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Wave & Selective Solder Process Optimizer

With the requirement for manufacturers to document all soldering processes, SolderStar has developed a range of specialise instrumentation providing the ultimate set-up tools for conventional Wave soldering, Mini-wave or Multi-wave selective processes

Manufactured from 10 mm anti-static composite and fitted with durable titanium side rails, the systems are designed to survive the rigours of daily production use. These unique  measurements fixtures incorporates titanium contact sensors on the underside which captures wave parameter data as it moves through the solder wave, including a true measurement of wave heights.

All key process parameters are captured with a single run through the machine, data is then downloaded via USB or wireless interface for analysis on the engineer’s computer. All parameters can be then be quickly analysed by using the unique Solderstar Process Checker function showing the good/bad limits to allow periodic process verification to be performed without the need for specialist knowledge.

SYSTEM ADVANTAGES

  • Most comprehensive parameters measurement with a single pass through a machine.
  • Titanium contact sensors give highest measurement accuracy on Wave Height, Main and Chip wave parameters.
  • Pre-heat and solder pot temperature measurement sensors.
  • High quality 10mm fixtures provides a robust platform for daily production testing.
  • Custom widths and sensor positions available for fixed width production lines or special applications.
  • Dedicated Wave Central PC analysis software with integrated SPC charting package.
Wave & Selective Solder Process Optimizer

Wave Solder Optimizer

The SolderStar WaveShuttle PRO quickly allows you to analyse, improve and gain control of your wave soldering process.

This unique fixture incorporates two measurement systems to give the most comprehensive and repeatable measurement results of any analyser on the market today. Measurement of wave contact timewave heightwave parallelism and temperature profile are all required to correctly setup the wave solder machine correctly, these measurements can now be captured in one single pass using this innovative and convenient device.

The WaveShuttle Pro is designed for the rigours of daily production testing, manufactured from 10mm anti-static composite and fitted with durable titanium side rails. This intelligent measurement fixture incorporates titanium contact sensors on the underside that capture wave parameters data as it moves through the solder wave, including a true measurement of wave height. Additionally the system measures preheat profiles and solder pot temperatures.

Date Capture and Analysis

All key process parameters are captured with single run through the machine, data is then download via USB or Wireless interface for analysis on the engineers computer. All parameters can be quickly analysed and using the unique Solderstar Process Checker functions allow good/bad limits to be defined to allow periodic process verification to be performed without the need for specialist knowledge.

The WaveShuttle Pro is supplied with Wave Central PC Software, a dedicated package for the analysis of all key wave soldering parameters.  Based on SolderStar’s interface and navigation system it allows users of other SolderStar products to perform detailed wave solder analysis with minimal training. Your perfect tool for wave solder optimization.

WAVESHUTTLE PRO HIGHLIGHTS

  • Immersion Depth / Wave Height Measurement.
  • Contact timing accuracy +/-10mS.
  • Temperature measurement accuracy +/1⁰C.
  • Titanium side rails for maximum durability.
  • Accurate solder temperature sensing method.
  • Quick release datalogger to prevent sensor damage or channel mix-up.
  • Spare thermocouple ports for product profiling.
  • 2.4Ghz Wireless telemetry option.
Wave & Selective Solder Process Optimizer

Selective Solder Optimizer

The SolderStar WaveShuttle Selective has been specifically designed for daily testing of Mini-Wave Selective soldering machines. A specially configured array of titanium wave contact sensors are arranged on the underside of this measurement fixture to allow quick and comprehensive verification of the machine functionality.

Nozzle strikes on clinched components or the PCB due to PCB warp or general tolerances can result in the positioning mechanism of the machine becoming mis-aligned. X and Y positioning mechanism and speed are verified by sweeping the selective soldering nozzles between pre-defined datum’s. An array of stepped contact sensors are employed to allow nozzle wave height measurements to be made and periodically verified.

Flux Sensing

When crystallisation occurs in the selective fluxer nozzle mis-fluxing of components can occur causing problems with poor wetting or leaving un-activated flux on area of the assembly. To combat this problem SolderStar has developed flux measurement sensors which can be optionally installed to the measurement fixture, this allows for flux presence and position to be obtained as part of the daily tests.

Date Capture and Analysis

Captured data is download via USB or Wireless interface for analysis on the engineers computer. All parameters can be quickly analysed and using the unique Solderstar Process Checker functions allow good/bad limits to be defined to allow periodic process verification to be performed without the need for specialist knowledge.

