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Focus On 11th Vision Awards
Metcal:CV-5200焊接和返修系统
材料来源:The 11th Vision Awards           录入时间:2017/5/8 11:11:29

参赛公司:Metcal (OKI)
       参赛类别:手工焊接工具
       获奖名称:远见奖 - Vision Awards


具有连接验证功能的CV-5200焊接和返修系统
CV-5200 Soldering and Rework Systems with Connection Validation technology

创新性:焊接时,形成的理想的金属间化合物(IMC)厚度为1~4μm。Metcal公司的具有连接验证功能的CV-5200系统内含一种专利算法,在焊接过程中可对焊点质量进行评估。连接验证功能根据负荷量确定正确的烙铁头几何形状,检测从固态到液态的焊料变化,并计算IMC的形成。该系统通过集成在手持件的一个红色/绿色LED信号光环,向操作员闭环反馈焊接操作是成功的还是失败的。连接验证功能在烙铁头上使用了获专利的微芯片(烙铁头上芯片)技术,能够在烙铁头和电源之间双向通信。

兼容现有技术:目前的技术标准是在焊接操作完成后检验焊接连接性,遵照标准对焊点进行视觉检测。通过肉眼或使用自动光学检查系统进行检测。连接验证功能通过实时计算IMC的形成,在通过最终的视觉检验前,为焊点质量符合预期要求提供了保证。

成本效益:操作者所涉及的任何时间都将增加焊接操作成本。Metcal公司具有连接验证功能的CV-5200,向操作者提供实时反馈,减少了不正确焊接印制电路板的风险,减少了与报废相关的成本。

设计:Metcal公司具有连接验证功能的CV-5200提供了许多的新功能和设计选项。在过去的35年里,Metcal公司以其基本的黑色设计而闻名,现在Metcal改变了这一现状,将日出色彩方案引入到连接验证的产品中。该系统提供大的彩色触摸屏与大胆的图形用户界面。触摸屏显示多种信息,如净有效功率、系统信息、烙铁头选择、可追溯信息和Metcal的开始提示温度显示。

环保:Metcal公司具有连接验证功能的CV-5200减轻了手工焊接的相关风险。减轻了这些风险,就减少了错误,从而减少了报废品。与手工焊接相关的一些风险是选择了不恰当的烙铁头几何形状。选择错误的烙铁头几何形状,由于采用了超负荷要求的烙铁头,会导致不当的IMC形成或损坏基板。连接验证功能解决了这两个问题,并向操作员提供反馈。

可靠性:焊接取决于工艺变量的控制,包括操作技能、工艺过程中和之后的验证视觉标准。连接验证功能通过在目前的工艺过程中增加向操作员提供闭环反馈信息,或指明形成的金属间化合物是成功的,或指出工艺过程中的错误,例如相对于负荷不正确的烙铁头几何形状。

柔性:Metcal公司具有连接验证功能的CV-5200提供了众多的烙铁头几何形状,以及固定的系列温度,从500 °F~900 °F,以满足各种应用要求。增加通信端口允许系统更新,新固件是可用的,并可以与Metcal的新数据采集软件进行通信。这些功能将使得工艺控制工程师能够监测和跟踪焊接工艺的性能。

可维护性/维修性:Metcal为连接验证功率系统提供业界领先的5年保修。Metcal的连接验证和SmartHeat®技术不需要校准,出厂时就已一切就绪,从而降低了拥有成本,确保了该系统可随时用于焊接操作。

性能:Metcal公司具有连接验证功能的CV-5200采用了内置于每个Metcal系统的相同的SmartHeat技术。连接验证系统实时工作,为80W功率焊接和快速的恢复时间减轻了风险。这使得Metcal公司具有连接验证功能的CV-5200系统非常适合于各种应用,并能满足所有的生产挑战要求。(SMTC@ACT)


图解:Metcal全球销售兼市场副总Bryan Gass先生代表上台领奖留念。图片来源:SMT China

Creativity and Innovation: In soldering, the ideal intermetallic compound (IMC) formation is between 1μm and 4μm thickness. Metcal’s CV-5200 with Connection Validation features a patented algorithm, which evaluates the quality of the solder joint during the soldering process. Connection Validation identifies the correct solder tip geometry to the load, detects the transition of solder from solid to liquid, and calculates IMC formation. The system then provides closed loop feedback to the operator via a red/green LED light ring integral to the hand-piece signaling to the operator either the success or failure of solder event. Connection Validation uses a patented microchip in cartridge (Chip in Cartridge) technology that enables bi-directional communication between the cartridge and the power supply.

Compatibility with existing technology: The current technological standard is to inspect the solder connection at completion and make visual determination on the solder joints adherence to that standard. That inspection is by eye or with the use of an automatic optical inspection system. Connection Validation compliments those technologies by calculating the IMC formation in real time and provides an assurance that the quality of the solder joint meets expectations before passing the final visual inspection.

Cost effectiveness: Anytime an operator touches adds costs to the soldering operation. Metcal’s CV-5200 with Connection Validation provides real-time feedback to the operator reducing the risk of incorrectly soldering the printed circuit board reducing the cost associated with scrap.

Design: Metcal’s CV-5200 with Connection Validation features a number of new features and design choices. Metcal, known for its basic black approach to design for the last 35 years, changes the status quo with the introduction of the Metcal Sunrise color scheme to the Connection Validation products. The system features a large, color touchscreen with a bold graphical user interface. The touchscreen displays information such as a net power meter, system messages, cartridge selection, traceability information and Metcal’s first tip temperature display.

Environmental friendliness: Metcal’s CV-5200 with Connection Validation works to mitigate risks associated with hand soldering. Mitigating those risks reduces the errors that in turn reduces scrap. Some of the risks associated with hand soldering are improper tip geometry selection. Choosing the wrong tip geometry can lead to either improper IMC formation or damage to the board due to the tip exceeding the load requirements. Connection Validation addresses both conditions and provides feedback to the operator.

Expected reliability: Soldering depends on the control of variables into the process including operator skill, visual standards during the process and verification after the process. Connection Validation compliments the current process by adding closed loop feedback to the operator indicating either successful formation of the intermetallic compound or indicating an error in the process e.g. incorrect tip geometry to the load.

Flexibility: Metcal’s CV-5200 with Connection Validation offers numerous tip geometry configurations and fixed temperature series from 500°F to 900°F to meet a wide variety of applications. The addition of a communication port allows system updates as new firmware becomes available and enables communication to Metcal’s new data collection software. These features will allow the process control engineer to monitor and track the performance of their soldering processes.

Expected maintainability/repairability: Metcal supports the Connection Validation power systems with an industry leading five-year warranty. Metcal’s Connection Validation and SmartHeat® technologies continue to require no calibration. The system is ready to go from the factory reducing the cost of ownership and ensuring that the system will be ready to use whenever you are ready to solder.

Performance: Metcal’s CV-5200 with Connection Validation utilizes the same SmartHeat technology built into every Metcal System. The Connection Validation system works in real-time providing mitigating risk features in conjunction with 80 watts of power and fast recovery time. The makes Metcal’s CV-5200 with Connection Validation system ideally suited to meet all production challenges.



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