MEDICAL DEVICE - AUTOMATED INLINE SOLDERING

CSC Project Photo

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Customer Need

A medical device manufacturer was integrating two materials with a continuous soldering application to manufacture a cable with a process that wasn't controlled and was subjective by the operators. This process was time consuming and didn't always produce consistent results.

The existing methodology limited the lengths that could be produced without a line stop and restart. Additionally, fibers from part of the process were adhering to the final product which was requiring servicing of some devices in the middle of a product run.

Due to a projected increase in demand for the client’s product they wanted to prepare for increased production by automating the process and remove any subjectivity.

Solution

Initially, since a lot of the specifications and requirements were still unknown, the project was broken into two phases. The first phase was several small proofs of concept development studies to enable finalization of the specification. The second phase was the development of the automated system for production.

CSC designed and fabricated an automated line that consisted of a PLC for overall system and process control. It was coupled with 3 HMI locations; this allows the operator to view and modify all process parameters from a central location or either end. The HMI stores parameters as recipes for future recall. The system is also be capable of logging certain process variables for post-run analysis. The current inspection system and spray marking equipment installed on the existing machine was moved to this new system.

Some specifications of this project were:

  • Cable payoff tension with alarm if out of range
  • Take-up Speed
  • Ramp up/down speed
  • Solder Temperature
  • Flux Pump Rate
  • Preheater Temperature control
  • Integrate 3500m continuous length of product
  • Defect Location via existing inspection system

System Components

Mitsubishi L-Series PLC

Minarik DC Motor Drive

Linear Encoder

Thermcraft 24" Tube Furnace

Wenesco M6 Wave Solder Pot

Broomfield Dereeler

Broomfield Tensioning Stands

Julabo FL300 Recirculating Cooler

Mitsubishi Touch Screens

Mitsubishi 500W Servo Motors

Success

The client was able to reduce the production time of a complete cable from 4 - 5 days to 1 day. The final product was better quality and allowed for a more consistent result.