Wave Soldering Machine: A Comprehensive Guide
Wave soldering machine is used for soldering the through-hole and SMD board in the DIP process. According to the maximum PCB width and different configuration, there are 6 models in total.
What is Wave Soldering?
Wave soldering uses a pumped wave of molten solder to solder electronic components onto PCBs. The PCB passes over the crest of the solder wave, allowing the solder to wet and adhere to the metal surfaces of the board and components. This forms a strong solder joint to mechanically and electrically connect the components.
A Brief History of Wave Soldering
The origins of wave soldering can be traced back to the 1950s when the first reliable soldering machines were developed. The method became popular in the 1960s and 70s for soldering through-hole components on PCBs in the electronics manufacturing industry. The first automated wave soldering machines were introduced in the 1980s.
Key Benefits of Wave Soldering
- The highly efficient and fast soldering process
- Ability to solder many joints simultaneously
- Consistent and repeatable soldering quality
- Suitable for high-volume PCB production
- Low operational costs compared to other soldering methods
Types of Wave Soldering Machines
There are several types of wave soldering machines:
- Single wave – A single linear solder wave for basic soldering
- Dual wave – Separate waves for soldering and fluxing
- Multi-wave – Multiple solder waves in a single machine
- Lead-free wave – Using lead-free solder alloys
How Wave Soldering Machines Work
Wave soldering machines operate by passing PCBs over a wave of molten solder to form reliable solder joints. Let’s look at the stages involved:
The Wave Soldering Process
There are five main stages:
- Flux application – Flux is applied to remove oxides and improve solder flow
- Preheating – PCBs are preheated to prevent thermal shock
- Wave soldering – PCBs pass over the solder wave to wet components and form joints
- Cooling – PCBs are cooled to solidify the solder joints
- Cleaning – Excess flux is removed from the PCBs
Components of a Wave Soldering Machine
Key components include:
- Solder pot – Holds the molten solder
- Solder pump – Generates the solder wave
- Heat exchangers – Control the solder temperature
- Fluxer – Applies flux onto PCBs
- Preheater – Heats PCBs before soldering
- Conveyor – Transports PCBs through the machine
Choosing a Wave Soldering Machine
Several factors should be considered when selecting a wave soldering machine:
Factors to Consider
- Board size – The machine must accommodate the PCB size
- Throughput – The number of boards soldered per hour
- Alloy compatibility – Suitability for lead or lead-free alloys
- Temperature control – Accurate heat control for good solder joints
- Maintenance – Ease of routine maintenance and servicing
Types of Wave Soldering Machines
- Benchtop – Compact units for low-volume soldering
- Inline – For automated high-volume soldering lines
- Multi-wave – For complex or high-speed soldering
Top Wave Soldering Machine Models
Some of the best wave soldering machines are:
- WS-350 – Lead free wave soldering machine
- WS-250 – Small wave soldering machine
- EW-300 – Medium wave soldering
- WS-200 – Raliable Mini wave soldering machine
Using a Wave Soldering Machine
Following proper techniques and safety is key to successfully using a wave soldering machine:
Step-by-Step Machine Operation
- Program soldering parameters into machine
- Set up board holders and conveyors
- Turn on the pump to generate a solder wave
- Set preheating temperature
- Load flux and solder into reservoirs
- Feed boards into the machine
- Inspect soldered boards at the outlet
Important Safety Precautions
- Wear protective equipment
- Handle molten solder carefully
- Ensure mechanical guards are in place
- Follow manufacturer safety guidelines
Troubleshooting Wave Soldering Issues
Some common wave soldering problems and solutions:
Common Wave Soldering Problems
- Solder bridges – Excess solder between joints
- Icicles – Jagged solder protrusions
- Cold solder joints – Weak bonding of solder
- Solder balls – Spheres of solder between joints
Troubleshooting Tips
- Adjust conveyor speed and solder temperature
- Use higher-quality flux
- Clean and maintain solder pot
- Ensure even heat distribution
Conclusion
Wave soldering is an efficient and high-quality soldering technique suitable for automated PCB production. Choosing the right soldering machine and following good soldering practices helps ensure a smooth soldering process with reliable solder joints. Additional resources for learning more about wave soldering include industry associations, equipment manufacturers, and soldering handbooks.