In addition to being time-efficient, this induction soldering was also reliable, energy-efficient and completely safe for the operator. When used on the line, it would ensure consistent and repeatable results every time.
The extremely fast and energy-efficient induction soldering process for an AC wire has recently been demonstrated by UltraFlex Power Technologies. UltraFlex - a leading manufacturer of advanced, digitally-controlled induction heaters - is frequently setting up demos per request of potential customers looking to evaluate the parameters and results of induction-based heating.
In this demo scenario, a semiconductor manufacturer was looking to evaluate the replacement of flame soldering with induction soldering to flow solder into the voids of a crimped joint part of an AC wire, so better electrical connectivity would be obtained. By replacing the current flame-based soldering with induction, the manufacturer aimed at optimizing the current manufacturing process by improving reliability, repeatability, precision and time-/energy-efficiency.
UltraFlex engineers recommended an UltraFlex induction heater from the UltraHeat S series as most appropriate for this heating scenario. UltraHeat S are small and economical 2kW induction heaters which operate with water-cooled or air-cooled remote heat station. All systems utilize the latest switching power supply technology and adaptive digital phase control which provide efficient operation in a wide frequency range.
A key requirement for this process was to use a high-temperature solder that can withstand up to 400-500 °C (752°F - 932°F). The solder feeding could either be manual or automated via using a preform solder ring or wire feeder. To ensure that the solder would stick well to the surface, flux was first applied to clean the surface oxides.
This induction soldering process was performed with a custom open-end soldering coil. At a power output of 2 kW, it took mere 5 seconds to accomplish the soldering successfully. In addition to being time-efficient, this induction soldering was also reliable, energy-efficient and completely safe for the operator. When used on the line, it would ensure consistent and repeatable results every time.
Finally, thanks to the lack of open flame this had been a green, environment-safe process, with no smoke, waste heat and noxious emissions.
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About UltraFlex Power Technologies:
UltraFlex Power Technologies (ultraflexpower.com) offers the most advanced and innovative digitally controlled induction heating equipment in the industry. Its compact modular and flexible systems are used for a wide variety of induction heating, casting and melting applications.