The WaveShuttle Pro is supplied with Wave Central PC Software, a dedicated package for the analysis of all key wave soldering parameters.  Based on Solder Star’s interface and navigation system it allows users of other SolderStar products to perform detailed wave solder analysis with minimal training.

SYSTEM HIGHLIGHTS

  • Verification X/Y speed and positioning.
  • Measurement of nozzle solder height.
  • All titanium wave contact measurement.
  • Flux measurement option.
  • Pre-heat and solder temperature measurement sensors.
  • Custom widths and sensor positions available for fixed width production lines or special applications.
  • Dedicated Wave Central PC analysis software with integrated SPC charting package.
Wave & Selective Solder Process Optimizer

Multi-Wave/Dip Solder Instruments

The WaveShuttle Multi-Wave Selective gives precise measurement and control for Multi-Wave Selective soldering machines.

Multi-Wave Selective Soldering machines offer electronic manufacturers the fast throughput while maintaining the benefits of only introducing the solder wave to the areas where through hole components need to be soldered. The throughput increase does however results in a reduction in flexibility, with dedicated nozzle designs needed matching the assemblies being soldered in production. Different nozzle shapes and sizes employed in the production soldering tooling exhibit different dynamics when the PCB is presented to the solder. The perfect process would result in contact between PCB and solder occurring both simultaneous and for the same contacts time, until now it was not possible to measure these crucial parameters.

The SolderStar Multi-Wave PRO allows Production Engineers to better understand the contact dynamics of this soldering process. A compact and flexible instrument has been designed to allow dedicated test fixtures to be produced quickly and cost effectively for multi-wave soldering machines, measurement sensors are fitted to customer specific locations which correspond to the soldering areas within the multi-wave solder pot tooling, this technique provides contact time and difference data to quickly allow engineers to identify any problem areas within the tool design. Any differences in nozzle to PCB contact can be easily measured providing a powerful platform for process capability analysis, improvement and on-going testing.

Date Capture and Analysis

Captured data is download via USB or Wireless interface for analysis on the engineers computer. All parameters can be quickly analysed and using the unique Solderstar Process Checker functions allow good/bad limits to be defined to allow periodic process verification to be performed without the need for specialist knowledge.

The WaveShuttle Multi-Wave Pro is supplied with Wave Central PC Software, a dedicated package for the analysis of all key wave

SYSTEM HIGHLIGHTS

  • Flexible design allows measurement system to be installed to multiple fixtures.
  • Solder Nozzle / PCB Contact Time.
  • Solder Nozzle Wave Height / Immersion Depth.
  • Time of first contact delta.
  • Pre-heat profilers.
  • Solder Pot temperature.
  • Heating Rates.
Wave & Selective Solder Process Optimizer

Wave/Selective Analysis Software

Wave Central is a natural extension to the Profile Central concept, allowing for existing users of Profile Central to be analysing their wave or selective soldering in a matter of minutes. This dedicated tool package has been specifically designed for users of through-hole soldering machines, streamlining the whole procedure of machine calibration and daily testing. All tools are included for profile analysis, reporting and SPC chart generation.

Profile Viewer and Explorer

Profile Explorer automatically stores downloaded profiles against the user's product name, creating a chronological record of profiles for each wave soldering process they wish to analyse.

Process Checker – Preheat/Temperature Performance

Wave Central automatically takes captured temperature profile data and calculates all the process parameters of interest, plotting them against pre-defined production limits to give an instant view on machine heater performance.

Process Checker – Wave / Nozzle Performance

Correct solder wave contact parameters are crucial to obtaining high quality production soldering of electric assemblies. Wave Central displays in-depth information captured from Solderstar wave or selective soldering products which provide the highest levels of measurement accuracy available for these process types. Parameters such as wave height, wave parallelism and contact time can be measured and verified with the click of a mouse.

Process Manager

The Process Manager functions within Wave Central provides all the necessary tools for the engineer to manage and configure profiling limits for each of the wave soldering process in use within the manufacturing lines. Bespoke production settings can be configured for each individual soldering process to allow simple daily testing.

Test Reports

Professional, configurable test reports and process documentation can be generated at the click of a mouse. Reports on products, recipes and machine settings, temperature profiles and process checker graphs can be printed out or emailed.

SPC Reporting

Process trends can be monitored and process yields and quality can be improved through continuous SPC. Using SPC Manager, users can evaluate process trends for profiles selected from the database, illustrating these on professional Xbar and Range charts that include Cp, Cpk and control limits. Charts can be output in hard copy or digital format.

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