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Best Practice: InnoSenT

Reliable precision for assembly of prototype boards

The trend towards miniaturization in the entire electronics sector also influences the sensor technology used – sensors should be as small as possible and at the same time extremely powerful and robust. These requirements give rise to numerous tasks that demand high flexibility and accuracy at the same time. For the best possible production and development results, the radar technology company InnoSenT relies on advanced machinery, which has recently included an Ersa HR 550 Rework System.

Use in InnoSenT prototype construction: Ersa HR 550; source: InnoSent
Use in InnoSenT prototype construction: Ersa HR 550; source: InnoSent

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

 

Reliable processing of very small assemblies

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

The new IMD-3000 radar system is uncomplicated to use as an alternative to pushbutton switches thanks to its user-friendly design
The new IMD-3000 radar system is uncomplicated to use as an alternative to pushbutton switches thanks to its user-friendly design

Overall, 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 convection components. The components, some of which are very sensitive, are heated gently and homogeneously. The use of component-specific nozzles is unnecessary, which makes the system universally applicable. Compared to hot-air technology, Ersa IR technology eliminates the risk of unintentional blowing away of very small components with low weight. Damage to surrounding components caused by hot gases is also ruled out.

Self-explanatory pictograms facilitate handling of the system
Self-explanatory pictograms facilitate handling of the system
Highly precise: component pickup and placement
Highly precise: component pickup and placement
The HR 550 enables processing of component sizes from 01005 to 70 x 70 mm
The HR 550 enables processing of component sizes from 01005 to 70 x 70 mm

The high-precision vacuum pipette integrated in the heating head ensures precise component pickup and placement of the smallest components. In view of the increasing variety of component types and solder connections, InnoSenT attaches great importance to flexibility – the HR 550 enables components with sizes from 01005 to 70 x 70 mm to be processed. In addition to placement and soldering processes, prototyping often involves replacing components or making changes to the circuit after extensive testing with regard to service life or function. Rework of this kind can also be carried out safely and reliably with the HR 550.

 

HRSoft2: Overview and clear user guidance

The intuitive HRSoft2 software also contributed positively to the decision in favor of the system: Thanks to the clear operation and clear user guidance by means of pictograms, even new employees learn to use the system very quickly. Since all rework processes and system statuses are automatically documented and stored, the Ersa HR 550 Rework System meets all InnoSenT´s documentation and traceability requirements. It is possible to trace at any time which parameters were used to process a particular assembly – an essential requirement, especially for the manufacture of products from the automotive and railroad industries. In practical use, the HR 550 fully met expectations and worked extremely reliably. InnoSenT is very satisfied with its choice and performance and glad to have a reliable partner at its side to master upcoming tasks and future challenges

Company headquarters of InnoSenT GmbH
Company headquarters of InnoSenT GmbH

Due to the short distance of about 100 km between InnoSenT and the Ersa Demo Center in Wertheim, on-site demonstrations and test soldering could be carried out easily and at short notice. The two companies are very closely linked, and not just because of their physical proximity. InnoSenT 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 i-CON VARIO 4, EASY ARM solder fume extraction systems and other soldering equipment are in use.

 
 

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