor velocity, flux specific- gravity, solder bath temp., etc., play a critical role to the quality of the solder joint. So in the Analysis phase of the SS project we use DOE to screen out and then optimize the significant parameter(s), Fractional Factorial Design for screening and Response Surface for optimizaion. The screening experiments are now in process. And after the DOE analysis, we will perform confirming experiments to ensure the sucess of the analysis. Finally, we will work out a control plan to monitor the wave soldering process based on the DOE analysis.

Hope this help.
Wing
 
Thread starter Similar threads Forum Replies Date
R DFMEA (Design FMEA) on Printed Circuit Boards (PCB's) FMEA and Control Plans 2
C Any CQI-Special Process related to Printed Circuit Boards (PCB)? IATF 16949 - Automotive Quality Systems Standard 1
B Manual Inspection Tools for PCB (Populated Printed Circuit Boards) Inspection, Prints (Drawings), Testing, Sampling and Related Topics 11
quality1 Workmanship on PCB (Printed Circuit Board) Assembly Manufacturing and Related Processes 14
P PCB (Printed Circuit Board)/Electronics Inspection Training? IPC-A-610? Career and Occupation Discussions 10
A PCB (Printed Circuit Board) Assembly Inspection Checklist Inspection, Prints (Drawings), Testing, Sampling and Related Topics 5
J Auditing PCB (Printed Circuit Board) Assembly Lines - Fire And Safety Systems ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 21
S Receiving Inspection Instructions for PCB's (Printed Circuit Boards) Inspection, Prints (Drawings), Testing, Sampling and Related Topics 4
P I need to make an MSDS for PCB (Printed Circuit Board) Assembly Product Miscellaneous Environmental Standards and EMS Related Discussions 11
M PCB (Printed Circuit Board) Root Cause Fault Analysis Problem Solving, Root Cause Fault and Failure Analysis 1
O Identifying KPI for AS9100 8.1.4 - Prevention of Counterfeit Parts - PCB assembly contract manufacturer AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 16
V PCB internal insulation treated as insulation formed by insulating compound IEC 60601 - Medical Electrical Equipment Safety Standards Series 2
E AS9102 FAI - What makes a COTS modified? (PCB assemblies) AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 11
N Creepage - Does a surface mount isolator body negate a PCB slot? IEC 60601 - Medical Electrical Equipment Safety Standards Series 6
Y Where can I get 14 Layers PCB with BGA 0.2MM Space? Buy, Sell or Trade - NO Commercial Advertisements 0
H Reliable Prototype PCB service manufacturer Manufacturing and Related Processes 3
B China GB4943.1 Safety Requirements - PCB Markings China Medical Device Regulations 0
A IEC 60601 Creepage and Clearance Requirements on PCB IEC 60601 - Medical Electrical Equipment Safety Standards Series 5
MDD_QNA Medical Device PCB component change IEC 60601 - Medical Electrical Equipment Safety Standards Series 4
J Help!Rigid-flex PCB, huanyupcb supplier Service Industry Specific Topics 0
L Inspection of PCB provided by customer Misc. Quality Assurance and Business Systems Related Topics 2
alonFAI Finished PCB Final Visual Inspection Inspection, Prints (Drawings), Testing, Sampling and Related Topics 7
Q FAIR Requirement Flowdown to our PCB Supplier AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 3
A AS9100. 7.1.3 Configuration Management. PCB production. ECN. Revision Control. AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 4
J RoHS Components with Lead Exemptions (Capacitors on a PCB) RoHS, REACH, ELV, IMDS and Restricted Substances 11
L Baking of PCB's and Delamination Manufacturing and Related Processes 11
T Is IEC 61010 needed for a populated PCB within a unit? CE Marking (Conformité Européene) / CB Scheme 2
B The best way to manage changes to the documentation of PCB files & BOM Inspection, Prints (Drawings), Testing, Sampling and Related Topics 8
A Contact Resistance issue - Gold plating on PCB Manufacturing and Related Processes 3
M IEC 60601-1 Single fault conditions of electronic PCB components IEC 60601 - Medical Electrical Equipment Safety Standards Series 2
N PCB Creepage and Air Clearance on 8 Layer Boards IEC 60601 - Medical Electrical Equipment Safety Standards Series 3
N Requirements for PCB Component Replacements in an IEC 60601-1 Compliant Device IEC 60601 - Medical Electrical Equipment Safety Standards Series 9
A Qualification and Acceptance Requirements of PCB's from Multiple Suppliers Inspection, Prints (Drawings), Testing, Sampling and Related Topics 2
JoCam PCB Functional Test Equipment Regulations and Requirements Occupational Health & Safety Management Standards 3
V HALT vs. HASS (acronyms) - Tests for PCB and Cable Assemblies Inspection, Prints (Drawings), Testing, Sampling and Related Topics 1
T Does the Layout Design of a PCB fall under clause 7.3 in ISO 9001 Design and Development of Products and Processes 7
L MSA in Automatic Equipment - PCB Assembly - Help! Quality Tools, Improvement and Analysis 6
S PCB Handling Requirements - What to do if we drop a PCB during the assembly Manufacturing and Related Processes 4
E Ethernet Isolation Transformer for Medical Grade PCB IEC 60601 - Medical Electrical Equipment Safety Standards Series 9
I Material Certificates for a PCB Carbon Print Product Quality Manager and Management Related Issues 2
L Sample of Solder supplied with PCB by supplier - What is this sample for? Manufacturing and Related Processes 9
M Importance of Polarized Light for PWB/PCB Inspection Inspection, Prints (Drawings), Testing, Sampling and Related Topics 1
N PCB (medical device) Surface Finish Selection. Manufacturing and Related Processes 2
A Scrap vs. Rework Classification - Scraping the resistor or reworking the PCB board? Quality Tools, Improvement and Analysis 10
R Sample Size for PCB used in a Medical Device Inspection, Prints (Drawings), Testing, Sampling and Related Topics 6
C CE Marking for PCB Components for Laser Printer Cartridges CE Marking (Conformité Européene) / CB Scheme 5
V PPAP for electronics - What do we have to require for PCB compare to mechanical parts APQP and PPAP 4
Qwatcher2 FAI Help - Subcontracting out all manufactured items (PCB & machined parts) AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 4
C Only appearance and PCB are changed - Do we need to submit a new 510(k)? 21 CFR Part 820 - US FDA Quality System Regulations (QSR) 5
P Design an experiment to optimize the PCB solder reflow profile Design and Development of Products and Processes 4

Similar threads

Top Bottom