Precision and reliability during the equipping of prototype boards


The increasing trend towards miniaturisation throughout the electronic segment has a major influence on the sensor systems used. Sensors should be as small as possible, yet at the same time extremely powerful and sturdy. With these requirements in mind, a series of tasks that demand a high level of both flexibility and precision have to be performed. In order to achieve best possible qualitative production and development results, the radar technology company InnoSenT counts on its high-quality advanced machinery and recently invested in an Ersa HR 550 rework system.

Founded in 1999, InnoSenT GmbH is now one of the leading companies in the world in the radar technology segment. At its company headquarters in Donnersdorf, Lower Franconia, the manufacturer and developer of innovative sensor solutions offers the entire scope of engineering services and electronics production: from customer-specific development through prototype manufacturing and series production of its own products, to contract manufacturing (EMS). Thanks to the strong focus on quality and innovation, InnoSenT is considered a technology driver for industrial and automotive sensors and has been on the road to success for years.

In order to meet the requirements of increasingly difficult assemblies, InnoSenT was looking for a system that could reliably equip and solder very small assemblies and could also be used to carry out rework if necessary. Specifically, this involved the processing of special radar high-frequency chips with unusually small dimensions of less than 1mm². For this, the system must correctly pick up the chip with its 150µ diameter connections, align and solder them in a safe and controlled process. The HR 550’s high-precision component placement with force detection as well as the computer-assisted component placement can reliably meet this challenge.

Powerful and flexible reworking

All in all, Ersa hybrid heating technology is ideally suited for processing such miniature components. The energy input for soldering is a combination of medium-wave infrared radiation and a convection component. The components, some of which are very sensitive, are thus heated gently and homogeneously. The use of component-specific nozzles is not necessary, which means that the system can be used universally. Compared to hot-air technology, Ersa IR technology eliminates the risk of unintentionally blowing away very small, lightweight components from the outset. Damage to surrounding components caused by hot gases also is ruled out.

A high-precision vacuum pipette integrated in the heating head ensures precise component pick-up and placement of the smallest components. With regard to the increasingly diverse types of components and soldered joints, it is important to InnoSenT to be as flexible as possible. With the HR 550, it is possible to process components with sizes from 01005 to 70 x 70 mm.

In addition to equipping and soldering processes, prototype construction often involves replacing components or making changes to the circuit after extensive tests with regard to service life or function. Rework of this kind also can be carried out safely and reliably with the HR 550.

Collaboration a success

The intuitive HRSoft 2 software also was a decisive advantage for the system. Due to the clear operation and user guidance by means of pictograms, even new employees learn how to use the system very quickly. Since all rework processes and system statuses are automatically documented and saved, the Ersa HR550 rework system fulfils all the documentation/traceability requirements made by InnoSenT. It is possible to trace which parameters were used to process a specific assembly at any time, which is essential especially for the production of products from the automotive and railway industries. Practical use has shown that the HR 550 fully meets expectations and works extremely reliably. InnoSenT is very satisfied with its choice and the performance, and is glad to have a reliable partner at its side to master the upcoming tasks as well as future challenges.

Due to the short distance of about 100 km between InnoSenT and the Ersa demo center in Wertheim, Baden-Württemberg, demonstrations and test soldering could be carried out on site at short notice. The two companies are not only very closely connected due to their physical proximity. The company has been relying on Ersa’s 100 years of experience in soldering technology since 2016. In addition to the rework system, several soldering stations such as the i-CON VARIO 4 as well as EASY ARM soldering fume extraction units and other soldering equipment are in use.

Article Author

Ralf Walk Sales Engineer, Ersa GmbH

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